1 University of Glasgow School of Engineering UGRacing Formula Student Garage James Watt South Building Level 4 CODE OF PRACTICE Emergency telephone number is 4444 Fire extinguishers located next to emergency exit door First aid kit and eye wash kit in storage shelves next to welding area Safety glasses and other PPE in storage shelves Emergency exit next to roller door Emergency isolation buttons are positioned on the wall all around the workshop. 1) Only trained students and staff will be allowed to operate the power and machine tools and ancillary equipment in the workshop. Training will be provided by experienced team members and by video. 2) No-one may use the workshop and its equipment unaccompanied. 3) Everyday clothing should normally be covered while working in the workshop so Personal Protective Equipment (PPE) (dust coats/overalls, safety specs, safety footwear, ear-defenders and respirators) are provided and must be worn when operating machinery and carrying out tasks around the workshop as necessary. Loose clothing and jewellery should be removed, and long hair tied back as appropriate. 4) Specialist equipment and PPE is provided for use with the welding equipment and other hotworking processes. These processes will be carried out in designated welding area where extraction and relevant eye protection is provided. Users in this area must ensure the safety and protection of others in the local vicinity. Where welding is of a larger nature, the main garage area is used, with welding screens placed appropriately. 5) All walkways will be kept free of blockages as far as possible depending on activities within the workshop. 6) Compressed gas cylinders will always be attached to suitable rack or trolley. Transportation of gas cylinders is carried out using appropriate trolleys. 7) All workshop users are responsible for good housekeeping. Workshop users should replace tools and equipment immediately after use and remove swarf, filings and other debris from machines, workbenches and the floor as soon as possible. Tools should not be left on machinebeds while the machine is running. The floor should be kept clear of obstructions, and all spillages must be cleaned up immediately. Metal waste bins are provided and should be used 8) Portable extractors should be used when generating excessive dust, fumes and or cuttings. should be fitted with the correct filters for each process. Appropriate masks should be worn when creating dust or fumes. 9) Separate risk assessments are available which covering normal workshop activities. A separate risk assessment should be produced when the need arises for activities not covered by the garage risk assessment, such as use of new/unfamiliar materials, chemicals, solvents etc.
2 UGRacing Formula Student Garage Risk Assessment University of Glasgow School of Engineering Location: Building: Formula Student Workshop James Watt South, University Avenue, Glasgow G12 8QQ Level 4 lab besides goods lift Summary of activities covered by this assessment: Static power tools Use of hand held portable power tools Hand tool operations Electric welding/soldering Human factors Workplace and working environment Manual handling and use of lifting equipment Electrical safety Compressed air Compressed gases Solvents and fuels Engine tuning Assessed by Name : James Beeley Signature : Date : Oct 2014 Approved by Name : : Andrew Glidle Signature : Date : Oct 2014 Further actions required/comments: Note: engine dynamometer is covered by a separate risk assessment Dates of Reviews January 2012 Oct 2014 Oct 2016
3 1. Significant hazards Workshop Activity Static Power Tools Hand held/portable power tools Hand / foot operated machine tools Hand tools Electric welding/soldering Human factors Workplace and working environment Manual handling operations Electricity in the workplace Materials Compressed air Compressed gases Solvents and fuels Engine tuning Hazards associated with Activity Entanglement, friction/abrasion, cutting, shearing, stabbing/puncturing, impact, crushing, drawing in of body parts to moving/rotating machinery, ejection Electric shock/burns/fire, materials, dust, small projectiles, noise, cuts and abrasions, trips. Cutting, shearing, crushing Abrasions, stabbing, dust temperature, hot work-pieces, fire, materials, fumes, compressed gases, flashbacks electrical, UV radiation, arc flashes, noise Unsafe person and practices Access, slips, trips, falls, heating, lighting, ventilation, fume extraction, noise, welfare facilities and fire. Musculo-skeletal injury, cuts, abrasions, impact. Electric shock, burns, fire. Inhalation of dusts, fumes, aerosols, skin/eye contact. Injection and ejection Injection, ejection, fire and explosion Fire, explosion, vapour inhalation, poisoning Fire, explosion, entanglement, friction/abrasion, cutting, shearing, stabbing/puncturing, impact, crushing, drawing in of body parts to moving/rotating machinery, ejection, noise, fume poisoning, electric shock, burns 2. Individuals who may be harmed by the hazards. Those who may be harmed Members of the team Staff supervising/assisting the UGRacing project Estates & Buildings/security/cleaning staff Other visitors, including schools open day attendees Staff and postgrads using research lab area in garage
4 Hazards associated with use of powered machinery. Entanglement, Friction/Abrasion, Cutting, Shearing, Stabbing/Puncturing, Drawing in, and Ejection. (Electrical hazards are dealt with in the section on Electricity in the workplace ) out Severity to Mitigate Risk hood Guards are either permanent fixtures, or are available to be fitted to machines as necessary. They are correctly adjusted and used by operators to prevent injury from the following: Moving/rotating machine parts. Moving/rotating cutting tools and blades. Moving/rotating work-pieces Flying cuttings Abrasive wheels or parts thereof Work-pieces are securely held by suitable vices, fixtures and clamps. Emergency stop/brake mechanisms are fitted as appropriate. Space is available around machines to allow safe movement and prevent crushing and impacts. Abrasive wheels are mounted and dressed by trained and competent persons. Work-rests on bench and pedestal grinders are properly set by experienced and competent persons. Machine operators wear suitable protective clothing including lab coats and eye/face protection. Loose clothing and jewelery, including rings with large protrusions, are not worn. Long hair is required to be tied back. Machinery is kept in good working condition by regular maintenance and cleaning.
5 Hazards associated with maintenance of powered machinery: Entanglement/ drawing in, crushing, electricity. Hazards associated with the use of hand held/portable power tools: Electric shock, burns, fire. Materials, dust and small projectiles Noise Cuts, abrasions. Trips. out Severity to Mitigate Risk hood Machinery is stopped and electrically isolated during maintenance. Electrical fault diagnosis or testing requiring power to be switched on is only done by experienced, competent electrical engineers working to IET standards. Portable electrical equipment and power tools are maintained, inspected and PAT tested 6 or 12 monthly in compliance with the University Electrical Safety policy. An in line Residual Current Device (RCD) is provided and used. Eye, face, respiratory protection and gloves are provided and used and a flexible dust extraction arm is provided and used as necessary. Ear defenders are provided and used where noise levels are high. Guards are fitted, correctly adjusted and used where required and are periodically checked and maintained. Gloves and overalls/lab coats are provided and used as necessary to protect hands and body. Trailing leads are routed away from walkways or are covered to reduce trip hazard.
6 Hazards Associated with the use of hand/ foot operated machine tools: out Severity to Mitigate Risk hood Cutting, shearing, and crushing. Hazards associated with the use of hand tools: Cutting, crushing, abrasions, stabbing, dust Hazards associated with hot work processes and electric welding/soldering: temperature, hot work-pieces, fire, materials, fumes, compressed gases, flashbacks Electrical, UV Radiation, arc flashes, noise Moderate Moderate Guards are fitted and used to prevent access to shear blades, punch tools and dies. Suitable tools for holding and moving work-pieces are provided. Suitable hand tools in good condition are provided and maintained as appropriate. Eye protection, overalls /lab coats, gloves, safety shoes and dust masks are provided and used where appropriate. Suitable tools for holding and moving hot work-pieces are provided and used. Suitable fire resistant overalls, lab coats, aprons, hats and gloves are used. Suitable welding shields and goggles are supplied and used and maintained as appropriate. Working area is kept clear of combustible materials. Materials are selected carefully to minimise the health risks. Adequate ventilation, or a flexible fume extraction arm is provided and used. Face masks are supplied and used where appropriate. Mobile welding screens are provided and used. Electric welders are checked periodically by a competent electrical technician in line with the University Electrical Safety Policy. Ear defenders are provided and used where appropriate. Very Low Very Low
7 Hazards Associated with Human Factors: Unsafe person/practices out Severity to Mitigate Risk hood Only people who are adequately trained or are experienced and deemed as competent are allowed to work independently in the workshop. New members, or others with limited experience, are instructed and closely supervised when working in the area. A range of personal protective equipment is provided and instructions on its proper use and maintenance are provided as appropriate. Lone working is not allowed in the workshop. Hazards associated with the workplace and the working environment: Access. Slips, trips, fall. There is adequate provision of first aiders and FA equipment. Access to the workshop is controlled by code lock. The consumption of food and drink is not allowed in the workshop. Moderate Moderate A good standard of housekeeping is maintained. Passages are kept free of obstructions. Spills and/or leaks are dealt with promptly. Storage and work areas are kept separate. Floor surfaces are sound and are painted periodically.
8 Environmental factors. (Heating, lighting, ventilation/fume extraction.) Noise. out Severity to Mitigate Risk hood Fan assisted convector heaters are provided. General and local lighting is provided Fume extraction is provided by means of a 24 Dia, high level, general extract fan, a flexible arm and several local expelair fans. Ventilation is by means of a variable speed, filtered, ducted fresh air supply fan. Ear defenders are provided and used when required. Where noise levels are likely to exceed 85dB (A) this can be verified using meter available in the department and measures to reduce noise level and/or protect people working in the vicinity are taken as appropriate. Welfare facilities. Fire. Adequate facilities for personal hygiene are provided. Sinks, hot water, soap and towels are provided. Toilet facilities are available nearby. A common room for the consumption of food and drink is provided. A conditioned drinking water supply is available in the common room. A full detection fire alarm system is in place, maintained and tested. Adequate fire escape routes are provided, sign posted and kept clear of obstructions. Adequate emergency lighting is provided. Fire drills are done twice annually. Appropriate fire extinguishers are accessible at strategic points in the workshop and are properly maintained. Training in the use of fire extinguishers is provided through the UFO. Combustible waste materials are disposed of on a daily basis.
9 Hazards associated with the use of electricity in the workplace: Electric shock, burns, fire. Hazards associated with Manual Handling Operations. out Moderate Severity to Mitigate Risk hood Moderate Fixed and portable electrical equipment is maintained and tested by experienced and competent electrical technicians in accordance with the University s Electrical Safety Policy. Musculo-skeletal injury, cuts, abrasions, impacts. Hazards associated with the use of materials: Moderate Materials are stored so as to minimise manual handling. Key staff are trained and/or are experienced in manual handling tasks. Adequate lifting and moving equipment is provided and used only by trained and experienced staff. Lifting equipment is maintained and inspected in accordance with the Lifting Operations & Lifting Equipment Regulations Gloves and safety glasses are provided and used. Training specific to handling of compressed gases has been undertaken by appropriate team members Materials are selected so as to avoid risks to health where possible. Proprietary products are used in accordance with manufacturers instructions or safety data sheets. COSHH assessments are done for all substances hazardous to health. All substances, including cleaning materials and oils are stored in appropriate locations and labelled as required. Inhalation of dusts, fumes and aerosols. Where possible harmful dusts, fumes and aerosol vapours are extracted at source using a portable fume extraction unit. ( Borrowed from Civil Engineering when required) Face masks are provided and used as required.
10 Hazards associated with the use of compressed air and gases: Compressed air: out Severity to Mitigate Risk hood Compressed air system is checked for leaks or malfunction on a regular basis by workshop staff. Air compressors are inspected annually by Zurich Insurance Services as part of a University wide programme. All faults are repaired as per inspectors recommendations. Compressors are serviced in house by a competent technician. Compressed gases: Only trained and experienced technicians handle compressed gases. Workshop gas systems are checked and maintained to BCGA standards by a trained technician Hazards associated with the use of solvents and fuels Fire, explosion, vapour inhalation, poisoning. Solvents/fuels stored in appropriate and clearly labelled containers, caps properly secured, and kept in appropriate metal solvent cabinet when not in use. Proper ventilation. Solvents kept well away from heat ignition sources, e.g. welding, grinding, soldering. Smoking/naked flames prohibited.
11 Hazards associated with engine tuning: Fire, explosion, burns out Severity to Mitigate Risk hood Properly constructed, fully enclosed and mechanically robust engine test rig fuel system. Inspection prior to use. Labelling of hot components. Appropriate fire extinguisher within immediate reach. Entanglement, friction/abrasion, cutting, shearing, stabbing/puncturing, impact, crushing, drawing in, ejection Noise Fume poisoning Electric shock Enclosure of exposed moving parts in engine test rig. Solid construction. Inspection prior to use. Operators wear suitable protective clothing including overalls and eye/face protection. Loose clothing and jewelery, including rings with large protrusions, are not worn. Long hair is required to be tied back. Ear protection to be used. Appropriate exhaust silencer fitted. Sufficient ventilation/use of fume extraction system. Sufficient insulation of high voltage ignition system.
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