1. Mechanical and Handling Hazards
TE-MSC Safety Day
Mechanical and Handling Hazards
F. Savary

2. Part I: Mechanical hazards
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Mechanical and Handling Hazards

3. Types of mechanical injuries
Definition
A mechanical hazard is any hazard involving a machine or process
Are essentially due to machine, components of the machine, moving parts of the machine, or any other source, which can injure a person
Compressed gases or liquids can also be considered a mechanical hazard
Types of mechanical injuries
Cut
Laceration
Bruises
Puncture
Crush
Bone
Hematomas
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4. Machining* operations
*Or more generally, operations on/with machinery/tools
Conventional and CNC machine tools … but also folding presses, rolling machines, and cabling machines are other types
There are more special machines, e.g. M-line orbital cutting machines (LS1) and bus bar surfacing, grinding machines, sawing, …
Against metal chips, burrs, powders, lubricants, cleaning agents, solvents:
Goggles, gloves
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5. Some materials are more aggressive
Fiberglass and composite materials require particular precautions
Always wear respirator/face mask, and goggles
Many resins are inflammable or contain additives that are inflammable, so be careful with heat sources
Many materials used in fiberglass work are corrosive, or have some undesirable effect on the skin (irritant), so protect your skin/eyes … again goggles and gloves!
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6. Heavy loads may fall on the floor!
… and worst, on your foot!
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7. Welding, soldering, brazing
Personal protection (the welder)
Burns (adapted cloth, gloves), arc flash - “coup d’arc” (protect your face/eyes with a welding mask)
Protection of personnel working at the vicinity of a welding area (not the welder)
Use curtains to surround the welding area
Soldering, e.g. when using tin lead alloy (soldering of the shunts)
Analyses of fumes, in collaboration with HSE, have shown no trace of Pb, i.e. no need of a specific filter for this. However, a filter was used to prevent other hazards due to traces of rosin and alcohol
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8. Welding press for dipole shells, 1
On top of obvious welding related hazards
Mechanical hazards due to the necessity for the welder to watch carefully the weld pool during welding, … in a small space
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9. Welding press for dipole shells, 2
emergency cable pull switch
Help is recommended in certain circumstances … allocate sufficient resources
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10. Hydraulic and pneumatic systems, 1
Collaring press:
Up to 375 MN over 15 m!
High pressure up to 700 bar
Hydraulic group of the welding press:
Up to 162 MN over 16 m
High pressure up to 550 bar
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11. Hydraulic and pneumatic systems, 2
High pressure fluids hazards, hydraulically and pneumatically driven tools hazards
Crushing, high pressure / hot fluid leaks / jets
High pressure oil easily punctures skin causing serious injury, gangrene or death
If injured, seek emergency medical help. Immediate surgery is required to remove oil
Do not use finger or skin to check for leaks
Lower load or relieve hydraulic pressure before loosening fittings
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12. Real case: pressure test
When: March 2007
Where: LHC tunnel
Need: verify/accept triplets after installation in the tunnel
Action: carry out pressure test
Incident: due to movement of one of the cold masses, rupture of a helium piping with strong detonation
Consequence: 2 of the 7 persons who witnessed the test (even if at 25 m of the incident) presented signs of hearing loss (that disappeared after some time). Only one of the seven was wearing hearing protection
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Mechanical and Handling Hazards

13. Mechanical and Handling Hazards
Machine conformity – Mise en conformité des machines
To be checked with EN-MME, Emmanuel Ravry / Alain Stalder
Safety Form M Workshop machine tool - Authorization of use
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14. For new and special machines
For example, a 6.5 m long reaction furnace currently in assembly in B180
Risk assessment file shall be developed by the manufacturer
There are guidelines available at:
Safety Guideline on risk assessment
Safety Tool for risk assessment
List of generic hazards typically present in workshops
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15. Safety form – Risk assessment form
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16. See next presentation by John Pedersen
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17. Part II: Handling hazards
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18. Mechanical and Handling Hazards
Definition
Manual handling of loads (MHL) and manual material handling (MMH) involve the use of the human body to lift, lower, fill, empty, or carry loads
When performed incorrectly or excessively, these tasks may expose workers to physical risk factors, fatigue, and injury
A variety of MMH techniques and tools exist to alleviate these potential problems
Forklifts, overhead cranes, lifting girders, SpanSet® slings, …
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19. Manual handling and lifting
There are legal limits, depending on the age/sex, but also the distance and the characteristics of the task (articles R à R du code du travail, norme AFNOR X et décret n° du 3 septembre 1992)
Boys
From age 14 to 15: 15 kg
From age 16 to 17: 20 kg
Men
Max 55 kg
May be allowed to carry loads above 55 kg, if recognized able to do so by the occupational physician
In any case the load shall not exceed 105 kg. Article R of «code du travail» says: «Lorsque le recours à la manutention manuelle est inévitable, et que les aides mécaniques ne peuvent pas être mises en oeuvre, un travailleur ne peut être admis à porter d’une façon habituelle des charges supérieures à 55 kgs, qu’à condition d’y avoir été reconnu apte par le médecin du travail, sans que ces charges puissent être supérieures à 105 kgs»
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20. Recommendations for manual handling of loads
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21. Real case: bus bars in ISR
When: March 2012
Need: remove 16-m long bus bars from storage in the ISR (B181)
Action: 3 persons intervene, one of them climb on wooden crates to reach the bb stored in height
Accident: a person falls down between crates
Safety rules for work in height were somehow neglected
Consequence: the person was absent for 7 weeks
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22. Mechanical and Handling Hazards
Heavy Handling
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23. Heavy Handling Section – EN-HE-HH
In principle, any overhead crane is driven by a professional from EN-HE-HH
However, a specific training course “pontier-élingueur” is available and allows using overhead cranes of up to 20 t
Authorizations to operate a crane are given exclusively by the EN-HE Group Leader, CERN-wide, for a specific crane (we do not get authorization for any crane on the CERN site)
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24. Design/use of handling tools/girders
May not be used if not formally approved by HSE
CE conformity required
Load test needed
Design work may be done on our side; however, one needs to follow codes and norms in force for handling/lifting equipment
Again, support from HSE is possible
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25. Norms regarding lifting / handling
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26. Some concluding words …
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27. Put priorities in the right order!
No room for procrastination* in safety
Safety first, remember the ranking put in force for LS1:
SAFETY
QUALITY
SCHEDULE
COST
Your
health,
physical integrity,
life
are concerned!
*Procrastination:
The action of delaying or postponing something
The practice of carrying out less urgent tasks in preference to more urgent ones, or doing more pleasurable things in place of less pleasurable ones, and thus putting off impending tasks to a later time
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Mechanical and Handling Hazards

28. Mechanical and Handling Hazards
Things to remember
Act as a professional, qualification and training are essential to ensure safety at the workplace
Do not improvise if you are not sure of what you do (or are asked to do), always ask to experienced staff in case of doubt
Safety is the matter of all
You can always talk to your supervisor, section leader, group leader, Territorial Safety Officer, Departmental Safety Officer (Thomas Otto)
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29. Mechanical and Handling Hazards
Useful links
HSE: Occupational Health and Safety and Environmental Protection Unit
In particular safety rules and
Regulatory watch that provides you with a list of referenced documents (laws, standards, guides, ...) applicable in matters of Safety:
Call them in case of doubt
Departmental safety plan – TE
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