Key Features

• Explains which standard is relevant for which type of machine
• Helps manufacturers to self-certify their machines for the EU market
• All types of safeguards are discussed - mechanical, interlocking, electrical/electronic/programmable, hydraulic, pneumatic

Description

John Ridley and Dick Pearce, both recognized specialists in machinery safety, guide the reader through the various standards, regulations and best practices relating to the safe design and use of machinery and show which standard is relevant for which type of machine.

Safety with Machinery provides a basic grounding in machinery safety and covers safeguarding philosophy and strategy, typical hazards, risk assessment and reduction, guarding techniques, ergonomic considerations, safe use of equipment and plant layout. All types of safeguards are discussed – mechanical, interlocking, electrical / electronic / programmable, hydraulic, pneumatic.

The new edition has been updated throughout in line with changes in regulations and standards. The section on electric, electronic and programmable safety systems has been expanded to reflect their increasing importance. The book now focuses on the harmonised standards (e.g. EN ISO 13849, IEC/EN 61131-2) which can be used by manufacturers to self-certify their machines for the European market without the need for third party examination, but also covers other relevant standards (e.g. IEC 62061). Many practical examples set the regulations in context and assist in the interpretation of the various standards.

Safety with Machinery is essential reading for all engineers involved in machinery design and maintenance all over the world as every machine sold within or into the EU needs to conform to the harmonised standards. It also provides health and safety professionals, students and employee representatives, as well as certification bodies, health and safety inspectors and safety regulators with a comprehensive overview of machinery safety.

Readership

Engineers, technicians and managers in machinery design, manufacture and maintenance; health and safety professionals and safety representatives in manufacturing industries; certification and audit bodies; health and safety inspectors and safety regulatory organisations. Vocational students on design of machinery and health and safety courses.

Quotes

Reviews of the previous edition:
"The text is very readable and well supported with examples, diagrams, photographs and illustrations. Overall the book provides an excellent overview of machinery safety. It is well written and will be of particular help to designers and engineers tasked with developing solutions to the sometimes conflicting demands of operators, employers and enforcement bodies. The authors clearly have extensive knowledge and practical experience in relation to the safety of machinery." - HEALTH AND SAFETY AT WORK, October 2003

"Clearly written and well illustrated, the book is aimed at engineers, designers and safety officers, and would also be usful to students taking courses in health and safety." - SAFETY MANAGEMENT, February 2004

Table of Contents

• Preface to the second edition.
• Preface to the first edition
• PART I – SAFEGUARDING PHILOSOPHY AND STRATEGY
• 1 Safeguarding of work equipment
• 1.1 Introduction
• 1.2 Design considerations
• 1.3 Life cycle
• 1.4 Designer’s responsibility
• 1.5 Safeguarding principles
• 1.6 Guarding strategy
• 1.7 Unit vs holistic approach to safeguarding
• 1.8 EU Directives in machinery safety
• 1.9 Standard-making bodies
• 1.10 European approach to machine guarding
• 1.11 Interpretation of standards
• 1.12 Arrangements in the USA
• 2 Factors affecting the selection and effectiveness of machine safeguards
• 2.1 Introduction
• 2.2 Basic factors
• 2.3 Quality assurance
• 2.4 Reliability
• 2.5 Integrity
• 2.6 Validation
• 2.7 Difficulties in applying some safety standards
• 2.8 Summary
• 3 Typical hazards of machinery
• 3.1 Identification
• 3.2 Agents of hazards
• 3.3 Hazards from parts of machinery and work equipment
• 4 Risk assessment, risk reduction and selection of safeguards
• 4.1 Introduction
• 4.2 What is a risk assessment?
• 4.3 Risk reduction strategy
• 4.4 Relevant standards
• 4.5 Determining a safety integrity level for machinery hazards
• 4.6 Selecting a safeguarding system
• 4.7 Summary
• Part II – GUARDING TECHNIQUES
• 5 Mechanical guarding
• 5.1 Introduction
• 5.2 Guard selection
• 5.3 Guard types
• 5.4 Other factors to consider
• 5.5 Other techniques
• 6 Interlocking safeguards
• 6.1 Introduction
• 6.2 Interlocking devices
• 6.3 Guard locking
• 6.4 Interlocking systems
• 6.5 Levels of risk
• 6.6 Interlocking media
• 6.7 Two hand controls
• 6.8 Hold-to-run controls
• 6.9 Limited movement control
• 6.10 Person sensing devices
• 6.11 Lasers
• 6.12 Pressure sensitive mats
• 6.13 Pressure sensitive edges and wires
• 6.14 Grab wires
• 6.15 Emergency stop switches
• 6.16 Telescopic trip switches
• 6.17 Proximity switches
• 6.18 Key exchange systems
• 6.19 Key interlock switches
• 6.20 Delayed start
• 6.21 Other interlocking devices
• 7 Ergonomic aspects of machinery safeguarding
• 7.1 Introduction
• 7.2 Physiology
• 7.3 Controls
• 7.4 Machine layout
• 7.5 Colours
• 7.6 Lighting
• 7.7 Noise
• 7.8 Vibrations
• 7.9 Rate of working
• 7.10 Temperature and humidity
• 7.11 Ventilation
• 7.12 Repetitive actions
• 7.13 Warnings
• 7.14 Vision
• 7.15 Radiations
• 7.16 Indicators and instruments
• 7.17 Coda
• Part III - SAFEGUARDING SYSTEMS
• 8 Mechanical safety arrangements
• 8.1 Introduction
• 8.2 Guards
• 8.3 Distance fencing
• 8.4 Safety gaps
• 8.5 Feed and take-off stations
• 8.6 Work-holding devices
• 8.7 Counter-weights
• 8.8 Safety catches
• 8.9 Braking systems
• 8.10 Clutches
• 8.11 Summary
• 9 Electrical safety circuits
• 9.1 Introduction
• 9.2 Effect on safety
• 9.3 Basic safety requirements
• 9.4 Selection of interlocking switches
• 9.5 Switching contact requirements
• 9.6 Factors influencing the selection of interlocks
• 9.7 Circuit fault protection
• 9.8 Safety control circuits
• 9.9 Quantitative analysis
• 10 Hydraulic safety circuits
• 10.1 Introduction
• 10.2 Hydraulic systems for safety circuits
• 10.3 Hydraulic safety circuits
• 11 Pneumatic safety circuits
• 11.1 Introduction
• 11.2 Pneumatic installations
• 11.3 Pneumatic safety circuits
• 11.4 Summary
• Part IV - OTHER SAFETY RELATED ARRANGEMENTS
• 12 Safety in the use of lifting equipment
• 12.1 Introduction
• 12.2 Common safety features of lifting equipment
• 12.3 Additional features for particular lifting equipment
• 12.4 Lifting accessories
• 12.5 Circumstances requiring special precautions
• 12.6 Precautions when handling lifting equipment
• 13 Safety with pressure systems
• 13.1 Introduction
• 13.2 Compressed air
• 13.3 Hydraulic installations
• 13.4 Steam
• 13.5 Process plant
• 14 Safe working with equipment
• 14.1 Introduction
• 14.2 Systems of work
• 14.3 Protection from electric shock
• 14.4 Locking off
• 14.5 Ergonomics
• 14.6 Anthropometrics
• 14.7 Openings in guards
• 14.8 Operating instructions and manuals
• 14.9 Labels on equipment
• 14.10 Supervision
• 14.11 Use of jigs and fixtures
• 14.12 Safety clothing
• 14.13 Stored energy
• 14.14 Signs and signals
• 15 Plant layout and the working environment
• 15.1 Introduction
• 15.2 Space
• 15.3 Buildings
• 15.4 Services
• 15.5 Ventilation
• 15.6 Lighting
• 15.7 Temperature
• 15.8 Machine layout
• 15.9 Noise
• 15.10 Vibrations
• 15.11 Materials handling
• 15.12 Maintenance
• 15.13 Waste
• 15.14 Access
• 15.15 Lubrication
• 15.16 Dust and fumes
• 15.17 Floors and foundations
• 15.18 Hygiene
• 15.19 Notices and signs
• 15.20 Explosive atmospheres
• Part V - APPENDICES
• 1. Published standards
• 2. Glossary of terms
• 3. Abbreviations
• 4. Smooth shaft pick-up
• 5. Pipeline colour codes
• 6. Permit-to-work
• 7. Protection of enclosures
• Index

Author Information

By John Ridley, BSc, CEng, MIMechE, FIOSH, DMS, Independent Consultant, U.K. Formerly Chief Safety Engineer, Reed International.; and

Dick Pearce, BSc, CEng, FIEE, Independent Electrical Safety Consultant, U.K. Formerly Principal Electrical Inspector with the Health and Safety Executive.