1 - AS 4024.1-1996 SAFEGUARDING OF MACHINERY - GENERAL PRINCIPLES
4 - PREFACE
5 - CONTENTS
9 - SECTION 1 SCOPE AND GENERAL
9 - 1.1 SCOPE
9 - 1.2 OBJECTIVE
9 - 1.3 APPLICATION
9 - 1.4 REFERENCED AND RELATED DOCUMENTS
10 - 1.5 DEFINITIONS
10 - 1.5.1 Administrative controls
10 - 1.5.2 Control device
10 - 1.5.3 Control system
10 - 1.5.4 Danger
10 - 1.5.5 Danger zone
10 - 1.5.6 Designer
10 - 1.5.7 Exposed person
11 - 1.5.8 Failure to danger
11 - 1.5.9 Failure to safety
11 - 1.5.10 Guard
11 - 1.5.11 Hazard
11 - 1.5.12 Integrity
11 - 1.5.13 Interlock
11 - 1.5.14 Lifting attachments
11 - 1.5.15 Machinery
11 - 1.5.16 Minimize
11 - 1.5.17 Negative mode
11 - 1.5.18 Operator
11 - 1.5.19 Positive mode
11 - 1.5.20 Practicable
11 - 1.5.21 Risk
11 - 1.5.22 Safe working practice
11 - 1.5.23 Safeguard
11 - 1.5.24 Safety device
11 - 1.5.25 Scotch block
11 - 1.5.26 Shall
11 - 1.5.27 Should
12 - SECTION 2 GENERAL GUIDANCE
12 - 2.1 PRINCIPLES OF MACHINE SAFETY
12 - 2.2 EXISTING MACHINERY
12 - 2.3 SELECTION OF RISK CONTROL METHODS
12 - 2.4 PHASES OF MACHINE LIFE
13 - 2.5 CONSULTATION
14 - SECTION 3 THE APPLICATION OF ERGONOMICS TO THE SAFE USE OF MACHINE SYSTEMS
14 - 3.1 GENERAL
14 - 3.2 ANTHROPOMETRY
14 - 3.2.1 General
14 - 3.2.2 Out of reach height
15 - 3.2.3 Barriers
15 - 3.2.4 Openings in guards
15 - 3.2.5 Position of controls
16 - 3.2.6 Posture
16 - 3.2.7 Space in the workplace
16 - 3.3 HUMAN PERFORMANCE
16 - 3.3.1 General
17 - 3.3.2 Reaction times
18 - 3.3.3 Movement speed
18 - 3.3.4 Strength
18 - 3.3.5 Other characteristics
18 - 3.4 HUMAN ERROR
18 - 3.4.1 General
18 - 3.4.2 Short-term memory
18 - 3.4.3 Information handling capacity
18 - 3.4.4 Habit
19 - 3.4.5 Fatigue
19 - 3.5 THE WORKING ENVIRONMENT
19 - 3.5.1 General
19 - 3.5.2 Lighting and vision
19 - 3.5.3 Noise and hearing
19 - 3.5.4 Heat and cold
19 - 3.5.5 Housekeeping
20 - SECTION 4 IDENTIFICATION OF HAZARDS
20 - 4.1 DANGERS FROM MACHINERY
20 - 4.2 MECHANICAL HAZARDS
20 - 4.2.1 Entanglement
23 - 4.2.2 Friction and abrasion
24 - 4.2.3 Cutting
24 - 4.2.4 Shear
24 - 4.2.5 Stabbing and puncture
28 - 4.2.6 Impact
28 - 4.2.7 Crushing
28 - 4.2.8 Drawing-in (see also Clause 4.2.1)
28 - 4.2.9 Compressed air or high pressure fluid injection
30 - 4.2.10 Material ejected from the machine
30 - 4.2.11 Release of potential energy
30 - 4.3 NON-MECHANICAL HAZARDS
30 - 4.3.1 General
31 - 4.3.2 Source of danger
31 - 4.3.3 Linking mechanical and non-mechanical hazards
32 - SECTION 5 RISK ASSESSMENT
40 - SECTION 6 MACHINERY DESIGN
40 - 6.1 GENERAL
40 - 6.2 ELIMINATION OF HAZARDS BY DESIGN
40 - 6.2.1 Entanglement
40 - 6.2.2 Friction and abrasion
41 - 6.2.3 Cutting
41 - 6.2.4 Shear traps
42 - 6.2.5 Impact, stabbing and puncture
42 - 6.2.6 Crushing
42 - 6.2.7 Drawing-in
43 - 6.3 CONTROL DEVICES AND SYSTEMS
43 - 6.3.1 Position
44 - 6.3.2 Identification
44 - 6.3.3 Operation
44 - 6.3.4 Controls for machinery setting or adjustment and for feeding material
45 - 6.3.5 Limited movement devices
46 - 6.3.6 Handles and handwheels
46 - 6.3.7 Emergency stop device
47 - 6.3.8 Warning signals
49 - 6.4 INDICATORS
49 - 6.5 CLUTCHES
49 - 6.6 BRAKING SYSTEM
49 - 6.6.1 General
49 - 6.6.2 Mechanical (friction) braking systems
50 - 6.6.3 Electrodynamic braking systems
51 - 6.7 SAFETY CATCHES, OVERRUN, RUN-BACK AND FALL-BACK PROTECTION DEVICES
51 - 6.8 SUSPENDED EQUIPMENT
51 - 6.8.1 Secondary means of support
51 - 6.8.2 Counterweights and similar devices
51 - 6.9 ROTATING SHAFTS, SPINDLES AND COUPLINGS
53 - 6.10 FEEDING AND TAKE-OFF DEVICES
53 - 6.11 HYDRAULIC AND PNEUMATIC SYSTEMS
53 - 6.12 ELECTRICAL SYSTEMS
54 - 6.13 WORKHOLDING DEVICES
54 - 6.13.1 Power loss during operation
54 - 6.13.2 Clamping for automatic machinery
54 - 6.13.3 Prevention of inadvertent unclamping of the workpiece
54 - 6.14 LIFTING, HANDLING AND TRANSPORT
54 - 6.15 MECHANICAL RESTRAINT DEVICE
54 - 6.15.1 General
55 - 6.15.2 Downstroking platens
55 - 6.16 LUBRICATION
55 - 6.17 STABILITY
56 - 6.18 LIGHTING
57 - 6.19 HYGIENE
57 - 6.20 SAFETY COLOURS AND SYMBOLS
57 - 6.21 ACCESS
57 - 6.21.1 Operating stations
57 - 6.21.2 Platforms and steps
58 - 6.21.3 Access for adjustment, lubrication and maintenance
58 - 6.22 ASSURANCE OF SYSTEM INTEGRITY
58 - 6.22.1 General
58 - 6.22.2 Re-programmable systems
59 - 6.22.3 Relationship between safety, reliability and availability for machinery
60 - SECTION 7 SELECTION OF SAFEGUARDS
60 - 7.1 GENERAL
60 - 7.2 ACCESS
60 - 7.2.1 Operational access
60 - 7.2.2 Maintenance access
60 - 7.2.3 Casual access
60 - 7.2.4 Safeguarding
62 - 7.3 OPERATIONAL ACCESS (WHERE ACCESS IS REQUIRED DURING NORMAL OPERATION)
63 - 7.4 MAINTENANCE ACCESS (WHERE ACCESS IS NOT REQUIRED DURING NORMAL OPERATION)
68 - SECTION 8 PHYSICAL BARRIERS - DESIGN AND CONSTRUCTION
68 - 8.1 GENERAL
68 - 8.2 TYPES OF PHYSICAL BARRIERS
68 - 8.2.1 Stationary guards
82 - 8.2.2 Moving non-interlocking guard
84 - 8.2.3 Interlocking guard
89 - 8.3 GUARD CONSTRUCTION
89 - 8.3.1 General
89 - 8.3.2 Design requirements
89 - 8.3.3 Material
90 - 8.3.4 Supports
91 - 8.3.5 Cover plates
91 - 8.4 ANTHROPOMETRIC CONSIDERATIONS
91 - 8.4.1 General
92 - 8.4.2 Opening in a guard
92 - 8.4.3 Barriers
93 - SECTION 9 SAFETY DEVICES
93 - 9.1 GENERAL
93 - 9.2 TRIP DEVICES
93 - 9.2.1 General
93 - 9.2.2 Mechanical trip device
98 - 9.2.3 Electro-sensitive safety systems
99 - 9.2.4 Pressure-sensitive systems
99 - 9.3 CONTROL DEVICE
99 - 9.3.1 General
99 - 9.3.2 Controlled movement
100 - 9.3.3 Two-hand control device
103 - SECTION 10 INTERLOCKING CONSIDERATIONS
103 - 10.1 FUNCTIONS OF AN INTERLOCK
103 - 10.2 INTERLOCKING MEDIA
103 - 10.3 TYPES OF INTERLOCKING DEVICES
104 - 10.4 INTERLOCKING PRINCIPLES
104 - 10.4.1 Control interlocking
104 - 10.4.2 Power interlocking
104 - 10.5 TYPICAL FORMS OF INTERLOCKING DEVICES
104 - 10.5.1 Interlocking device (without guard locking)
104 - 10.5.2 Interlocking device with guard locking
105 - 10.6 ACTUATION MODES OF MECHANICALLY ACTUATED POSITION DETECTORS
105 - 10.7 ARRANGEMENT AND FASTENING OF POSITION DETECTORS
106 - 10.8 ARRANGEMENT AND FASTENING OF CAMS
107 - 10.9 REDUCING THE POSSIBILITY OF COMMON CAUSE FAILURES
107 - 10.9.1 General
107 - 10.9.2 Positive and non-positive mode association of mechanically actuated position detectors
107 - 10.9.3 Cross-monitoring of position detectors
107 - 10.9.4 Power medium diversity
108 - 10.10 GUARD LOCKING DEVICE
108 - 10.11 DELAY DEVICES
109 - 10.12 DESIGN TO MINIMIZE DEFEAT POSSIBILITIES
109 - 10.12.1 General
109 - 10.12.2 Design to minimize defeat of mechanical actuated position detectors
110 - 10.12.3 Design to minimize defeat of proximity and magnetic switches
110 - 10.12.4 Design to minimize the possibility of defeating plug and socket interlocking devices
110 - 10.13 ENVIRONMENTAL CONSIDERATIONS
110 - 10.14 INTERLOCKING DEVICES INCORPORATING MECHANICALLY ACTUATED POSITION SWITCHES
110 - 10.14.1 Interlocking devices incorporating one single mechanically actuated position switch
110 - 10.14.2 Interlocking devices incorporating two mechanically actuated position switches
111 - 10.15 INTERLOCKING DEVICES INCORPORATING NON-MECHANICALLY ACTUATED POSITION SWITCHES (PROXIMITY SWITCHES AND MAGNETIC SWITCHES)
111 - 10.15.1 General
111 - 10.15.2 Equivalence with mechanically actuated position switches
111 - 10.15.3 Immunity from disturbance
111 - 10.15.4 Mutual influencing
111 - 10.15.5 Electrical operating conditions
111 - 10.15.6 Specific provision for magnetic switches
111 - 10.16 SELECTION OF INTERLOCKING DEVICES
111 - 10.16.1 General
111 - 10.16.2 Conditions of use and intended use
111 - 10.16.3 Risk assessment
113 - 10.16.4 Stopping time and access time
113 - 10.16.5 Frequency of access
113 - 10.16.6 Performance consideration
113 - 10.17 DESIGN OF SAFETY RELATED PARTS OF CONTROL SYSTEMS
113 - 10.17.1 The safety related parts of control systems
115 - 10.17.2 Category specification
117 - 10.17.3 Selection and combination of safety related parts of different categories
117 - 10.18 MECHANICAL CONSIDERATIONS
117 - 10.18.1 Interlocking devices
118 - 10.18.2 Clutches and brakes
119 - 10.18.3 Overall system design
119 - 10.18.4 Mechanical interlocking methods
120 - 10.19 HYDRAULIC AND PNEUMATIC CONSIDERATIONS
120 - 10.19.1 General
122 - 10.19.2 Hydraulic interlocking systems
123 - 10.19.3 Pneumatic system design
124 - 10.19.4 Pneumatic interlocking systems
125 - 10.20 ELECTRICAL CONSIDERATIONS
125 - 10.20.1 General
125 - 10.20.2 Overall system design
125 - 10.20.3 Electrical interlocking methods
128 - 10.20.4 Systems incorporating solid-state devices or components
129 - 10.20.5 Interconnections
130 - SECTION 11 WORKING ENVIRONMENT CONSIDERATIONS
130 - 11.1 ENVIRONMENT
130 - 11.2 CORROSION
130 - 11.3 HYGIENE AND GUARD DESIGN
130 - 11.4 COOLANT AND SWARF
130 - 11.5 GASES, MIST, FUMES, VAPOUR AND DUST
130 - 11.6 NOISE
130 - 11.7 LIGHTING
132 - SECTION 12 INSTALLATION CONSIDERATIONS
132 - 12.1 GENERAL
132 - 12.2 LAYOUT OF MACHINERY AND PLANT
132 - 12.3 MOVING PARTS OF MACHINERY
132 - 12.4 SERVICES
132 - 12.4.1 Cables and pipes
132 - 12.4.2 Access to machinery for maintenance
132 - 12.5 COMMISSIONING
134 - SECTION 13 MAINTENANCE
134 - 13.1 GENERAL
134 - 13.2 SERVICE LIFE
134 - 13.3 INSPECTION OF SAFEGUARDS
134 - 13.3.1 General
134 - 13.3.2 Inspection during production
134 - 13.3.3 Inspection during routine maintenance
134 - 13.4 REPLACEMENT OF SAFEGUARDS
134 - 13.5 GENERAL MAINTENANCE
134 - 13.6 CONFINED SPACES
135 - SECTION 14 ISOLATION AND ENERGY DISSIPATION
135 - 14.1 GENERAL
135 - 14.2 MACHINE START-UP
135 - 14.2.1 General
135 - 14.2.2 Unintended (or unexpected) start-up
136 - 14.2.3 Intended (or expected) start-up
136 - 14.3 ISOLATION AND ENERGY DISSIPATION
136 - 14.4 MEANS INTENDED FOR ISOLATION AND ENERGY DISSIPATION
136 - 14.4.1 General
136 - 14.4.2 Means for isolation from power supplies
137 - 14.4.3 Locking means
137 - 14.4.4 Energy dissipation or restraint (containment) means
139 - 14.4.5 Provisions for verification and testing
140 - SECTION 15 SAFEWORK PROCEDURES
140 - 15.1 GENERAL
141 - 15.2 INSTRUCTION AND TRAINING
141 - 15.2.1 General
141 - 15.2.2 Training topics
142 - 15.3 SAFEWORK PROCEDURES
142 - 15.3.1 General
142 - 15.3.2 Safework practices
144 - 15.3.3 Workplace inspections and audits
144 - 15.3.4 Permit to work systems
145 - 15.4 PERSONAL PROTECTION
145 - 15.5 PROVISION OF INFORMATION
145 - 15.5.1 General
145 - 15.5.2 Instruction placards and warning labels
145 - 15.5.3 Installation, operation and maintenance instructions
146 - 15.5.4 Preventative maintenance
147 - APPENDIX A - ERGONOMIC DATA
147 - A1 GENERAL
147 - A2 REACHING UP
147 - A3 UPPER LIMB REACH DISTANCE WITH FIXED FENCES
147 - A3.1 General
147 - A3.2 Reaching down and over
148 - A3.3 Reaching under
149 - A4 REACHING AROUND WITH UPPER LIMBS
151 - A5 REACHING IN AND THROUGH REGULAR OPENINGS WITH UPPER LIMBS
151 - A6 OPENINGS OF IRREGULAR SHAPE
152 - A7 LOWER LIMB REACH DISTANCE
152 - A7.1 General
152 - A7.2 Reaching in and through regular openings
153 - A8 MINIMUM GAPS TO PREVENT CRUSHING
155 - APPENDIX B - HAZARD IDENTIFICATION
155 - B1 GENERAL
155 - B2 PRELIMINARY HAZARD ANALYSIS (PHA)
155 - B3 HAZARD AND OPERABILITY STUDY (HAZOP)
155 - B4 EXAMPLES OF HAZARDS
155 - B4.1 General
155 - B4.2 Mechanical hazards
156 - B4.2 Electrical hazards
156 - B4.3 Thermal hazards
156 - B4.4 Noise hazards
156 - B4.5 Vibration hazards
156 - B4.6 Radiation hazards
157 - B4.7 Hazards generated by material and substances
157 - B4.8 Neglect of ergonomic principles
157 - B4.9 Combination of hazards
157 - B5 HAZARDOUS EVENTS
157 - B6 ADDITIONAL HAZARDS AND EVENTS DUE TO MOBILITY
158 - B7 ADDITIONAL HAZARDS AND EVENTS DUE TO LIFTING
159 - APPENDIX C - METHODS FOR ANALYSING HAZARDS AND ESTIMATING RISKS
159 - C1 GENERAL
159 - C2 ' WHAT-IF' METHOD
159 - C3 FAILURE MODE AND EFFECT ANALYSIS (FMEA)
159 - C4 DEFI METHOD
159 - C5 MOSAR METHOD (METHOD ORGANIZED FOR A SYSTEMIC ANALYSIS OF RISKS)
160 - C6 FAULT TREE ANALYSIS
160 - C7 DELPHI TECHNIQUE
161 - APPENDIX D - TWO-HAND CONTROL DEVICES
169 - APPENDIX E - INTERLOCKING DEVICES
169 - E1 GUARD-OPERATED INTERLOCKING DEVICE WITH ONE CAM-OPERATED POSITION DETECTOR
169 - E1.1 Principle
169 - E1.2 Advantages
169 - E1.3 Disadvantages
169 - E1.4 Remarks
169 - E1.5 Example: Electrical interlocking device incorporating one single cam-operated switch (see Clause 10.12.2.1)
170 - E2 GUARD-OPERATED INTERLOCKING DEVICE WITH TONGUE-OPERATED SWITCH
170 - E2.1 Principle:
170 - E2.2 Advantages
170 - E2.3 Disadvantage
170 - E2.4 Remark
171 - E3 DIRECT (MECHANICAL) INTERLOCKING BETWEEN GUARD AND START/STOP MANUAL CONTROL
171 - E3.1 Principle
171 - E3.2 Advantage
171 - E3.3 Remark
171 - E4 CAPTIVE-KEY INTERLOCKING DEVICE
171 - E4.1 Description
171 - E4.2 Principle
171 - E4.3 Advantages
171 - E4.4 Remarks
173 - E5 TRAPPED-KEY INTERLOCKING DEVICE
173 - E5.1 Principle
173 - E5.2 Advantages
174 - E5.3 Disadvantages
174 - E5.4 Remarks
174 - E6 PLUG AND SOCKET INTERLOCKING DEVICE (PLUG/SOCKET COMBINATION)
174 - E6.1 Principle
174 - E6.2 Advantage
175 - E6.3 Disadvantages
175 - E6.4 Remarks
175 - E7 GUARD-OPERATED INTERLOCKING DEVICE INCORPORATING TWO CAM-OPERATED POSITION DETECTORS
175 - E7.1 Principle
175 - E7.2 Advantages
175 - E7.3 Remark
177 - E8 MECHANICAL INTERLOCKING BETWEEN A GUARD AND A MOVABLE ELEMENT
177 - E8.1 Principle
177 - E8.2 Remarks
177 - E9 ELECTRICAL INTERLOCKING DEVICE INCORPORATING MAGNETICALLY ACTUATED (MAGNETIC) PROXIMITY SWITCHES
177 - E9.1 Principle
177 - E9.2 Advantages
177 - E9.3 Disadvantages
178 - E9.4 Remarks
178 - E10 ELECTRICAL INTERLOCKING DEVICE INCORPORATING TWO PROXIMITY DETECTORS
178 - E10.1 Principle
178 - E10.2 Advantages
178 - E10.3 Disadvantages
178 - E10.4 Remarks
179 - E11 PNEUMATIC/HYDRAULIC INTERLOCKING DEVICES
179 - E11.1 Principle
179 - E11.2 Remark
179 - E12 INTERLOCKING DEVICE WITH SPRING APPLIED/POWER RELEASED GUARD LOCKING DEVICE
179 - E12.1 Principle
179 - E12.2 Remark (valid for both variants)
181 - E13 INTERLOCKING DEVICE WITH GUARD LOCKING, AND MANUALLY OPERATED DELAY DEVICE
181 - E13.1 Principle
181 - E13.2 Advantage
182 - APPENDIX F - GUIDANCE FOR THE SELECTION OF CATEGORIES
182 - F1 SCOPE
182 - F2 METHOD
182 - F3 GUIDANCE IN SELECTING PARAMETERS S, F AND P FOR RISK ESTIMATION
182 - F3.1 Severity of injury (S1 and S2)
182 - F3.2 Frequency or exposure time to the hazard (F1 and F2)
183 - F3.3 Possibility of avoiding the hazards (P1 and P2)
185 - APPENDIX G - SELECTION OF CATEGORY AND INTERLOCK SYSTEM
185 - G1 GENERAL
185 - G2 CATEGORY OF CONTROL SYSTEM SELECTION
185 - G3 EXAMPLES OF USE
185 - G3.1 Machine details
185 - G3.2 With manual loading
186 - G3.3 With automatic loading