Plant and Equipment Risk Management

Plant And Equipment Risk Assessment

Last Updated: 12 July 2018

 Plant and Equipment Risk Management Form
3. Hazard Identification
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
ENTANGLEMENT unlikely low low Entanglement in the moving Appropriate safe system of work
Can anyone’s hair, clothing, gloves, cleaning parts of conveyor belt and emergency stop buttons
brushes, tools, rags or other materials become No Inspections for safety guards of
entangled with moving parts of the plant or moving parts
materials?

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
IMPACT AND CUTTING INJURIES unlikely low low Cutting and impact injuries All the machinery should be
Can anyone be crushed/cut/struck etc. due to: possibilities by contacting selected for the appropraite use
moving parts of the machinery
• Material falling off the plant? N Machines should be routinely
inspected
• Uncontrolled/unexpected movement of plant/load? N Material falling and flying objects
may cause injury
• Lack of capacity to slow, stop or immobilise plant? N
Creating an SSW safe system
of work to carry out the
Mechanical hazards – mainly
• The plant tipping or rolling over? N activities safe
from contact with or being
• Parts of the plant disintegrating or collapsing? caught by dangerous moving
N Should wear appropriate PPE
parts.
• Contact with moving parts during testing, inspection, by operators
N • Non-mechanical hazards –
operation, maintenance, cleaning or repair? mainly from the power source or
All the emergency stop buttons
• Being thrown off or under the plant? N
things emitted by the machine.
and safety guards should be
properly and routinely check
• Contact with sharp or flying objects? (e.g. work N
pieces being ejected)
• The mobility of the plant? Y
• Inappropriate parts and accessories being used? N
• Other Y N

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
SHEARING unlikely low low Guards and other protection
Can anyone’s body parts be sheared between two parts methods have to be used to
of plant, or between a part of the plant and a work piece control the risks associated with
or structure? all such types of machinery.
• Protection from machinery
hazards can be achieved by
using guards that physically
enclose the hazard and prevent
contact. Fixed guards are most
effective at preventing contact,
but interlocked guards,
adjustable guards and self-
adjusting guards may be
required.
• If it is not possible to completely
N guard in a hazard then other
forms of protection will have to be
used, such as sensitive
protective equipment; two-hand
controls; protective appliances;
emergency stops; PPE; or
information, instruction, training
and supervision.
• Guards and safety devices
must: meet relevant standards,
be strong and robust, be
compatible with machine
operation, not be easy to defeat,
allow visibility and ventilation,
take maintenance into account,
and not increase overall risk.
PRESSURISED CONTENT N N/A N/A
Can anyone come into contact with fluids or gases
N
under high pressure, due to plant failure or misuse of the
plant?
ELECTRICITY All the live electrical conductors Electrical equipment must be
Can anyone be injured or burnt due to: are exposed in many places carefully selected to ensure

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
• Live electrical conductors? (e.g. exposed wires) High Possibl Extrem that it is suitable for the
Y e e Working is closed near to live electrical system, purpose
conductors and environment of use.
• Working in close proximity to electrical conductors?
Y • Various protective systems
No isolation can be used for electrical
• Access to electricity? equipment, such as:
Y
Water and some chemicals are – Fuses – a weak link in the
• Damaged or poorly maintained electrical leads, stored near electrical system circuit.
cables or switches? Y – Earthing – a low-resistance
Lack of inspections and testing path to earth for fault current.
• Water near electrical equipment?
Y the electrical system – Isolation – cutting the
power.
• Lack of isolation procedures? These hazards can cause – Double insulation –
Y
electrical shocks separating people from the
• Other conductors using two layers
Broken bones
of insulation.
Heart fibrillations
– Residual Current Devices
Muscle cramps (RCDs) – sensitive and fast-
Burn injuries acting trips.
Fire ignition – Reduced and low voltage –
death so that less current flows
during an electric shock
accident.
• Each of these protective
systems has advantages and
limitations.
Y • Work on electrical systems
should be restricted to
competent people only.
• Safe Systems of Work
(SSWs) should be used when
risk is created by work on, or
near, electrical systems.
• All electrical installations,
equipment and appliances
should be subject to user
checks, formal visual
inspections, and combined

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
inspection and testing to
ensure electrical safety.

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
ERGONOMICS Musculoskeletal disorders (MSDs), the control of MSD risk can be
Can anyone be injured due to: such as back pain and Work-Related achieved by introducing
Upper Limb Disorders (WRULDs), changes to the:
• Poorly designed workstation? High Possibl High can result from repetitive tasks, such
N e as Display Screen Equipment (DSE) task and the way that it is
use, checkout operation and done;
• Repetitive body movement? bricklaying. • tools, equipment and
Y
• Many factors influence ergonomic machinery being used; and
• Constrained body posture or the need for excessive risk, such as repetition, force, • workplace environment;
Y posture, twisting, rest breaks,
effort? to suit the individuals carrying
equipment design and adjustability,
out the work
• Design deficiency causing psychological stress? and workplace lighting.
Y • DSE use can cause WRULDs,
back pain and eye strain.
• Inadequate or poorly placed lighting? • Precautions for safe use of DSE
Y include: ergonomic assessment of
the workstation; provision of basic
• Does the plant impact on the surrounding workplace equipment; short, frequent breaks;
and create potential hazards? (Consider safe access eye tests; and the provision of
N
and egress from plant, workflow and design of the information and training.
workplace)
• Is the location of the plant inappropriate? (Consider
potential effects due to environmental conditions and N
terrain)
• Other
N

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
RADIATION High Possibl High Friction or abrasion – contact is Noise exposure should be
Can anyone using the plant, or in the vicinity of the plant e made with a fastmoving surface assessed by undertaking a noise
suffer injury or illness due to exposure to radiation in the which may be smooth survey using a sound level meter.
form of any of the following: N • Control of exposure to noise
Exposure to excessive noise can be achieved by:
• infra-red radiation
causes Noise-Induced Hearing Loss – Reducing the noise at source:
• ultra violet light (NIHL) as well as other health and by elimination, substitution,
• microwaves safety risks. maintenance, damping and
NOISE • Noise exposure standards are silencing.
Can anyone using the plant, or in the vicinity of the Y based on a worker’s daily personal – Interrupting the pathway from
plant, suffer injury due to exposure to noise? noise exposure. An exposure of 85 source to receiver: by isolation
VIBRATION dB(A) over an eight-hour work shift and absorption.
Can anyone be injured or suffer ill-health from exposure Y is generally considered to be the – Protecting the receiver: by
upper exposure standard at which providing an acoustic haven or
to vibration? action has to be taken to reduce Personal Protective Equipment
FRICTION exposure. (PPE).
Can anyone be burnt due to contact with moving parts, Y • There are two types of hearing
materials or surfaces of the plant? Exposure to excessive vibration into protection: ear defenders and ear
SUFFOCATION the hand can cause Hand-Arm plugs. Both types have
Can anyone be suffocated due to lack of oxygen, or Y Vibration Syndrome (HAVS). Health advantages and limitations.
atmospheric contamination? effects can also be seen for whole- • Health surveillance in the form
CONDITION body vibration. of hearing tests (audiometry) is
Is a hazard likely due to the age and condition of the • Exposure standards exist for both required where employee
N hand-arm vibration and whole-body exposure is above the upper
plant? (Consider how hard the machine has been
vibration. exposure action value.
worked, and whether it is used constantly or rarely).
• Can anyone be injured as a result of the plant not Vibration exposure can be
serviced appropriately and/or maintained in line with controlled by:
manufacturer’s recommendations? – Reducing the vibration at
source – by eliminating the
source, substituting the source,
changing work techniques and
N maintenance.
– Interrupting the pathway from
source to receiver – isolation.
– Limiting the duration of
exposure.
• Health surveillance is required
where workers are exposed to
high levels of hand-arm vibration.

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
SLIPS/TRIPS/FALLS High Possi High Pedestrians are exposed to the risk Use of non-slip surfaces.
Can anyone using the plant, or in the vicinity of the ble of slips and trips while moving – Spill control and good
plant, slip, trip or fall due to: around in workplaces. Common drainage.
causes include slippery surfaces,
• Uneven, slippery or steep work surfaces? – Using signs and PPE.
N uneven surfaces and trailing cables.
• The risk can be controlled through – Good housekeeping.
• Poor housekeeping, e.g. spillage in the vicinity? the risk assessment process and by – Information, instruction,
Y careful design, construction and training and supervision.
operation of the workplace.
• Obstacles being placed in the vicinity of the plant?
Y For Housekeeping:
Poor housekeeping in sizing area
Floors and walkways should be
• Inappropriate or poorly maintained floor or walking cleaned routinely to ensure that
surfaces (i.e. lack of a slip-resistant surface, Y Unsuitable guardrails on the stairs
surfaces are kept free of
unprotected holes, penetrations or gaps?) contamination.
If operating or maintaining plant at height can anyone • Spills should be cleaned up
slip, trip or fall due to: N FLT are not inspected routinely and
no SSW for their use quickly and safely.
• Use of work platforms, stairs or ladders? • Housekeeping routines should
Y No procedure for their safe be established to ensure that
movement in the workplace pedestrian routes are free of
• Lack of guardrails or other suitable edge protection? trip hazards and obstructions.
Y
• Floors and walkways should
• Use of Equipments like Forklift trucks and their be inspected and repaired to
safe movement keep them in a safe condition
(e.g., potholes should be
repaired as soon as possible).
• Access and egress routes
should be inspected routinely
and cleaned or repaired as
 necessary. This is particularly
important for outdoor areas
where snow and ice can make
external pedestrian walkways
hazardous (in which case,
gritting or clearing the snow
and ice may be appropriate).

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
• Emergency exit routes should
be kept free of slip and trip
hazards and obstructions at all
times.
• Lighting is essential for safe
movement through a workplace
and lights should therefore be
routinely inspected and
replaced/repaired as necessary

Vehicles should be:

• Suitable for their intended
use.
• Suitable for the environment
and conditions in which they
are used.
• Maintained in safe working
order.
• Only driven by suitably
trained, qualified staff.
• Inspected routinely before
use.

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Cons Like Risk
Level
FIRE AND EXPLOSION High Possi High Cleaning chemicals – chemicals Spill control is best achieved by
Can anyone be injured by fire? N used for cleaning could affect the preventing the spill from happening
ble
atmosphere directly or interact with in the first place. This might be
• Can anyone be injured by explosion of gases, residual substances present in the done by implementing:
N
vapours, liquids, dusts, or other substances? confined space. • maintenance and inspection (e.g.,
TEMPERATURE/MOISTURE • Sources of ignition – welding could of pipelines, valves or taps); or
Can anyone come into contact with objects at high or N act as an ignition source for gases • behavioural controls (e.g.,
low temperatures? and vapours inside the space. Tools banning drinks from an area).
and equipment such as lighting may Floors and walkways should be
• Can anyone suffer ill-health due to exposure to high N need to be ATEX rated (i.e., rated cleaned routinely to ensure that
or low temperatures? for use in an explosive atmosphere; surfaces are kept free of
• Can anyone be injured or suffer ill-health due to see Element 10) so that they do not contamination.
N
exposure to moisture? present a source of ignition. • Spills should be cleaned up
OTHER • Increasing temperature – hot work quickly and safely.
Can anyone be injured or suffer ill-health from exposure and strenuous work activities can • Housekeeping routines should be
to: have an effect on the thermal established to ensure that
comfort of workers, particularly
• Chemicals? Y when PPE is being worn. This may
pedestrian routes are free of trip
hazards and obstructions.
lead to heat stress and heat stroke • Floors and walkways should be
• Toxic gases or vapours? N inspected and repaired to keep
Spillage of chemicals and water in them in a safe condition (e.g.,
• Fumes/Dusts? N the workplace. potholes should be repaired as
soon as possible).
• Access and egress routes should
be inspected routinely and cleaned
or repaired as necessary. This is
particularly important for outdoor
areas where snow and ice can
make external pedestrian
 walkways hazardous (in which
case, gritting or clearing the snow
and ice may be appropriate).
• Emergency exit routes should be
kept free of slip and trip hazards
and obstructions at all times.

4. Risk Assessment Signoff

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 Plant and Equipment Risk Management Form
Hazards Inspected Risk Assessment Description of Risk Control Measures
Authorised By: Signature: Date:

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 Plant and Equipment Risk Management Form
1. Consequence - Evaluate the consequences of a risk occurring according to the 2. Likelihood - Evaluate the likelihood of an incident occurring according to
ratings in the top row the ratings in the left hand column
Descriptor Level Definition
Descriptor Level Definition

Insignificant 1 No injury Rare 1 May occur somewhere, sometime (“once in a life time
/ once in a hundred years”)
Minor 2 Injury/ ill health requiring first aid
Unlikely 2 May occur somewhere within the Department over an
Moderate 3 Injury/ill health requiring medical extended period of time
attention
Possible 3 May occur several times across the Department or a
Major 4 Injury/ill health requiring hospital region over a period of time
admission
Likely 4 May be anticipated multiple times over a period of
Severe 5 Fatality time
May occur once every few repetitions of the activity or
event
3. Risk Matrix – Using the matrix, calculate the level of risk by finding the
intersection between the likelihood and the consequences Almost 5 Prone to occur regularly
Certain It is anticipated for each repetition of the activity of
Likelihood Consequence event

Insignificant Minor Moderate Major Severe

4. Risk Level/Rating and Actions
Descriptor Definition
Almost Medium High Extreme Extreme Extreme Extreme: Notify Workplace Manager and/or Management OHS
Certain Nominee immediately. Corrective actions should be taken
Likely Medium Medium High Extreme Extreme immediately. Cease associated activity.

Possible Low Medium Medium High Extreme High: Notify Workplace Manager and/or Management OHS
Nominee immediately. Corrective actions should be taken
Unlikely Low Low Medium Medium High within 48 hours of notification.
Medium: Notify Nominated employee, HSR / OHS Committee.
Rare Low Low Low Medium Medium
Nominated employee, OHS Representative / OHS Committee
is to follow up that corrective action is taken within 7 days.
Low Notify Nominated employee, HSR / OHS Committee.
Nominated employee, HSR / OHS Committee is to follow up
that corrective action is taken within a reasonable time.

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