Equipment and Machinery Guarding

DOC.
SAFETY
STANDARD
DIVISION STEEL WORKS EFF. DATE 30.08.2009
DOC# SS/GEN-09 TITLE Equipment and
Machinery Guarding
REVISION 01
SHEET Page 1 of 16 DUE FOR REVISION 30.08.2012
COMP.BY Atri
Mahapatra
SIGNED DATE 27.06.2009
AUTH. BY Rajesh Mishra
Manish
Kumar Pandey
SIGNED DATE

1.0 Purpose: The standard provides information regarding safeguarding of equipments and
the material and construction of the guards. Section 6 describes safeguarding based on
classification of equipments.
2.0 Reference: SS/ GEN -09, SS/ ENG 18, Workers Compensation Board (BC).
3.0 Associated Hazards: Injury due to rotating equipments, components flying out due to
centrifugal force, body parts like hand/ finger or clothing getting caught in the rotating
component.
4.0 Applicability: Inside Tata steel works
5.0 Responsibility: Working departments and contractors
6.0 Procedure:
6.1 Safe guarding of the equipments can be classified in the following ways:
6.1.1 Safe guarding of mechanical power transmission equipments
Belt and pulley
Chain and sprocket
Couplings- Input/ output shafts
Flywheels/ Bull gears/ Open gears
Tail end of belt conveyor
Brakes and clutches.
Other projected parts

DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.1.2 Safeguarding of equipments at working site.
Safe guarding of equipments during lubrication
Safe guarding of equipments while online cleaning.
Safe guarding of equipments while condition monitoring and sampling.
6.1.3 Safe guarding of accessory equipments
Exhaust fan, man cooler fan, pedestal fan, grinders
6.2 Guarding can again be classified according to the nature of the job:
6.2.1 Temporary safeguarding-
Where jobs are carried out onetime near the rotating or projected part of an
equipment (described in section 6.1).
The guards must be designed that it can easily be refitted. The large guards
must be made from a number of sections and provide handles and locating
points.
The safety guard shall be in pieces of convenient size, bolted/ hooked to fix
the structure for easy removal during maintenance/ condition monitoring.

6.2.2 Permanent safeguarding-
Where regular jobs are carried out near the rotating or projected part of an
equipment (described in section 6.1).
6.3 Materials for safe guard:
Wire mesh, Metal sheet, and transparent plastic sheet.
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.4. Construction of safeguard:
1. The choice of material of construction is largely a matter of local preference based
upon operating conditions, types of guards already installed.
2. Frame work / Railing of the safeguard: - Angles/ Flat, hollow structure or pipe can
be used
3. Filler Material: - Wire mesh, perforated or solid sheet metal, high strength plastic.
4. If guards are located out door, painted or galvanized steel sheets to be used.
5. Guards furnished with purchased equipments are desirable if they meet the general
requirements of this standard.
6. Filler Dimensions- Wire mesh (Refer Fig 1)
a is the sides of square in wire mesh - 12 to 20 mm (1/2 in and in).
b is the minimum clearance between guard and machinery - 120mm (4 in) .
The wire diameter should be between 1.5mm to 3mm

Figure1
a
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

Metal, transparent plastic sheet (Refer Fig 2)
Sheet thickness - 2 mm to 5 mm
Minimum clearance between safe guard and rotating machine- 120 mm

7. Transparent sheet shall be used on rotating equipment from where there is a chance
of oil/ coolant splashing.
8. Framework dimension For SHS 25 X 25 X 2.5 mm.
For Flat 25X25X3.0 mm
For Angle 25 X 25 X 3.15 to 45X 45X3.15 mm.

UMC no. of some materials is given in annexure-1

Figure 2
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.5 Equipments
6.5.1 Belt and pulley
6.5.1.1 All power transmission belts, any part of which is 8 feet or less from the
floor or working platform, shall be guarded fully except slow moving (less
than 250 ft per minute) belts of the following specification: flat belts 1 inch
or less in width; flat belts 2 inches or less in width, which are free from
metal lacings or fasteners; round belts onehalf inch or less in diameter; and
single strand Vbelts, 13/32inch wide or less.

6.5.1.2 Horizontal overhead belts, 7 feet or more above the floor or platform, shall
be guarded for their entire length under the following conditions:
i. If located over passageways or work places and traveling 1800 feet or
more per minute
ii. If centertocenter distance between pulleys is 10 feet or more
iii. If belt is 8 inches or more in width

6.5.1.3 Vertical and inclined belts shall be enclosed in a manner similar to
horizontal belts.

6.5.1.4 Overhead belts belt drives are governed by the same rules as overhead
horizontal

6.5.1.5 Metallic belt lacing or fasteners shall not be used in areas containing
explosives or Flammable vapors.

DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

Figure :3

6.5.1.6 Pulleys, any part of which are 8 feet or less from the floor or working
platform, shall be caged.

6.5.1.7 Unless the distance to the nearest fixed pulley, clutch, or hanger exceeds the
width of the belt used, a guide shall be provided to prevent the belt from
leaving the pulley on the side where insufficient clearance exists.

6.5.1.8 Where there are overhanging pulleys on line, jack, or countershafts, with no
bearing between the pulley and the outer end of the shaft, a guide to prevent
the belt from running off the pulley should be provided.
Frame
Filler (wire mesh)
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.5.1.9 Where separate pulley guards are used under conditions and the belt does not
require guarding, the guard should enclose the pulley so as to protect the run
in point of the belt. The guard should extend slightly higher than the top of the
pulley, the belt running through a slot or narrow opening which would not
permit the hand to be drawn into the nippoint.

6.5.2 Chain and sprocket: The safeguarding is similar as explained in section 6.5.1.1 to
6.5.1.5.
6.5.3 Couplings Input/output shafts- Couplings mounted at input or output shaft of
the machine must be guarded by a stationery guard as explained in section 6.4.

6.5.4 Flywheels/Bull gears/ open Gears
6.5.4.1. Guards shall be provided on flywheel/ bull gear/ open gear as explained in
section 6.4

Frame
Coupling
Filler (Wire
mesh)

Figure 4
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.5.4.2. When the upper rim of flywheel / bull gear/ open gear protrudes through a
working floor it shall be enclosed entirely or surrounded by a guardrail and
toe board.
6.5.4.3. When flywheel/ bull gear/ open gear extends into pit or within 12 inches of
floor standard toe board shall be provided.

6.5.5 Tail end of belt conveyor
The tail end of a belt conveyor having rotating pulley must be guarded as explained in
SS/ENGG 18
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

Figure5: Guarding of tail end pulley
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.5.6 Brakes and clutches:
Brakes and clutches mounted at input or output shaft of the machine must be guarded by a
stationery guard as explained in section 6.4.

6.5.7 Other projected parts.
This includes (Refer Figure 7)--
Protruded parts of stationery structures in the walkway/ nearby the working
area,
Uncoupled shaft of gearbox / pulleys/ rolls.

Figure 6
Brake

Figure 7
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

The safeguard shall be provided as explained in section 6.4.
6.6 At working site
6.6.1 Lubrication
If the lubrication point is near to the rotating equipment the safeguard and the lubrication
facility shall be given as follows:
6.6.1.1 The guards must be designed to reduce the need to remove them. For example
provide access to tracking mechanisms in figure 8: (A) and greasing points (B).

Figure: 8 Lubrication points

6.6.2 Online cleaning / Condition Monitoring/ Sampling
6.6.2.1 During online cleaning/ condition monitoring / sampling the rotating or
projected part of an equipment must be guarded.

6.6.2.2 The difficulties associated with frequent removal of guards and the continual
stopping for cleaning purposes may be overcome by using hinged guards
which allow access.
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.7 Accessory equipments
6.7.1 Grinders
The associated risk of bench grinders, pedestal grinders, and portable grinder is
fragmentation of an abrasive wheel.
The main objective of safeguarding is to contain pieces of the abrasive wheel if a rupture
occurs.
The maximum wheel exposures for guards on two types of abrasive equipment: bench and
pedestal grinders (90 exposure) and hand-held angle grinders (180 exposure) is illustrated
in the figure10. The protective hood of a portable grinder must cover at least 120 of the
wheel periphery.

Figure9
Guarding at position of condition
monitoring & sampling
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

Figure 10

6.7.2 Man cooler Fan/ Exhaust Fan/ Pedestal Fan
The Fan Must be guarded by a galvanized wire mesh. The dimension of wire mesh should
be between 4 to 8 mm and minimum clearance between fan and guard should be at least 15
mm.
6.8 Training
All personnel whose job requires working close to rotating equipment shall be trained
by a competent person prior to starting the job.
Safety precautions specific to the equipment in which the person is supposed to work
should be explained to him a competent person prior to starting the job.
A hazards assessment by working unit or function is required for the area concerned.
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

6.8 Safeguarding Checklist

The checklist attached below is a guideline for safeguarding

DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

UUA
DOC. SAFETY
STANDARD
Machinery Guarding
REVISION 01
COMP.BY Atri
Mahapatra
Manish
Kumar Pandey
SIGNED DATE

Annexure: -1

Item UMC No. Specification
Square Hollow Section 1227A0112 38X38X3.2 mm
1227A0106 25X25X3.2 mm
1227A0109 49.5X49.5X3.6 mm
Acralic Transparent Plastic
sheet
0265A0078 130 mmX5mmX10m
Flat 1573A3394 MS Flat 25X3mm
Angle 1227ZA002 MS25X25X3mm

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