Safe Design, Manufacture, Import and Supply of Plant. Draft Code of Practice

Transcription

1 Safe Design, Manufacture, Import and Supply of Plant Draft Code of Practice

2 Table of Contents FOREWORD... 4 SCOPE AND APPLICATION INTRODUCTION The meaning of key terms Who has health and safety duties in relation to plant? What is required to manage health and safety risks associated with plant? 6 2 HOW TO MANAGE PLANT RISKS Identifying hazards Assessing the risks Controlling the risks Reviewing risk control measures Information sources SAFE DESIGN OF PLANT What is safe design? The role of designers Integrating safe design and risk management Pre-design and concept development phase Design phase Testing and examination of plant Providing information Registering plant design DESIGN CONSIDERATIONS Physical characteristics of users Design to facilitate safe use Reasonably foreseeable misuse Minimising human error Environmental conditions Erection and installation Maintenance Guarding Operator control devices Emergency stops Failure of the control circuit Warning devices MANUFACTURE OF PLANT The role of manufacturers Plant construction Testing and examination of plant Information about the safe use of plant Registration of plant design Item registration IMPORT AND SUPPLY OF PLANT Examination and testing of plant Information about the safe use of plant Compatibility of plant Imported plant PAGE 2 OF 48

3 6.5 Design registration Hire of plant Second-hand plant SPECIFIC RISK CONTROLS Confined spaces Manual tasks Noise Energy sources Static electricity Lightning Fire and explosion Plant capable of entangling an operator Vibration Exposure to radiation Risk of being trapped Hazardous chemicals Combined plant Stability Mechanical or structural failure during operation Software Lighting APPENDIX A EXAMPLES OF TECHNICAL STANDARDS APPENDIX B REGISTRABLE PLANT APPENDIX C DESIGN SOURCES OF HUMAN ERROR PAGE 3 OF 48

4 FOREWORD This Code of Practice on the safe design, manufacture, import and supply of plant is an approved code of practice under section 274 of the Work Health and Safety Act (the WHS Act). An approved code of practice is a practical guide to achieving the standards of health, safety and welfare required under the WHS Act and the Work Health and Safety Regulations (the WHS Regulations). A code of practice applies to anyone who has a duty of care in the circumstances described in the code. In most cases, following an approved code of practice would achieve compliance with the health and safety duties in the WHS Act, in relation to the subject matter of the code. Like regulations, codes of practice deal with particular issues and do not cover all hazards or risks which may arise. The health and safety duties require duty holders to consider all risks associated with work, not only those for which regulations and codes of practice exist. Codes of practice are admissible in court proceedings under the WHS Act and Regulations. Courts may regard a code of practice as evidence of what is known about a hazard, risk or control and may rely on the code in determining what is reasonably practicable in the circumstances to which the code relates. Compliance with the WHS Act and Regulations may be achieved by following another method, such as a technical or an industry standard, if it provides an equivalent or higher standard of work health and safety than the code. An inspector may refer to an approved code of practice when issuing an improvement or prohibition notice. This Code of Practice has been developed by Safe Work Australia as a model code of practice under the Council of Australian Governments Inter-Governmental Agreement for Regulatory and Operational Reform in Occupational Health and Safety for adoption by the Commonwealth, state and territory governments. A draft of this Code of Practice was released for public consultation on 2 April 2012 and was endorsed by the Select Council for Workplace Relations on [to be completed]. SCOPE AND APPLICATION This Code provides practical guidance for persons conducting a business or undertaking who design (including redesign or modification of a design), manufacture, import or supply plant that is used, or could reasonably be expected to be used, at a workplace on how to meet the requirements under the WHS Act and Regulations. The Code of Practice: Managing Risks of Plant on the Workplace provides guidance on how to manage health and safety risks of plant once it is in the workplace, from installation, commissioning and use through to decommissioning and dismantling. How to use this code of practice In providing guidance, the word should is used in this Code to indicate a recommended course of action, while may is used to indicate an optional course of action. This Code also includes various references to provisions of the WHS Act and Regulations which set out the legal requirements. These references are not exhaustive. The words must, requires or mandatory indicate that a legal requirement exists and must be complied with. PAGE 4 OF 48

5 1 INTRODUCTION Plant is a major cause of workplace death and injury in Australian workplaces. There are significant risks associated with using plant and severe injuries can result, including: limbs amputated by unguarded moving parts of machines being crushed by mobile plant sustaining fractures from falls while accessing, operating or maintaining plant electric shock from plant that is not adequately protected or isolated burns or scalds due to contact with hot surfaces, or exposure to flames or hot fluids. Other risks include hearing loss due to noisy plant and musculoskeletal disorders caused by manually handling or operating plant that is poorly designed. Designers, manufacturers, importers and suppliers have an important role in ensuring, so far as is reasonably practicable, that the plant they design, manufacture, import or supply is safe before it is introduced and used in the workplace. 1.1 The meaning of key terms Plant includes any machinery, equipment, appliance, container, implement and tool, and includes any component or anything fitted or connected to any of those things. Plant includes items as diverse as lifts, cranes, computers, machinery, conveyors, forklifts, vehicles, power tools and amusement devices. Plant that relies exclusively on manual power for its operation and is designed to be primarily supported by hand, for example a screw driver, is not covered by the WHS Regulations. The general duty of care under the WHS Act applies to this type of plant. Certain kinds of plant, such as forklifts, cranes and some pressure equipment, require a licence from the WHS regulator to operate and some high-risk plant must also be registered with the WHS regulator. Competent person means a person who has acquired through training, qualification or experience the knowledge and skills to carry out the task. A competent person has a more specific meaning in the following circumstances: For design verification, the person must have the skills, qualifications, competence and experience to design the plant or verify the design. For inspection of plant for registration purposes the person must have: o educational or vocational qualifications in an engineering discipline relevant to the plant being inspected, or o knowledge of the technical standards relevant to the plant being inspected. For inspection of mobile cranes, tower cranes and amusement devices the person must: o have the skills, qualifications, competence and experience to inspect the plant, and be registered under a law that provides for the registration of professional engineers (in jurisdictions where such a law exists), or o be determined by the WHS regulator to be a competent person. Fail safe means a state or condition where, if any component or function of the plant fails, a system exists to prevent any increase in the risks. For example, if the primary hoist brake fails on a crane lifting a person in a workbox, the secondary hoist brake will prevent uncontrolled dropping of the workbox. However, once the secondary brake is engaged, a PAGE 5 OF 48

6 lower level of safety has been reached. The situation must be made safe and the fault rectified so that the fail safe capability is re-established. The reliability or safety integrity of the fail safe system should be commensurate with the determined level of risk (for example, Category 1 to Category 4 applied in AS 4024: Safety of Machinery). 1.2 Who has health and safety duties in relation to plant? A person conducting a business or undertaking has the primary duty under the WHS Act to ensure, so far as is reasonably practicable, that workers and other persons are not exposed to health and safety risks arising from the business or undertaking. This duty includes ensuring, so far as is reasonably practicable: the provision and maintenance of safe plant, and the safe use, handling, storage and transport of plant. Persons who conduct a business or undertaking involving the management or control of fixtures, fittings or plant at a workplace must ensure, so far as is reasonably practicable, that the fixtures, fittings and plant are without risks to the health and safety of any person. Designers, manufacturers, suppliers, importers and installers of plant must also ensure, so far as is reasonably practicable, that the plant they design, manufacture, import, supply or install is without risks to health and safety. The WHS Regulations include more specific duties for designers, manufacturers, importers and suppliers of plant in relation to the risks of confined spaces, noise and musculoskeletal disorders. As there are generally a number of people involved with plant during its lifecycle (i.e. from its design through to its use and eventual disposal), a person can have more than one duty and more than one person can have the same duty at the same time. In some circumstances, a manufacturer, importer or supplier of plant will also have the duties of a designer. Officers, for example, company directors, have a duty to exercise due diligence to ensure that the business or undertaking complies with the WHS Act and Regulations. This includes taking reasonable steps to ensure that the business or undertaking has and uses appropriate resources and processes to eliminate or minimise risks that arise from plant used in the workplace. Workers have a duty to take reasonable care for their own health and safety and must not adversely affect the health and safety of other persons. Workers must comply with any reasonable instruction and cooperate with any reasonable policy or procedure relating to health and safety at the workplace. 1.3 What is required to manage health and safety risks associated with plant? R : In order to manage risk under the WHS Regulations, a duty holder must: identify reasonably foreseeable hazards that could give rise to the risk eliminate the risk so far as is reasonably practicable if it is not reasonably practicable to eliminate the risk, minimise the risk so far as is reasonably practicable by implementing control measures in accordance with the hierarchy of control maintain the implemented control measure so that it remains effective PAGE 6 OF 48

7 review, and if necessary revise, risk control measures so as to maintain, so far as is reasonably practicable, a work environment that is without risks to health and safety. This Code provides guidance on how to manage the risks associated with plant by following a systematic process that involves: identifying hazards if necessary, assessing the risks associated with these hazards, implementing and maintaining risk control measures reviewing risk control measures. Designers, manufacturers, importers and suppliers of plant should use this process as a way of making plant as safe as possible before it is used in the workplace. General guidance on the risk management process is available in the Code of Practice: How to Manage Work Health and Safety Risks. Providing and obtaining information Designers, manufacturers, importers and suppliers all have obligations to provide information about the plant to enable other duty holders to fulfil the responsibilities they have in managing the risks associated with it. This information must be given to each person to whom the plant (or its design) is provided. Information must be passed on from the designer through to the manufacturer and supplier to the end user. This information includes: the purpose for which plant was designed or manufactured the results of any calculations, analysis, testing or examination, and any conditions necessary for the safe use of the plant. Consulting workers A person conducting a business or undertaking must consult, so far as is reasonably practicable, with workers who carry out work for the business or undertaking who are (or are likely to be) directly affected by a work health and safety matter. If the workers are represented by a health and safety representative, the consultation must involve that representative. Consultation with workers and their health and safety representatives is required at each step of the risk management process. If you are designing or modifying plant for use in your own workplace, you must consult your workers so far as is reasonably practicable, as the plant and the way it is used may affect their health and safety. Your workers may have practical suggestions or potential solutions that can be included at the design stage. Consulting, cooperating and coordinating activities with other duty holders A person conducting a business or undertaking must consult, cooperate and coordinate activities with all other persons who have a work health or safety duty in relation to the same matter, so far as is reasonably practicable. Often, many different businesses or undertakings are involved in the design, manufacture, import and supply of an item of plant and their decisions may positively or negatively affect the safety of the product. In these situations, each duty holder will have health and safety responsibilities related to the safety of the plant. Where it is reasonably practicable to do so, the duty holders involved must consult each other on the risks associated with the plant and work together in a cooperative and coordinated way to control the risks. PAGE 7 OF 48

8 Further guidance on consultation is available in the Code of Practice: Work Health and Safety Consultation, Cooperation and Coordination. PAGE 8 OF 48

9 2 HOW TO MANAGE PLANT RISKS 2.1 Identifying hazards Identifying hazards involves finding all of the things and situations that could potentially cause harm to people. Hazards associated with plant generally arise from: The plant itself: For example, hazards associated with a forklift would include hazards relating to its mobility, it s electrical, hydraulic and mechanical power sources, its moving parts, its load-carrying capacity and operator protection. How and where the plant is used: The forklift, for example, may have hazards arising from the kind of loads it is used to lift, the size of the area in which it is used and the slope or evenness of the ground. Things to consider when looking for hazards Possible kinds of hazard Could the plant cause injury due entanglement, crushing, trapping, cutting, stabbing, puncturing, shearing, abrasion, tearing or stretching? Could the plant create hazardous conditions due to pressurised content, electricity, noise, radiation, friction, vibration, fire, explosion, temperature, moisture, vapour, gases, dust, ice, hot or cold parts? Could the plant cause injury or ill health due to poor ergonomic design? Suitability How suitable would the plant be for its intended purpose? What could happen if it was used for a purpose other than the intended purpose? How suitable are the materials used to make the plant? How suitable are any accessories to the plant? In what condition are they? How stable is the plant? Might it roll over? If the plant is intended to lift and move people, equipment or materials, how capable is it of doing this? Will there be an effective back-up system to support the load? Access What sort of access will be required during installation, operation, maintenance and in an emergency? Will workers be able to have safe access without injury from the plant itself or the risk of slips, trips and falls (walkway, gantry, elevated work platform, fixed ladders)? Location How would the plant affect the safety of the area where it will be located (e.g. its impact on design and layout of the workplace)? How would the location affect the safety of the plant (e.g. environmental conditions, terrain and work area)? Are there likely to be other people or other plant in the vicinity? What effect would this have? Systems of work What systems of work would be associated with the plant? Could they create any hazards? Would the plant s safety depend on the competency of its operators? What kind of training, information, instruction and supervision is needed for workers and other persons who may need to operate or be near the plant? PAGE 9 OF 48

10 Abnormal situations What abnormal situations, misuse or fluctuation in operating conditions can you foresee? What effects would failure of the plant have? Would it result in loss of contents, loss of load, unintended ejection of work pieces, explosion, fragmentation, collapse of parts? Would it be possible for the plant to move or be operated inadvertently? 2.2 Assessing the risks A risk assessment involves considering what could happen if someone is exposed to a hazard and the likelihood of it happening. A risk assessment can be undertaken with varying degrees of detail, depending on the complexity of the plant and the type of information available, and may involve specific risk analysis tools and techniques. A risk assessment is unnecessary if you already know the risk and how to control it. To assess the risk associated with plant hazards you have identified, you should consider the following: how often and for how long people would be exposed to each of the potentially hazardous situations you have identified (this affects likelihood as the longer and the more frequent the exposure to a potential hazard, the more likely it is to cause harm) how many people would be exposed to the potential hazard at the same time (this affects the consequence) both technical and human factors, including a person s ability to change behaviour to compensate for design changes. 2.3 Controlling the risks The ways of controlling risks are ranked from the highest level of protection and reliability to the lowest. This ranking is known as the hierarchy of risk control. The WHS Regulations require duty holders to work through this hierarchy to choose the control that most effectively eliminates, or where that is not reasonably practicable, minimises the risk in the circumstances. Specific controls are required under the WHS Regulations for certain types of plant, such as: powered mobile plant plant that lifts or suspends loads industrial robots lasers pressure equipment scaffolds. Elimination The most effective control measure is to remove the hazard or hazardous work practice associated with the plant. Many hazards can be addressed at the design, manufacture, supply and installation stages. For example, designing machinery to produce low noise levels is more effective than having to provide workers with personal hearing protection. This also avoids costly modifications to plant after it is purchased. If elimination is not reasonably practicable, you must minimise the risk by: Substitution substitute the plant (or hazardous parts of it) with plant that is safer. For example, a manufacturer may be able to substitute a component with one that has higher heat tolerance. PAGE 10 OF 48

11 Isolation separate the hazardous plant from people, either by distance or physical barrier. For example plant could be specified for use in an isolated or controlled environment. Engineering controls include modifications to tools or equipment, for example an importer could install guards to prevent contact with moving parts of machinery or retrofit a roll over protective structure on a tractor. If risk remains, it must be minimised by implementing administrative controls, so far as is reasonably practicable, for example using a lock-out system of work to ensure that plant can be physically isolated from its power source while maintenance or cleaning work is being done. Providing training and supervision, using warning signs or arranging work to minimise the time spent near noisy machinery are all examples of administrative controls. Any remaining risk must be minimised with suitable personal protective equipment (PPE), such as providing workers with breathing protection, hard hats, gloves, aprons and protective eyewear. Administrative control measures and PPE rely on human behaviour and supervision, and used on their own, tend to be least effective in minimising risks. Combinations of control measures In many cases, a combination of control measures will provide the best solution. For example, protecting workers from flying debris when using a concrete cutting saw may involve guarding the blade (engineering), isolating the work area by using barriers (isolation) and signs (administrative), and providing PPE such as a face shield. 2.4 Reviewing risk control measures The control measures that are implemented must be reviewed, and if necessary, revised to make sure they work as planned and that no new hazards have been introduced by the control measures. A person conducting a business or undertaking must review and as necessary revise control measures: when the control measure is not effective in controlling the risk before a change at the workplace that is likely to give rise to a new or different health and safety risk that the control measure may not effectively control if a new hazard or risk is identified if the results of consultation indicate that a review is necessary if a health and safety representative requests a review. Designers, manufacturers, importers and suppliers of plant may use quality assurance processes to check that the plant effectively minimises health and safety risks. Obtain feedback from users of the plant to determine whether any improvements can be made to make it safer. 2.5 Information sources There are a range of sources that may assist in managing risks associated with the plant and the systems of work used in connection with the plant. Researching information WHS legislation, codes of practice and technical standards covering design, manufacture, testing and use of plant Injury, faults, incident and accident reports, and plant failure data kept by manufacturers and users of the same or similar types of plant PAGE 11 OF 48

12 Statistics, hazard alerts or other reports from relevant statutory authorities, unions and employer associations, specialists, professional bodies representing designers, manufacturers, or engineers Information and documentation supplied by designers or manufacturers on safety and health issues, such as test reports on previous designs or similar plant Relevant reports or articles from occupational health and safety journals, technical references or data bases. Inspection and testing Inspect plant that has failed and been returned by users Develop prototypes, and inspect and test their design and manufacture Conduct walk-through surveys of the workplace where the plant will be used before beginning the design process and while the plant is being installed or erected (the latter to look for hazards which may be introduced during installation). Consultation Where possible, talk to other designers, manufacturers, installers and users. People actually working with the same or similar plant are often well aware of what can go wrong and why, and how the work environment can change. It also enables any issues to be discussed, for example the practicality of substituting materials in the manufacturing process. PAGE 12 OF 48

13 3 SAFE DESIGN OF PLANT 3.1 What is safe design? Safe design means the integration of control measures early in the design process to eliminate or, if this is not reasonable practicable, minimise risks to health and safety throughout the life of the plant being designed. The safe design of any type of plant will always be part of a wider set of design objectives, including practicability, aesthetics, cost and functionality. These sometimes competing objectives need to be balanced in a manner that does not compromise the health and safety of those potentially affected by the plant over its life. Safe design begins at the concept development phase when choices are made about design, materials used and methods of manufacture. Safer plant will be created when hazards and risks that could impact on downstream users over the lifecycle are eliminated or minimised during design and before manufacture. In these early phases there is greater scope to design-out hazards or incorporate risk control measures that are compatible with the original design concept and functional requirements of the product. 3.2 The role of designers A designer is a person conducting a business or undertaking whose profession, trade or business involves them in: preparing sketches, plans or drawings for plant that is to be used or could reasonably be expected to be used at a workplace, including variations to a plan or changes to the plant making decisions for incorporation into a design that may affect the health or safety of persons who manufacture, use or carry out other activities in relation to the plant. Designers include design professionals such as engineers, industrial designers and designers of plant systems such as software and electrical systems. A person will also have the duties of a designer if they alter the design during manufacture, or alter existing plant, so that new measures for controlling risk are required. For example, if the maximum working radius of a mobile crane is increased by fitting a longer boom, a new load chart needs to be prepared to control the increased risk of the crane overturning. The person designing the boom extension should contact the original designer to ensure the new boom extension does not compromise the existing design criteria or safety factors. Consider the lifecycle Safe design applies to every stage in the lifecycle, from conception through to disposal. The WHS Act requires the designer to ensure, so far as is reasonably practicable, that the plant is designed to be without risks to the health and safety of persons who: use the plant for a purpose for which it was designed store the plant at a workplace carry out any reasonably foreseeable activity at a workplace in relation the manufacture, assembly, use, storage, decommissioning, dismantling or disposal of the plant, or are at or in the vicinity of a workplace and are exposed to the plant or whose health and safety may be affected by an activity related to the plant. This means thinking about potential hazards and design solutions as the plant is manufactured, transported, installed, commissioned, operated, maintained, repaired, de-commissioned, dismantled and disposed of or recycled PAGE 13 OF 48

14 Knowledge and capability In addition to core design capabilities, the following skills and knowledge should be demonstrated or acquired by a designer: knowledge of work health and safety legislation, codes of practice and other regulatory requirements understanding the intended use of the plant throughout its lifecycle knowledge of hazard identification, risk assessment and control methods knowledge of technical design standards, and the ability to source and apply relevant data on human dimensions, capacities and behaviours. Many design projects are too large and complex to be fully understood by one person. Various persons with specific skills and expertise may need to be included in the design team or consulted during the design process to fill any knowledge gaps, for example ergonomists, engineers and occupational hygienists. 3.3 Integrating safe design and risk management The design brief should include a requirement to apply a risk management process in the design. The safe design of plant is usually an iterative process. After the initial control measures are incorporated into the design, the design is reviewed to determine whether there are remaining risks and whether redesign can eliminate or minimise these risks (see Figure 1). 3.4 Pre-design and concept development phase This stage of the process involves: Establishing the design context in terms of the purpose of the plant, its functions and limitations Identifying the roles and responsibilities of various parties in relation to the project, and establishing collaborative relationships with clients, manufacturers and users of the plant Conducting research and consultation to assist in identifying hazards, assessing and controlling risks (see section 2.5) Conducting hazard identification PAGE 14 OF 48

15 Establish the design context Conduct research and consultation Pre-design phase Obtain information including: Purpose of the plant, its functions and limitations Data from similar types of plant, test reports WHS legislation, codes of practice, technical standards. Identify hazards associated with the plant Develop prototype or initial design Conceptual and schematic design phase Hazard identification (technical and human factors): Hazardous conditions High consequence hazards Systems of work Plant access and location Abnormal situations. Determine how hazards will be eliminated or minimised through either: (a) implementing solutions from recognised technical Standards; or (b) conducting a risk management process. Design development phase (a) Implement solutions from recognised Standards. Identify hazards that can be adequately addressed by applying solutions/guidance from existing standards if appropriate (b) Conduct a risk assessment process for hazards which have no suitable solutions in recognised Standards or there is poor safety experience with this type of hazard. Design risk controls Test, trial or evaluate the design Determine information needs for safety during the lifecycle Redesign to reduce risks within the designers control Final design Yes Have risks been eliminated or minimised so far as is reasonably practicable? NO Figure 1: A systematic approach to integrating design and risk management PAGE 15 OF 48

16 Plant functions and limitations Identify the functions of the plant and its limitations, for example: the specifications (what is produced, materials to be used) expected place of use (environment, supporting surface) planned service life intended functions and operating modes expected malfunctions and faults the people interacting with the plant the products related to the plant the correct use of the plant, as well as reasonably foreseeable misuse. Plant limitations Use limits Space limits Time limits Environmental limits Interface limits Hazard identification Examples Intended use, production rates, cycle times, working load limits Range of movement, access for maintenance Wear and tear of materials, use of fluids Temperature, humidity, noise, location Other plant, energy sources Hazard identification should take place as early as possible in the concept development and design stages. It involves identifying the various activities that the plant would be subjected to throughout its life and the reasonably foreseeable hazards associated with each activity. Hazards may include but are not limited to the following.. Mechanical (crushing, cutting, trapping, shearing) Electrical Thermal Noise Vibration Radiation Hazardous chemicals Slipping, tripping and falling Manual handling Confined spaces Environmental conditions Hazards resulting from a combination of the above 3.5 Design phase The design phase may involve: developing a prototype or initial design testing, trialling or evaluating the prototype or design..in all phases of the plant lifecycle manufacture storage packing and transportation unloading and unpacking assembly installation commissioning use cleaning adjustment inspection planned and unplanned maintenance repair decommissioning dismantling disposal recycling. PAGE 16 OF 48

17 redesigning to control any remaining risks so far as is reasonably practicable finalising the design and prepare risk control plans for the lifecycle of the product. Some hazards may be adequately addressed by applying existing solutions in published technical standards. Alternatively, a risk management process should be used to develop and select the most effective control measure. Technical standards Plant should be designed by a competent person (for example, a qualified engineer) in accordance with acceptable engineering principles and relevant technical standards. Engineering principles include, for example, mathematical or scientific procedures outlined in an engineering reference or standard. A list of some relevant published technical standards is included at Appendix A. The list is not exhaustive and designers may consider using other technical standards when designing plant. 3.6 Testing and examination of plant Designers must carry out, or arrange the carrying out of, any calculations, analysis, testing or examination that may be necessary to ensure, so far is reasonably practicable, that the plant is designed to be without risks to health and safety. Analysis, testing or examination can be carried out when developing a prototype and during the manufacturing stage. Designers should require that consideration should be given to: simulation of the normal range of operational capabilities testing of design features incorporated to ensure fail-safe operation measurement of imposed stresses on critical components to ensure maximum design stresses are not exceeded testing of critical safety features such as overspeed and over-pressure devices under both normal and adverse operational conditions development of overload testing procedures to ensure plant safety during foreseeable misuse conditions. Records of tests and examinations should be maintained and provided to the manufacturer of the plant. 3.7 Providing information Designers must give adequate information to each person who is provided with the design in order to give effect to it concerning: the purpose for which the plant was designed the results of any calculations, testing, analysis or examination any conditions necessary to ensure that the plant is without risks when used for a purpose for which it was designed or when carrying out any activity related to the plant. The designer must also, so far as is reasonably practicable, provide this information to any person who carries out activities in relation to the plant. For example, if plant is to be located a specific distance from other plant, written instructions must be provided for the manufacturer, supplier, installer, owner and end user. If the manufacturer advises the designer that there are safety issues with the design, the designer must revise the information to take account of these concerns, or tell the manufacturer in writing the reasons why such revision is not necessary. PAGE 17 OF 48

18 Information provided to the manufacturer (or supplier if you are also manufacturing the plant) should include details of any risks you have not been able to eliminate. Information should be provided in a manner that can be clearly understood by persons who may use the plant and may be a combination of written text or visual information such as signs, symbols or diagrams. Where visual information is provided, it should conform to the relevant standard. Type of information to provide Under the WHS Regulations, designers must provide specific information to the manufacturer to enable the plant to be manufactured in accordance with the design specifications. If relevant, information must be provided on: the installation, commissioning, use, handling, storage, decommissioning and dismantling of the plant hazards associated with use of the plant testing or inspections required for the plant or structure systems of work and competency of operators required for the safe use emergency procedures if there is a malfunction. Examples of information that may be needed include: Manufacture of plant For example: any specific conditions relating to the method of manufacture instruction to the manufacturer for fitting or refitting plant parts and their location on the larger components of the plant or their housings where: o the direction of movement should be known in order to avoid a risk o associated errors which could be made in installation o instruction where hot or cold parts or material may create a hazard. In the case of registrable plant design, the information provided by the designer to the manufacturer should include the plant design registration number in order to provide evidence that the plant design has been registered in accordance with the WHS Regulations. Transport, handling and storage of plant For example: dimensions and weight indications for handling, for example, application points for lifting equipment conditions for storage. Installation and commissioning For example: exposure of dangerous parts prior to the fixing of guarding lifting procedures stability during installation the proposed method for installation and commissioning, including tests that should be carried out the use of special tools, jigs and appliances necessary to minimise any risk of injury during installation the interaction of plant with other plant environmental factors affecting installation and commissioning. PAGE 18 OF 48

19 Using, inspecting and testing plant For example: the comprehensive range of uses for which the plant is intended, including prohibited usages requirements for maintenance and repair, such as nature and frequency of maintenance, disposal of hazardous by-product and consumables emergency situations, for example, types of fire fighting equipment exposure to hazardous substances effects of environmental conditions on the use of the plant the results or documentation of tests and examinations carried out on the plant and design de-commissioning, dismantling and disposal of plant any known residual risks, that is, those that cannot be eliminated or sufficiently reduced by design and against which guarding is not totally effective the control measures, for example, personal protective equipment, that should be used to further reduce the risks associated with plant guidance, if required, on administrative controls requirements for special tools needed to use or maintain plant. Details of critical components 1 should be documented so that the specifications, applicable standards to which they comply and source of evidence that demonstrates compliance (i.e. test report, third party certificates) is readily available. In maintenance and repair, critical components should only be replaced by equivalents. 3.8 Registering plant design Schedule 5 of the WHS Regulations requires certain plant designs and items of plant to be registered (registrable plant). Schedule 5 is reproduced in Appendix B. Plant design registration involves registering a design from which any number of individual items can be manufactured to that same design. How to register a plant design In order to register a plant design, the design must be verified by a design verifier who must provide a statement that the design has been produced in accordance with published technical standards or engineering principles. Any drawings or other documents provided with the application must be capable of being kept in an electronic form. Design verification The design verification statement is prepared by a design verifier stating that the design has been checked for design integrity and that the design has been produced in accordance with the referenced technical standards and engineering principles. It must be in writing and signed by the design verifier. The statement must include the name and address details of the verifier and business or employment details. Design verifier R. 253: A design verifier must document the verification process carried out by that person and the results of that process. 1 critical components. These are components or sub-assemblies the failure of which will leave the plant in a condition that exposes operators or others to an unacceptable risk level. PAGE 19 OF 48

20 A design can only be verified by a person who is eligible to be a design verifier under the WHS Regulations. The types of people who would be competent to verify the design of plant may include someone who: has educational or vocational qualifications in an engineering discipline relevant to the design to be verified has knowledge of the technical standards relevant to the design to be verified has the skills necessary to independently verify that the design was produced in accordance with the published technical standards and engineering principles used in the design is certified by a body that is accredited or approved by the Joint Accreditation System Australia and New Zealand or an equivalent overseas body to undertake conformity assessments of the design against the relevant technical standards. For example, this could include someone who is registered on the National Professional Engineers Register administered by the Institution of Engineers Australia and is determined by that Institution to be competent to design the structure, verify the design or inspect the plant or structure (as the case requires), or is a member of the Institution of Engineers Australia with the status of Chartered Professional Engineer. The design verifier must not have been involved in the plant design process. The design verifier cannot have been engaged by the same organisation that produced the design unless the organisation has a quality system in place that has been certified by a body accredited or approved by the Joint Accreditation system of Australia and New Zealand (JASANZ). Once the design is registered When a plant design is registered, the WHS regulator will issue a plant design registration document that will contain the registration number for the plant design and the date of effect on which the registration takes place. This document must be kept and made available for any inspection required under the WHS Act. If it is lost, stolen or destroyed, then you will need to apply to the WHS regulator that registered the plant for a replacement document as soon as possible outlining the reasons for needing a replacement. The WHS regulator may impose any conditions it considers appropriate on the registration of the plant design, including conditions in relation to record keeping or provision of information to the WHS regulator. The registration number must be given to the manufacturer, importer or supplier of plant. These duty holders must ensure that the design registration number is provided to the person with management or control of the plant at a workplace. Changes to design registration If the design of a registered plant is altered so as to require any new risk control measures, the altered design must be registered. PAGE 20 OF 48

21 4 DESIGN CONSIDERATIONS 4.1 Physical characteristics of users Plant should be designed to accommodate the range of physical characteristics in the user population. You should take into account information about the range of human dimensions and capabilities, for example height, reach and weight, to provide an optimum match between plant and users. Designers should take into consideration the smaller stature of some cultural groups. A designer should apply ergonomic design principles so that when the plant is being used properly, the operator s discomfort, fatigue and psychological stress are minimised as much as practicable. Further information on the consideration of the human body and the design of plant is available in AS Human body measurements Basic human body measurements for technological design. 4.2 Design to facilitate safe use A designer should address the following issues: the required skill levels to operate or maintain the plant the complexity of functions an operator can be expected to perform the need for and the location of items such as aids, guides, indicators, guards, mounted instruction, signs, symbols and name plates, which may be useful to facilitate correct actions and prevent operator errors ensuring plant design is fail safe at least to the level of reliability/safety integrity level as determined by the plant risk assessment layout of the work stations, for example, the position of the worker in relation to plant controls instrumentation required at each work station or cabin, and the layout of this instrumentation the specific devices, tools or controls the operator and support people will need to perform their jobs safely the options available to enable quick recovery or to maintain the safety and integrity of the system in the event of operator error or plant failure and the means available to access the operator in the event that assistance is required environmental conditions that will tend to impair operator performance, for example, long periods where the operator engages in physical or repetitive activity or inactivity in a hot or cold environment separation of persons, including the operator, from entrapment as a result of plant operation i.e. being caught between the plant and other objects in operation. You should also take into account predictable human behaviour and never presume those who use or maintain plant have a full or continuous appreciation of essential safety features. Where there is a likelihood of operator error, higher order control measures should be incorporated into the design. For example: A driver used a tractor to haul a hydraulically operated tilt-up trailer loaded with grain. The gear lever of the tractor was positioned close to the control lever which operated the tip-up mechanism of the trailer. While underway, the driver s arm moved the control lever slightly so the trailer tray began to lift. The trailer rose and eventually overturned. PAGE 21 OF 48

22 4.3 Reasonably foreseeable misuse Sometimes plant may be used for applications other than those for which it was designed and originally intended, for example where an excavator is used to lift and transport concrete pipes. When designing plant the risk of reasonably foreseeable misuse should be assessed and appropriate control measures incorporated in the design. 4.4 Minimising human error Human or worker error is not always the result of carelessness or negligence. The desire for extra speed, increased production and making tasks easier are some of the main reasons why guards are bypassed or removed. Workers may also use unsafe practices to overcome poor plant design or become bored and distracted with repetitious work, which may cause loss of concentration. In designing plant, designers should be aware of the factors contributing to human error, including: forgetfulness workers diligence to get the job done or to find a better way capacity to understand information ergonomics psychological or cultural environment habit fatigue level of training. Further information on human error is included in Appendix C. 4.5 Environmental conditions A designer should consider the hazards created by the range of physical, environmental and operational conditions to which plant will be exposed during its life. For example, where moving parts may be exposed to dust which could cause the plant to malfunction, a designer should incorporate effective dust covers into the design. The same is true for extreme heat or cold. A designer should ensure that these hazards are minimised or guarded against. This may require the designer to provide instructions to erectors and installers of plant about the precise positioning of the installation. If an operator is physically uncomfortable in operating the plant this may lead to such problems as inattention, carelessness or fatigue which may in turn result in injury or death. For example a poorly designed workstation or cabin where layout design is not based on ergonomic principles can lead to the problems outlined above. 4.6 Erection and installation A designer should recognise that hazards associated with the erection and installation of plant are identified and eliminated or minimised. For example, poor access to fasteners such as clips and bolt holes may mean that an erector or installer needs to stretch or bend at an unnatural angle. This might result in musculoskeletal injury to the erector or installer. Designers should also design plant so it can be erected or installed safely, for example, so that it will have adequate stability and special supports if these are required, especially if a partly completed structure may be unstable, or be designed into sub-assemblies so that each is more manoeuvrable than if it were a complete assembly. PAGE 22 OF 48

23 4.7 Maintenance If the need to operate plant during maintenance or cleaning cannot be eliminated, the designer must ensure that the design provides for operator controls that: Permit the operation of plant during maintenance or cleaning, Cannot be operated by any other person than the person carrying out maintenance Will allow operation of the plant in such a way that any risk with maintenance and cleaning is eliminated or minimised, so far as reasonably practicable. A designer s responsibility extends to ensuring that maintenance on plant can be undertaken safely. Any reasonably foreseeable hazards with future plant maintenance and repair should be identified and designed out so far as is reasonably practicable. Where a worker is required to maintain operating plant, a designer should ensure: locations for undertaking adjustment, lubrication and maintenance are consciously designed to be outside danger zones. This may be achieved, for example, by placing clearly labelled lubrication points away from moving parts where locations for undertaking maintenance cannot be placed outside danger zones, the design should incorporate interlocks to ensure the plant cannot be activated while work is carried out in these zones safe access, for example walkways and guardrails need to be provided to enable safe maintenance and inspection of plant such as cooling towers or storage silos all relevant information is passed on to the manufacturer for inclusion in the manufacturer s instructions for maintenance parts of the plant where workers move or stand are designed to prevent injuries arising from slips, trips and falls, and the design eliminates or minimises the risk of inadvertently touching or coming into contact with hot or moving parts. 4.8 Guarding A guard is a physical or other barrier that can perform several functions, including: preventing contact with moving parts or controlling access to dangerous areas of plant screening harmful emissions such as radiation minimising noise through the application of sound-absorbing materials preventing ejected parts or off-cuts from striking people. Guards may include (see Figure 2): Permanently fixed or interlocked physical barriers Self-adjusting guards Presence-sensing systems PAGE 23 OF 48

24 Figure 2: Examples of guards on a press brake. If guarding is used, the designer must ensure that: the guarding will prevent access to the danger point or danger area of the plant if access to the area of plant requiring guarding is not necessary during operation, maintenance or cleaning, the guarding is a permanently fixed barrier, if access to the areas requiring guarding is necessary during operation, maintenance or cleaning, the guarding is an interlocked physical barrier, if it is not reasonably practicable to use a permanently fixed barrier or an interlocked physical barrier, the guarding is a physical barrier that can be altered or removed using a tool, or if it is not reasonably practicable to use a permanently fixed barrier, an interlocked physical barrier or a physical barrier fixed in position, the guarding includes a presence-sensing safeguarding system. Guarding must: be of solid construction and securely mounted so as to resist impact or shock make by-passing or disabling of the guard as difficult as reasonably practicable not create a risk in itself (for example it must not obstruct operator visibility, weaken the plant, cause discomfort to operators or introduce new hazards such as pinch points, rough or sharp edges) control any risk from potential broken or ejected parts and workpieces allow for servicing, maintenance and repair to be undertaken with relative ease, and if guarding is removed the plant cannot be restarted unless the guarding is replaced. Guard design The mechanisms and controls forming part of a machine guard should be of a fail-safe design. Guards must not in themselves create hazards. For example, the guarding should not weaken the PAGE 24 OF 48

25 structure of the plant, cause discomfort to the people using the plant or introduce new hazards such as pinch points, rough edges or sharp corners. Where some form of physical barrier is provided to prevent access to dangerous parts, the size and position of the barrier should take into account the range in height and build of people using the plant. The design of the guard should be for a specific function, with design consideration being given, where appropriate, to: the placement removal or ejection of work pieces lubrication inspection adjustment repair of machine parts. Guarding should be designed for safe operation of the plant as well as to minimise interference to the plant. The selection of a guard should take into consideration the environment in which it is to be used. Some examples of poor guard selection relative to the environment are: electrical charging of guards on high frequency welders; heating of guards in hot processes; and wire mesh guards on machines emitting splashes. Physical barrier guarding should be constructed of material that is strong enough to resist normal wear and shock that may arise from failure of the parts or processes being guarded; and to withstand long use with a minimum of maintenance. If a guard is likely to be exposed to corrosion, corrosion-resistant materials or surface coatings should be used. When an enclosure is used to prevent access to mechanical, chemical and electrical hazards, there may be an opportunity to control other risks. For example, risk associated with exposure to dust may be controlled by substituting a sheet metal guard for a mesh one provided the accumulation of dust within the guard does not constitute an additional hazard. Where there is a risk of jamming or blockage of moving parts, the designer should ensure that specific work procedures, devices and tools that will enable the plant to be cleared in a way that reduces the risk are documented. If applicable, the designer should ensure that safe systems of work associated with the use and maintenance of the guarding and the maintenance of the components being guarded, are specified in the information provided to the manufacturer. 4.9 Operator control devices A designer of plant must ensure that the design provides for any operator controls to be: identified so as to indicate their nature, function and direction of operation located so they can be readily and conveniently operated located or guarded to prevent unintentional activation, and locked into the off position to enable disconnection from power. Badly designed operator controls can lead to unintentional unsafe operation. For example, a control for setting the speed for a cutting device such as a saw or guillotine should not be a simple slider or rotary control. It should be graduated in fixed lockable steps. Control devices should be designed: to enable the plant to fail to a safe condition PAGE 25 OF 48

26 to be within easy access of the operator to enable extra emergency stops to be located so they can be operated from other parts of the plant. A risk assessment would assist in their location so they are clearly visible, identifiable and appropriately marked where necessary, for example, signed to indicate on/off so the intended function of the control is clearly indicated and the action used to operate the control is aligned with the effect on the plant for example, moving a control to the right should move the plant to the right using symbols as opposed to written instructions, wherever possible, so they can be easily read and understood, especially in the case of dials and gauges so the movement of the control is consistent with established convention, for example, anticlockwise to open, clockwise to close so the desired effect can only occur by intentional operation of a control, for example, provision of a starting control to withstand the rigours of normal use, undue forces and environmental conditions so they are located outside danger zones so they are located or guarded to prevent unintentional activation so they can be locked in the off position to enable disconnection of power so they are readily accessible for maintenance. It should only be possible to start plant by deliberately actioning a control provided for that purpose. The same requirement applies when restarting the plant after any stoppage. Each item of plant should be designed to accommodate a control so the plant or its relevant components can be brought to a complete stop safely. Further information on controls and symbols is available in AS 4024: Safeguarding of machinery general principles Emergency stops A designer of plant must ensure that if the plant is to be operated or attended by more than one person and more than one emergency stop control is fitted, the design must provide for multiple emergency stop controls to be of the stop and lock-off type, so that the plant cannot be restarted after an emergency stop control has been used unless that emergency stop control is reset. If the design of the plant includes emergency stop controls, the designer must ensure that the design provides: for the stop control to be prominent, clearly and durably marked and immediately accessible to each operator of the plant, for example EMERGENCY STOP PRESS for any handle, bar or push button associated with the stop control to be coloured red, and that the stop control cannot be adversely affected by electrical or electronic circuit malfunction. Emergency stop devices should not be the only method of controlling risks. They should be designed as a backup to other control measures. The emergency stop system should be compatible with the operational characteristics of plant. Emergency stops do not remove the need for adequate guarding. PAGE 26 OF 48

27 Once engaged, the emergency stop controls should remain that way. It should be possible to disengage the emergency stop controls only by a deliberate action. Disengaging the emergency stop control should not restart the plant. It should only permit the normal starting sequence to be activated. In the case of plant or parts of plant designed to work together, stop controls (including the emergency stop) should be capable of stopping the plant itself as well as all the equipment interrelated to its operation, where continued operation of this interrelated equipment may be dangerous Failure of the control circuit A control circuit used to control the plant should be designed in such a way as to prevent a fault in the control circuit logic, or a failure of or damage to the control circuit leading to the operator or others being placed at risk. In particular: the plant must not start unexpectedly the plant must not be prevented from stopping if such a command has already been given no moving part of the plant or workpiece being held by the plant must fall or be ejected automatic or manual stopping of moving parts must not be impeded the protection device/s must remain fully effective Warning devices If it is necessary to include an emergency warning device to minimise risk, the designer of plant must ensure that the design provides for the device to be positioned on the plant so that it will work to best effect. Warning devices include: Audible alarms Motion sensors Lights Rotary flashing lights Air horns Percussion alarms Radio sensing devices PAGE 27 OF 48

28 5 MANUFACTURE OF PLANT 5.1 The role of manufacturers S. 23: Manufacturers must ensure, so far is reasonably practicable, that the plant is manufactured to be without risks to the health and safety of persons who assemble or use the plant for a purpose for which it was designed or manufactured, or store, decommission, dismantle or dispose of the plant. The manufacturer must use the design specifications provided by the designer. If the manufacturer identifies a hazard in the design for which the designer did not provide a control measure, the manufacturer must: not incorporate that hazard into the item of plant during manufacture give the designer written notice of the hazard as soon as practicable take all reasonable steps to consult with the designer of the plant in relation to alteration of the design to rectify the hazard. Consultation between manufacturer and designer will facilitate the discharge of each other s obligations and any manufacturing issues to be discussed, e.g. practicalities of materials substitution in the manufacturing process. Where it is not possible for the manufacturer to advise the designer of an identified hazard and associated risk in relation to the design, the manufacturer must ensure the risk is eliminated or minimised so far as is practicable. If a manufacturer or any other person modifies the design of plant without consulting the original designer, that person will have the duties of a designer. All modifications should be approved by the original designer or by a competent person, for example, substitution of metals in a manufacturing process should be approved by the original designer or a person with relevant expertise before the substitute material is incorporated. The manufacturer must ensure the plant is supplied with appropriate information on safe use. 5.2 Plant construction The manufacturer must ensure that the plant is manufactured, inspected and, if required, tested in accordance with the designer s specifications. Connected, fabricated or machined materials are likely to be required in the construction of plant. Manufacturing processes require that design specifications are followed, for example, crane booms of a particular lifting capacity should have the particular grade of steel specified. Further the grade of steel used in the manufacture must be clearly identified in information provided with the finished product. The manufacturer may choose to consider other published technical standards for guidance on the materials used for the plant, the method of construction and testing to achieve safety of the plant. Guarding A manufacturer of plant must ensure that guarding used as a control measure is of solid construction and securely mounted so as to resist impact or shock. Guarding must be of a kind that can be removed to allow for maintenance and cleaning of the plant at any time it is not in normal operation. The manufacturer must ensure, so far as is reasonably practicable, that if the guarding were to be removed, the plant cannot be restarted until the guarding is replaced. PAGE 28 OF 48

29 The selection of material from which guards can be constructed is determined by four main considerations, which are: strength and durability, for example use of non-metallic materials in corrosive environments effects on machine reliability, for example a solid guard may cause the machine to overheat while a mesh guard may allow dust into the working environment visibility, for example there may be operational and safety reasons for needing a clear view of the danger area the control of other hazards, for example the use of a material that will not permit the ejection of molten metal. 5.3 Testing and examination of plant S. 23: Manufacturers must carry out, or arrange the carrying out of, any calculations, analysis, testing or examination that may be necessary to ensure, so far is reasonably practicable, that the plant is manufactured to be without risks to health and safety. Details of the testing and examination carried out should be documented and must be provided to the each person to whom the manufacturer provides the plant. Typical testing nominated by the designer may include but will not be limited to: electrical testing (e.g. input current, safety contactor current, leakage current, protective earth continuity, dielectric strength test, and insulation resistance) safety function testing (e.g. safety circuit operation times, appropriate installation distances, use of appropriate components and reliability design) temperature rise tests (e.g. for exposed temperature hazards and to confirm components are used within their specification) pressure, stability, mechanical or structural testing to the levels required by the design specification abnormal condition tests (e.g. foreseeable component failures, unexpected start up, hazards following interruption, restoration of power sources electricity, air - as decided by the risk assessment process. Tests and examinations should include: all critical components the suitability of selected components mechanical devices pneumatic devices hydraulic devices sources of emissions e.g. lasers guarding and interlocking arrangements structural integrity material types and properties. There are both visual and non-visual techniques for checking the integrity of plant manufacture. For example, checking welded joints requires non-visual, non-destructive testing (NDT) techniques. For all high risk plant where welding is used as a joining technique, NDT techniques such as ultrasonic and x-ray procedures should be used to ensure the welds are defect free and fit for the intended purpose. Consideration should also be given to structural flexure and the avoidance of tri-axial stressing as a measure of reducing the tendency towards fatigue cracking. PAGE 29 OF 48

30 To ensure an accurate assessment of operational stresses is made consideration should be given to the use of techniques such as strain gauging and/or photo-elastic techniques. Stresses should be measured dynamically under a range of operational conditions. 5.4 Information about the safe use of plant Manufacturers must give adequate information to each person who is provided with the plant concerning: the purpose for which the plant was designed or manufactured the results of any calculations, testing, analysis or examination any conditions necessary to ensure that the plant is without risks when used for a purpose for which it was designed or manufactured or when carrying out any activity related to the plant. A manufacturer must take all reasonable steps to obtain the information from the designer of the plant and pass it on to the person to whom the manufacturer supplies the plant. See section 3.7 for the type of information that should be provided. Instructions should be trialled to ensure the intent of the instructions is achieved and that carrying out the instructions does not pose a risk to health and safety. Information may be provided in the form of written text or visual information such as signs, symbols or diagrams. 5.5 Registration of plant design Certain plant requires design registration as outlined in Appendix B. If the designer has registered the design, the designer must provide the design registration number to the manufacturer. The manufacturer must ensure that they pass on the design registration number to the person being supplied with the plant manufactured to the design. R. 231: A manufacturer must not supply plant that requires design registration unless the design of that plant has been registered. If the designer has not registered the plant design, then the manufacturer must register the plant design. If the manufacturing process has involved modifying an already registered plant design in such a way that it requires new risk control measures, the altered design must be registered. 5.6 Item registration Any plant that requires item registration (see Appendix B) must be registered with the WHS regulator. A manufacturer who produces a number of the same items of plant may apply for the item registration, noting that once it is sold to someone else, the manufacturer must notify the WHS regulator that they no longer have management of control of that item of plant. Marking of registered items of plant In the case of plant that requires item registration, the item registration number provided by the WHS regulator must be permanently marked on the plant in a location that will be readily accessible. It will generally be a simple task to mark large items of plant with the item registration number by either etching the number in place or by fixing the number in place in a position that will not lead to damage or removal over time On some items, such as a tower crane that may comprise many parts and is often assembled in a configuration to suit a particular workplace/task, it may not be feasible to mark each component. In such cases, the item registration number should be marked on those components that are readily accessible and able to be seen when the crane is fully assembled. PAGE 30 OF 48

31 6 IMPORT AND SUPPLY OF PLANT Importers and suppliers must ensure, so far is reasonably practicable, that the plant is without risks to the health and safety of persons who assemble or use the plant for a purpose for which it was designed or manufactured, or store, decommission, dismantle or dispose of the plant. Importers and suppliers must, so far as is reasonably practicable, eliminate or minimise risks to health and safety with regard to the plant being supplied, where the manufacturer has not already done so. This may be necessary where the importer has no direct connection to an overseas designer or manufacturer. 6.1 Examination and testing of plant Importers and suppliers must carry out, or arrange the carrying out of, any calculations, analysis, testing or examination that may be necessary to ensure, so far is reasonably practicable, that the plant is without risks to health and safety. Alternatively, they must ensure the calculations, analysis, testing or examination has been carried out. Importers or suppliers must take all reasonable steps to obtain information from the manufacturer of the plant and pass this information on to the person to whom the plant is supplied. If this is not available, the importer or supplier must undertake the necessary testing and examination required under the WHS Act themselves. 6.2 Information about the safe use of plant Importers and suppliers must give adequate information to each person to whom they provide or supply the plant, concerning: the purpose for which the plant was designed or manufactured the results of any calculations, testing, analysis or examination any conditions necessary to ensure that the plant is without risks when used for a purpose for which it was designed or manufactured or when carrying out any activity related to the plant. An importer or supplier must ensure that health and safety information from the designer or manufacturer is passed on when supplying the plant. See section 3.7 for the type of information that should be provided. The information may be provided in user manuals and manufacturers' instructions. The information should, wherever possible, be in plain English but it must always maintain the accuracy and quality of the technical information. 6.3 Compatibility of plant Some plant may be assembled from components from a variety of sources. The assembly of these by a manufacturer could present a risk to health and safety. A manufacturer using components from a variety of sources should provide the importer or supplier an assurance of compatibility of components and that the plant is safe and without risk to health when used properly. You should in turn pass this information on to the end user. If this information is not available then you must undertake the relevant testing to ensure that risks to health and safety are eliminated. PAGE 31 OF 48

32 6.4 Imported plant Importers of plant must take all reasonable steps to obtain information from the manufacturer about the purpose for which the plant has been designed and any conditions necessary to ensure it is without risks to health and safety. If the health and safety information is not provided to the importer by the original designer or manufacturer, the importer assumes responsibility for supplying the information normally provided and must undertake the necessary testing to obtain the information (see Sections 3.6 and 3.7 of this Code). The importer or supplier must inspect the plant in conjunction with any information provided by the manufacturer, and undertake any testing specified by the manufacturer. Any risks identified during inspection and testing must be eliminated or minimised so far as is reasonably practicable. The person to whom the plant is supplied must be advised of any residual risks. The importer must take all reasonable steps to ensure that the designer and manufacturer are consulted in relation to any alterations made to the plant to control risk. 6.5 Design registration R. 232: An importer must not supply plant that requires design registration unless the design of that plant has been registered. If the item of plant to be imported requires design registration under Schedule 5 of the WHS Regulations, the importer must apply for and receive design registration before supplying the plant to anyone within Australia (see section 3.8). This will require the importer to conduct any testing and develop the information required for design registration if it is not available. The design registration number must be provided to any person to whom the plant is supplied. If the importer or supplier makes modifications to the plant, for example to ensure compliance with Australian standards, they should take all reasonable steps to advise both the designer and manufacturer of this. When importing second-hand plant, the importer must ensure that the plant has been manufactured in accordance with the original design (based on which the plant design was registered). If the design is not the same or if the plant (as imported) has been modified to the extent that the safety has been compromised, the original plant design registration number must not be used. The duty holders must engage a competent person to verify the new or modified design and if necessary, register the new design. 6.6 Hire of plant If you supply hired or leased plant (the hirer or lessor ) to an end user you have the same obligations as a supplier of new plant and ensure, so far as is reasonably practicable, that hired plant is safe and without risk to health when used properly. A supplier must ensure the hired plant is accompanied by information about the way the plant must be used to ensure health and safety, if the information is available. The hirer of plant should ensure the plant is inspected between hiring and that any maintenance and repairs are carried out to minimise risks to health and safety. In the context of hired plant, between means every time the plant is hired or leased, but does not include an extension to the hiring or leasing period for the same user (that is, hiree or lessee). PAGE 32 OF 48

33 The supplier may consider an extension to the period of contract as being an extended lease provided that appropriate mechanisms are put in place to ensure adequate inspection and maintenance is carried out during the lease. The supplier is required to ensure that any excessive wear or damage to the plant is identified and rectified. Proper regard should be given to the designer's or manufacturer's specifications for inspection and maintenance. A regular testing program should be implemented. Testing should consider factors such as the amount of use of the plant and the operating and environmental conditions during the period. Where plant is to be transferred between hirees or lessees without being returned to the supplier's depot, the supplier is required to ensure that the plant is inspected and maintained before transfer. For example, this may be done "on-site" without returning the plant to the depot. Where the plant is hired or leased for an extended period of time, the supplier should make arrangements with the hiree or lessee to have the plant inspected and maintained, giving proper regard to the designer's or manufacturer's specifications for inspection and maintenance. With plant that is hired or leased with an operator, the supplier may fulfil their duty by preparing a comprehensive set of checks, and authorising the operator to carry out these checks between hiring and leasing. If this option is adopted, the supplier should ensure that the operator is competent to apply the checks and carry out, or arrange to carry out, the maintenance identified by the checks. The supplier should ensure that records are kept of inspections and maintenance carried out on the plant. If agreement is reached that the hiree or lessee undertake the necessary inspections and maintenance, the supplier should ensure that either during the hire or lease of the plant or at the conclusion of the hire or lease, all records associated with inspections and maintenance of the plant are obtained from the hiree or lessee. 6.7 Second-hand plant Suppliers must provide the purchaser with any information relating to the safe use of the plant that is in their possession. This should include information relating to commissioning, operation, maintenance and systems of work. The information may consist of data sheets, test certificates, operations and service manuals, reports and a safety manual. Persons who conduct a business or undertaking involved in the supply of second-hand plant must ensure, so far as is reasonably practicable, that any faults that cause a risk to health and safety (including excessive wear and damage) are identified and rectified before supplying the plant. Persons conducting a business or undertaking not involved in the supply of second-hand plant but who decide to sell or transfer a piece of plant they have used must provide a written notice outlining the condition of the plant, any faults identified and, if appropriate, that the plant should not be used until the fault is rectified. This notice must be provided to the person to whom the plant is supplied. If second-hand plant is to be used for scrap or spare parts, the supplier must inform the person they are supplying the second-hand plant to that the plant is being supplied as scrap or spare parts and that the plant in its current form is not to be used as plant. This must be done in writing or by marking the item of plant. PAGE 33 OF 48

34 Suppliers should identify any components of the plant that are unserviceable, or arrange to have this done by a competent person. The components of the plant that are unserviceable may constitute a hazard in the operation of the plant. If plant is identified as not fully serviceable, you should inform the purchaser that the plant should not be used until the plant is fully serviceable. PAGE 34 OF 48

35 7 SPECIFIC RISK CONTROLS 7.1 Confined spaces The design, manufacture or modification of any plant or structure that includes a confined space is critical. Thoughtful design can eliminate the need to enter a confined space or eliminate the risk of inadvertent entry and will therefore eliminate the associated risks. R. 64: Designers, manufacturers and suppliers of plant or structures must eliminate the need to enter a confined space and eliminate the risk of inadvertent entry. If this is not reasonably practicable, then: the need for any person enter the space must be minimised so far as is reasonably practicable the space must be designed with a safe means of entry and exit, and the risk to the health and safety of any person who enters the space must be eliminated or minimised as far as is reasonably practicable. The following features should be incorporated in the design and manufacturing stages: use of lining materials that are durable, require minimal cleaning and do not react with materials contained in the confined space design of mechanical parts to provide for safe and easy maintenance, to reduce the need for persons to enter, and access points (including those within the confined space, through divisions, partitions or obstructions) should be large enough to allow people wearing the necessary protective clothing and equipment to pass through, and to permit the rescue of all people who may enter the confined space. Further guidance on confined spaces is available in the Code of Practice: Confined Spaces. 7.2 Manual tasks R. 61: Designers and manufacturers must: design the plant to eliminate the need to carry out a hazardous manual task where this is not reasonably practicable, minimise the risk of musculoskeletal disorders arising from hazardous manual tasks provide adequate information about the features of the plant that eliminate or minimise the need for any hazardous manual task to be carried out. The importer or supplier of plant must take all reasonable steps to obtain the information and provide it to any person to whom the plant is supplied. Designers and manufacturers should consider: characteristics such as the weight, size, shape, surface characteristics and stability of plant or its various component parts. Where these characteristics present a risk to users, plant should be equipped with items such as hand-grips, to enable it to be picked up and moved safely and eliminate the risk vertical and horizontal reach distances of people who may use or manually handle plant requirements for operational controls/levers either on a console or inside a cabin conditions in which the plant will be used, serviced, maintained and repaired. For instance, in some situations it may not be possible to make use of mechanical lifting devices and so items of plant or their components should be designed to eliminate risk to the user/worker. PAGE 35 OF 48

36 Methods designers and manufacturers may consider to reduce risks associated with manual tasks include: modular components designed to dismantle so that they can easily be carried or repaired attachments such as handles to make lifting easier or wheels to make moving easier using lightweight materials designated lifting points. Further guidance is available in the Code of Practice: Hazardous Manual Tasks. 7.3 Noise R. 59: A designer and manufacturer of plant must: design the plant so that its noise emission is as low as reasonably practicable provide information on the noise emission values of the plant (for example, data on sound power level or sound pressure level), the operating conditions of the plant when the noise emission is measured and the methods used to measure the noise emission. They must also provide information on any conditions required for safe use. The importer or supplier of plant must take all reasonable steps to obtain the information and provide it to any person to whom the plant is supplied. In eliminating or minimising the risks associated with noise, you should consider: preventing or reducing the impact between machine parts replacing metal parts with quieter plastic parts combining machine guards with acoustic treatment enclosing particularly noisy machine parts selecting power transmission which permits the quietest speed regulation; for example, rotation-speed-controlled electric motors, and isolating vibration-related noise sources within machines. good seals for doors for machines machines with effective cooling flanges which reduce the need for air jet cooling quieter types of fans or placing mufflers in the ducts of ventilation systems quiet electric motors and transmissions pipelines for low flow speeds (maximum 5m/sec.) ventilation ducts with fan inlet mufflers and other mufflers to prevent noise transfer in the duct between noisy and quiet rooms. Further guidance is available in the Code of Practice: Managing Noise and Preventing Hearing Loss at Work 7.4 Energy sources The design should recognise and accommodate the possibility of a dangerous situation occurring where the energy source to the plant fluctuates or the energy source is discontinued and then resumed. In particular: the plant should default to the off position, if there is a risk of injury due to the plant restarting when the power resumes, the plant should remain in a de-energised state until the start sequence is commenced, the plant should not be able to restart automatically after power fluctuations, and protective devices should remain fully effective before, during and after any change to the status of the energy source. PAGE 36 OF 48

37 Where electrical equipment has been designed for use within certain voltage limits, only those specific requirements such as electrical standards and statutory requirements that address the design requirement should apply. Where plant is powered by an energy source other than electricity, such as hydraulic, pneumatic, thermal or stored kinetic energy, it should be designed to allow the plant to be constructed and equipped so as to avoid all potential hazards associated with these types of energy. 7.5 Static electricity Static electricity may cause an electric shock to a person. As a consequence the person may fall, or drop an object. Static electricity may also cause unintended combustion, for example where flammable fumes may be emitted. Where the build-up of potentially dangerous electrostatic charges creates a risk to health and safety, plant should be designed to prevent or limit the discharge, and/or be fitted with a discharging system. For example, spark detection and suppression systems can be incorporated into dust extraction systems to minimise the risk of explosion or fire. 7.6 Lightning The design of plant that is likely to be exposed to lightning while being used should incorporate a system for conducting any resultant electrical charges to earth. 7.7 Fire and explosion Certain types of plant have the potential to be a fire or explosion risk. A designer should eliminate or reduce risk of fire, overheating or explosion posed by the plant itself or by gases, liquids, dusts, vapours or other substances produced or used by the plant or other plant nearby. 7.8 Plant capable of entangling an operator Designers should make certain that moving parts of machines are designed in a way that prevents operator contact that may cause injury. In some instances this may be difficult to achieve as there may be a need to have rotating elements exposed during normal use. Radial drills, surface planers and milling machines commonly operate with the rotating tool unguarded and this presents a real risk of entanglement should the operator or the operators clothing come into contact with the rotating part. The most likely causes of contact are where the operator applies cutting lubricant to the interface between the tool and the part being machined, removing swarf from around the part, or where the tool is not brought to a complete stop during re-setting of the workpiece. Modern metal-working machine tools often incorporate protective guards that surround the cutter and provide lubricant and swarf removal that can eliminate the need for operator intervention and in doing so, eliminate the risk of entanglement. Where plant is computer controlled, the need for operator interaction is further reduced. Older style machines however, should be protected by the use of, for example, physical barriers or pressure sensitive mats. Lubricant application and swarf removal can also be achieved by the retro- fitting of additional devices dedicated to these purposes and which allow the operator to remain outside the danger zone while the plant is operating. Woodworking machinery can also expose an operator to a risk of entanglement, especially when workpieces are being fed into machines. Such risks can be eliminated by the use of powered feed equipment that provides a safe distance between the operator from revolving cutters or blades. PAGE 37 OF 48

38 Plant such as grain augers or tree-limb mulchers also requires special attention to prevent operators becoming entangled in the plant. Controls for plant capable of entanglement should be able to bring the plant quickly to a complete stop. Plant capable of causing entanglement must not be able to continue rotating once the stop command is given. 7.9 Vibration Plant should be designed to avoid any risks resulting from vibration. Vibration may be transmitted to the whole body and particularly to hands and arms, when using plant. There are two approaches you can use to control vibration: preventing vibration happening in the first place, and separating the vibration from the person using the plant. Examples of prevention are substituting an internal combustion engine fitted to plant with an electric drive. Examples of separation are: suspended cabs, used on some commercial vehicles, and use of vibration isolation, for example, the use of rubber blocks or mounts on an engine to reduce (isolate) the vibration Exposure to radiation Plant should be designed so emission of any radiation is limited to the extent necessary for operation of the plant and so there is no risk to health and safety from emissions. The effects of radiation exposure are cumulative. Where necessary, instructions should be included stating the need for regular personal monitoring for radiation build-up. Radiation hazards are produced by a variety of sources and may be generated by non-ionising or ionising radiations. Information on non-ionising and ionising radiation for particular items of plant can be found in relevant Australian Standards. Plant should be designed so external radiation does not interfere with its operation or with people working on or in the vicinity of the plant. Lasers Lasers are devices that produce optical radiation with unique properties. They have varying power and applications. High power laser devices can present a hazard over considerable distances from the source. While exposure to some higher powered laser products may cause skin burns, most laser injuries are to the eyes. For example, some laser pointers available on the market are of sufficient power to cause eye injury. Laser products may consist of a single laser with or without its own power supply or multiple lasers in a complex system. R. 223: Lasers must be designed and installed to prevent accidental irradiation of any person. The laser equipment must be protected so that any operator or other person is not exposed to direct radiation, radiation produced by reflection or diffusion or secondary radiation. Visual equipment used for the observation or adjustment of laser equipment on plant must not create a risk to health or safety from laser rays. All laser devices must be sold with appropriate information about their safe use. This generally takes the form of a label with both the classification details and the warnings-for-use that are PAGE 38 OF 48

39 appropriate to that classification. The warning labels appropriate to the class should be permanently affixed to the housing in a highly visible position. Designers should consult with manufacturers, suppliers, owners and end users to ensure that the correct strength of laser is used and the housing of the laser unit is designed according to safe design principles. The designer should ensure that complete written information on the safe use of laser products is provided to manufacturers, erectors, installers, suppliers, owners and end users. Laser devices sold in Australia should be classified in accordance with AS/NZS :1997 Laser safety - Equipment classification, requirements and user's guide. Radio frequency radiation Radio frequency radiation (RFR) is electromagnetic energy (wave) that is transmitted at frequencies between 3 khz and 300 GHz. Radio frequency (RF) generating plant may be used at workplaces that perform forging, annealing, tempering, brazing or soldering, sealing of plastics, glue drying, curing particle boards and panels, heating fabrics and paper, or cooking by means of a microwave oven. Workers in industrial workplaces that use RF generating plant are at risk of exposure to levels of RF fields where radiation may cause adverse health effects. For example, RF fields greater than 10 MHz interact with human tissue to raise the temperature and cause heat stress related illness such as impaired concentration, numbness, and eye damage. Usually those workers operating the plant are the most likely to be exposed. However, workers who do not operate RF generating plant but are situated within its vicinity and people coming into the workplace can also be at risk from the generated radiation. Pregnant women and people with metallic implants or cardiac pacemakers may be at particular risk from RFR. Ultraviolet radiation Excessive exposure to ultraviolet (UV) radiation can cause not only sunburn but also lasting skin damage, premature skin aging and an increased risk of developing skin cancer. UV exposure also increases the risk of UV induced damage to the lens and cornea of the eye. UVR exposure can also result from artificial sources for example, from germicidal lamps and quartz-halogen lights. Designers need to identify ultraviolet risks associated with the plant they are designing. For example a designer of mobile plant should safeguard the driver from exposure to ultra violet radiation by incorporating an effective canopy into the design in order to eliminate or minimise the risk Risk of being trapped Where there is a risk of a person becoming trapped or enclosed within the plant, measures should be included to bring the plant to an immediate stop or prevent the plant being activated while a person is in that position, for example presence sensing systems used together with control systems that de-energise the plant. For mobile plant, the risk of the operator being trapped if the plant overturns can be minimised with rollover protective structures Hazardous chemicals Plant should be designed and manufactured to eliminate or minimise the release of any substances which are hazardous. This extends to controlling hazardous waste. PAGE 39 OF 48

40 7.13 Combined plant Where you have arranged plant to work in combination with other plant or parts of other plant, it must be designed so that the stop controls, including the emergency stop control, can not only stop the plant itself but all other plant related to the operation if the continued operation of the plant can present a risk to the operator or others. Designers must provide information about combined plant to the manufacturer and ensure that the instructions for operating the plant provide guidance for end users Stability Unstable plant is a hazard. It can topple, parts can fall off or it can unexpectedly move and result in workers or others in the workplace suffering crushing or impact injuries. Designers should ensure that plant is designed to be stable and without risk of overturning, falling or unexpected movement during erection or installation and under all operating conditions. It may be necessary for you to consult with other stakeholders such as manufacturers, erectors/installers and end users. Detailed erection, modification and dismantling procedures should be provided by the designer in writing to prevent unstable plant at the workplace. Stability testing requirements for the pant can be developed and specified at the design stage and verified after manufacture Mechanical or structural failure during operation The various parts of plant and their linkages must be able to withstand the stresses to which they are subjected during intended use and reasonably foreseeable misuse. The durability of materials used to construct the plant must be adequate for the nature of the specified working environment. In particular, when nominating the type of materials to be used, you must consider the possible effects of fatigue, ageing, corrosion and abrasion. The design specification must indicate the type and frequency of inspection and maintenance required to keep the plant in a safe condition. The design specification must, where appropriate, also indicate the parts subjected to wear and the criteria for determining replacement. Where a risk of rupture or disintegration of component parts remains despite the measures taken, the parts concerned must be mounted, positioned and/or guarded in such a way that in case of rupture their fragments will not put the operator or others at risk. Both rigid and flexible hoses/pipes carrying fluids such as gases or solids or a mixture of these, particularly those under high pressure, must be able to withstand the foreseen internal and external stresses and must be firmly attached and/or protected against those stresses. Precautions must be taken to make sure that there is no risk posed by rupture. Where material to be processed is automatically fed to moving parts of the plant, your design must include means to avoid risks to the operator and others which may arise from the material being ejected or being blocked in the moving parts of the plant. These means may include: allowing the moving parts to attain normal working condition before material comes into contact with the moving parts, and coordinating the feed movement of the material and the moving parts of the plant at all times including on start-up and shut-down regardless of whether the operation is intentional or unintentional. PAGE 40 OF 48

41 7.16 Software Designers considering the use of interactive software to be used by the operator to command or control the operation of the plant should make sure that the software is as intuitive as possible and not require complex manipulation that could be affected by repetition or fatigue Lighting Lighting should be provided to enable safe use and operation of plant. Poor lighting can lead to poor visibility, operator fatigue, wrong decisions and accidents. For example if an operator is unable to clearly see a hopper capacity indicator, he or she may not empty it at the right time thus creating a dangerous situation. Emergency lighting should operate on its own power supply and not be subject to cuts in power. Lighting may be internally or externally installed. If external lighting needs to be provided in the workplace to ensure the safety of workers at or near the plant, the designer should ensure that written information is provided to the erector/installer and end user. Technical standards cover lighting requirements for plant use, operation and maintenance, including: the direction and intensity of lighting, the contrast between background and local illumination, the colour of the light source, and reflection, glare and shadows. Technical standards also describe some specific situations where lighting design for use in industrial settings must meet electrical safety standards. Standards also detail design requirements to prevent lighting interactions causing a stroboscopic effect, particularly the following examples: fluorescent lighting on moving plant which makes moving parts of machinery look as if they are stopped, or rotating beacons in mobile plant in the internal environment. PAGE 41 OF 48

42 APPENDIX A EXAMPLES OF TECHNICAL STANDARDS The following table is a list of published technical standards that provide guidance on the design, manufacture and use of certain types of plant. These technical standards provide guidance only and compliance with them does not guarantee compliance with the WHS Act and Regulations in all instances. This list is not exhaustive. Plant Description Reference Number Standard Title Design Make Use Amusement AS 3533 Amusement Rides and Devices Structures Cranes, including AS 1418 (Series) Cranes Including Hoists and Winches hoists and winches AS Lifting devices AS 2550 (Series) Cranes Safe use Conveyers AS Conveyers - Safety requirements Electrical AS 3000 Electrical installation (known as the installation Electrical installation within an industrial plant Earthmoving machinery AS/IEC Aust/NZ wiring rules) Safety of machinery: Electrical equipment of machines-general requirements AS Earthmoving machinery Protective structures - General AS Earthmoving Machinery Safety Wheeled machines-brakes ISO 6165 Earthmoving machinery Basic types Identification and terms and definitions ISO Earth-moving machinery - Definitions of dimensions and codes - Part 1: Base machine ISO ISO 7133 Earth-moving machinery - Definitions of dimensions and codes - Part 2: Equipment and attachments Earth-moving machinery - Tractorscrapers Terminology and commercial specifications Explosive Powered tools AS/NZS 1873 (Series) Power-actuated (PA) hand-held fastening tools. Hand-held electric AS/NZS Hand-held motor operated electric tools tools Safety General requirements Fall arrest AS/NZS Industrial fall-arrest systems and devices - Harnesses and ancillary equipment AS/NZS Industrial fall-arrest systems and devices - Selection, use and maintenance BS EN :2002 Safety nets-safety requirements, test methods Gas cylinders AS Gas cylinders-general requirements (known as SAA Gas Cylinders Code ) AS Gas cylinder test stations AS/NZS 3509 LP (Liquefied Petroleum Gas) Fuel - Vessels for Automotive Use. Industrial (Forklift) AS 2359 (Series) Powered industrial trucks trucks Industrial rope AS Industrial rope access systems access systems Lasers AS/NZS 2211 (Series) Safety of laser products AS 2397 Safe use of lasers in the building and construction industry AS/NZS IEC : Safety of laser products Equipment PAGE 42 OF 48

43 Plant Description Reference Number Standard Title Design Make Use 2011 classification and requirements Lifts AS 1735 (Series) Lifts, escalators and moving walks (known as the SAA Lift Code) Machinery AS 4024 (Series) Safety of machinery AS 1657 Fixed platforms, walkways, stairways and ladders-design, construction and installation AS Abrasive wheels-selection, care and use AS Code of practice for the guarding and safe use of metal and paper cutting guillotines AS Vapour degreasing plant Design, installation and operation Safety requirements AS/NZS :2001 Low-voltage switchgear and control gear, switches, disconnectors, switchdisconnectors and fuse combination units AS Functional safety of safety related systems AS/IEC Functional safety Safety instrumented system for the process industry sector AS Safety of machinery: Functional safety of safety-related electrical, electronic and programmable electronic control systems ISO Safety of machinery: Safety-related parts of control systems-general principles BS/IEC :1997 Safety of machinery, Electro sensitive protective equipment AS :2007 Agricultural tractor power take-offs - rear-mounted power take-off types 1, 2 and 3 - General specifications, safety requirements, dimensions for master shield and clearance zone AS 1636 Agricultural wheeled tractors - Roll-over protective structures criteria and tests AS/NZS :1997 Tractors and machinery for agriculture and forestry - Technical means for ensuring safety - General SAE J Overhead protection for agricultural tractors - Test procedures and performance requirements Miniature boilers AMBSC Code Part 1 Copper Boilers - Issue AMBSC Code Part 2 Steel Boilers Issue AMBSC Code - Part 3 Sub-Miniature Boilers Issue AMBSC Code Part 4 Duplex Boilers Issue Pressure AS/NZS 1200:2000 Pressure Equipment equipment AS 2593:2004 Boilers Safety management and supervision systems AS 2971:2007 Serially produced pressure vessels AS/NZS 3788:2006 AS 3873 :2001 AS Boiler and pressure vessels In service inspection Boiler and pressure vessels Operation and maintenance Assurance of product quality Pressure equipment manufacture PAGE 43 OF 48

44 Plant Description Reference Number Standard Title Design Make Use ASME I Power boilers ASME II Materials ASME V Non-destructive examination ASME VII -1 Pressure vessels ASME VII - 2 Pressure vessels alternative rules ASME VIII-1 Pressure vessels Full NDE for AS1210 class1h (h=1) ASME IX Welding and brazing qualifications ANSI / NGV-2 Basic requirement of compressed natural gas vehicle fuel containers CSA B51 Part 2 High pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles ISO 11439:2000 High pressure cylinders for the on-board storage of natural gas as a fuel for automotive vehicles ISO/EN (Series) Cryogenic vessels Static vacuum insulated vessels Pressure piping AS Pressure piping Machinery AS 4024 (Series) Safeguarding of machinery general guarding principles ISO 12100:2010 Safety of machinery General principles for design Scaffolding AS/NZS :2010 Scaffolding general requirements AS Scaffold planks AS/NZS 4576 Guidelines for scaffolding Ladders AS/NZS Portable ladders /1892.2/ Spray painting AS/NZS Spray painting booths. Part 1: Design, construction and testing AS/NZS Spray painting booths. Part 2: Installation and maintenance Turbines BS/EN :1996 Rules for steam turbine acceptance tests API 612 Special purpose steam turbines for refinery services Ventilation AS The use of ventilation and air Work boxes- crane lifted Key: conditioning in buildings AS Cranes (including hoists and winches) 1996 AS 2550 Cranes Safe use AS Fixed guideway people movers ISO 2374 Lifting appliances Range of maximum capacities for basic models Abbreviations Name ANSI American National Standards Institute API American Petroleum Institute AMBSC Australian Miniature Boiler Safety Committee AS Australian Standard ASME American Society of Mechanical Engineers AS/NZS Australian Standard / New Zealand Standard BS British Standard CSA Canadian Standards Association EN Europaische Norm (European Standard) PAGE 44 OF 48

45 IEC ISO NZS SAE International Electrochemical Commission International Standards Organisation New Zealand Standards Society of Automotive Engineers PAGE 45 OF 48

46 APPENDIX B REGISTRABLE PLANT List of Plant requiring registration of design as outlined in Schedule 5 (Part 1) of the WHS Regulations Pressure equipment, other than pressure piping, and categorised as hazard level A, B, C or D according to the criteria in Section 2.1 of AS 4343 Pressure equipment hazard levels Gas cylinders covered by Part 1.1 of AS Gas cylinders - General Requirements Tower cranes including self-erecting tower cranes Lifts, including escalators and moving walkways Building maintenance units Hoists with a platform movement exceeding 2.4 metres, designed to lift people Work boxes designed to be suspended from cranes Amusement devices covered by Section 2.1 of AS : Amusement Rides and Devices, except Class 1 structures (see below) Concrete placement units with delivery booms Prefabricated scaffolding and prefabricated formwork Boom-type elevating work platforms Gantry cranes with a safe working load greater than 5 tonnes or bridge cranes with a safe working load of greater than 10 tonnes, and any gantry crane or bridge crane which is designed to handle molten metal or Schedule 10 hazardous chemicals Vehicle hoists Mast climbing work platforms Mobile cranes with a rated capacity of greater than 10 tonnes Note: The plant listed as requiring design registration does not include: a heritage boiler a crane or hoist that is manually powered an elevating work platform that is a scissor lift or a vertically moving platform a tow truck certain Class 1 structures including: o playground structures o water slides where water facilitates patrons to slide easily, predominantly under gravity, along a static structure o wave generators where patrons do not come into contact with the parts of machinery used for generating water waves o inflatable devices that are sealed o inflatable devices that do not use a non-return valve. PAGE 46 OF 48

47 List of Plant items requiring registration as outlined in Schedule 5 (Part 2) of the WHS Regulations Boilers categorised as hazard level A, B or C according to criteria in Section 2.1 of AS Pressure equipment - hazard levels. Pressure vessels categorised as hazard level A, B or C according to the criteria in Section 2.1 of AS Pressure equipment - hazard levels, except for gas cylinders; LP Gas fuel vessels for automotive use, and serially produced vessels. Tower cranes including self-erecting tower cranes. Lifts, including escalators and moving walkways. Building maintenance units. Amusement devices covered by Section 2.1 of AS : Amusement Rides and Devices, except for certain Class 1 structures (see below). Concrete placement units with delivery booms. Mobile cranes with a rated capacity of greater than 10 tonnes. Note: The plant listed as requiring item registration does not include: a crane or hoist that is manually powered certain Class 1 structures: o playground structures o water slides where water facilitates patrons to slide easily, predominantly under gravity, along a static structure o wave generators where patrons do not come into contact with the parts of machinery used for generating water waves o inflatable devices that are sealed o inflatable devices that do not use a non-return valve. PAGE 47 OF 48

48 APPENDIX C DESIGN SOURCES OF HUMAN ERROR The following table lists some human errors that may be associated with the use of plant and the possible causes due to poor design of the plant or systems of work associated with the plant. Common human errors Possible causes due to poor design Inadvertent activation of plant. Lack of interlocks or time lockouts. Lack of warning sign against activating equipment under specified damaging conditions. Several critical displays of information are too similar or too Errors of judgement, particularly during periods of stress or high job demand. close together. Job requires operator to make hurried judgements at critical times, without Critical components installed incorrectly. Inappropriate use or delay in use of controls. programmed back-up measures. Design and instructions are ambiguous on installation of components. Lack of asymmetrical configurations or guides on connectors or equipment. Critical controls are too close, similar in design, awkwardly located. Readout instrument blocked by arm when making adjustment. Labels on controls are confusing. Information is too small to see from operator's position. Inadvertent activation of controls. Controls easy to activate by brushing past or too close to other controls. Controls can be easily activated accidentally. Lack of guards over critical controls. Critical instruments and displays not read or information misunderstood because of clutter. Critical instruments or displays not in most prominent area. Design of many displays similar. Failure to notice critical signal. Lack of suitable auditory and visual warning to attract operator's attention to information. Plant operation results in unexpected direction or response. Activation direction of controls conflicts with population norms or expectancies. Lack of understanding of Instructions are difficult to understand. procedures. Following prescribed procedures results in error or incident. Written prescribed procedures not checked for accurate operation. Lack of correct or timely actions. Available information incomplete, incorrect or not available in time. Response time of system or plant too slow for making next appropriate action. Lack of automatic corrective devices on system with fast fluctuations. Exceeding prescribed limitations Lack of governors and other parameter limiters. on load or speed. Lack of warnings on exceeding parameters. PAGE 48 OF 48