Safety First August 2014

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Solutions Guide

August 2014

www.sick.com.au

Manager’s Occupational Health and Safety

ON THE SAFE SIDE

RELIABLY MINIMISE RISKS WITH SICK INSIDE:

Mining Safety l Materials Handling l Body Protection l Production Line l OH&S l Waste Handling

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>>> a special supplement produced by cirrus media

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CONTENTS

SafetyFirst.

Publisher Martin Sinclair E-mail: martin.sinclair@cirrusmedia.com.au Editor Brent Balinski Tel: (02) 8484 0680 E-mail: brent.balinski@cirrusmedia.com.au Victoria sales Project Manager Michael Northcott Mobile: 0448 077 247 E-mail: michael.northcott@cirrusmedia.com.au New South Wales sales Anthony Head Tel: (02) 8011 3184 Fax: (02) 8484 0915 E-mail: anthony.head@cirrusmedia.com.au Queensland sales Sharon R. Amos Tel: (07) 3261 8857 Fax: (07) 3261 8347 E-mail: sharon.amos@cirrusmedia.com.au Production Co-ordinator Mary Copland Tel: (02) 8484 0737 Fax: (02) 8484 0722 E-mail: mary.copland@cirrusmedia.com.au Graphic Design Dave Ashley Tel: (02) 8484 0710 E-mail: david.ashley@cirrusmedia.com.au Circulation/Customer service Tel: 1300 360 126 E-mail: customer.service@cirrusmedia.com.au

contents Mining Safety

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New oxygen sensor launched at mining show Synchronous lifting system replaces manual control of hydraulic heavy lifting Confined spaces air management improves work atmosphere

Materials Handling

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New high-rise storage shelving maximises footprint Hand pallet jacks offers improved safety

Body Protection

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New women’s workwear Protecting tradies’ health Staples launches Staples Safety Solutions

Production Line

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Robot safety courses to serve growing automation needs Easy-to-use safety relay solution

OH&S

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New app for safe working at heights Customised ergonomic workspaces for industry Programmed signs up Kiwi driver training company Cirrus Media Tower 2, Level 3, 475 Victoria Avenue Chatswood NSW 2067, Australia Locked Bag 4700 Chatswood Delivery Centre, NSW 2067, Australia Tel: (02) 8484 0888 Fax: (02) 8484 0633 ABN 80 132 719 861 www.cirrusmedia.com.au © Copyright Cirrus Media, 2014

Waste & Hazardous Environments A “bigger picture” compressed air system

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Printed by Offset Alpine Printing All rights reserved. No part of this publication may be reproduced or copied in any form or by any means without the written permission of the publisher. Utmost care is taken to ensure the accuracy of editorial matter. Product specifications and claims are those of the manufacturers.

Printed four times a year, Safety First is inserted in the March, June, August and October issues of Manufacturers’ Monthly, FEN, Food, Australian Mining and PACE with a distribution of 15,000.

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Solutions Guide

August 2014

www.sick.com.au

Manager’s Occupational Health and Safety

Behind the cover SICK Australia & New Zealand www.sick-safetyplus.com

ON THE SAFE SIDE

RELIABLY MINIMISE RISKS WITH SICK INSIDE: l l

Mining Safety l Materials Handling l Body Protection l Production Line OH&S l Waste Handling >>> A SPECIAL SUPPLEMENT PRODUCED BY CIRRUS MEDIA

SICK is a leader in industrial safety systems, offering scalable solutions for many applications. They offer trendsetting products and application-oriented functionality from simple machine guard door interlocks to intelligent light curtains, cameras, laser scanners and programmable safety controllers with motion monitoring capabilities. SICK’s offering is completed by its holistic ‘Safety PLUS’ philosophy, combining experience, competence, high technology, system openness, clever safety solutions and a comprehensive suite of safety services. SICK safety solutions enhance investment, achieve greater potential for savings through more efficient processes and always focus on the primary goal – human and machine safety.

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MINING SAFETY

New oxygen sensor launched at QME

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ITY Technology, a Honeywell company, unveiled an addition to its gas sensing range at the QME Mining show in Queensland last month.

Protecting workers in underground mines from oxygen depletion and the hazards of toxic and flammable gases is a continuous challenge.

Companies must maximise safety, adhere to stringent regulations, leverage operational cost efficiencies, whilst ensuring their people and assets are protected.

Selecting the right gas sensing solution is an intrinsic aspect of fulfilling this remit.

The new AN/NZS 4641

Also meets the demanding Chinese Mining Specification, AQ6205-2006.

compliant 4OxLL has an unsurpassed stability in challenging environmental conditions, according to its maker, minimised nuisance

alarms and extended operational life.

One of the drivers of the launch in Australia was improving the reliability of

Synchronous lifting system ENERPAC, a high-pressure hudraulics specialist, displayed its latest workplace efficiency and safety technologies at this year’s Queensland Mining Exhibition in Mackay last month.

Enerpac – which operates in 22 countries with more than 1000 employees, displayed a range of products, including its new generation Enerpac EVO Replaces manual control of hydraulic heavy lifting. synchronous lifting systems used to lift entire structures, plant or accurately and safely lift some of the machinery weighing thousands of tons. largest and most challenging structures EVO is a new generation Enerpac on earth, including mineral and oil and synchronous lifting system that replaces gas processing equipment. manual control of hydraulic heavy The new EVO synchronous system lifting with PLC control of multiple offers eight standard hydraulic control cylinder lifts offers accuracy, safety and modes and can control 4, 8 or 12 points productivity benefits for precision with one hydraulic power unit (HPU). A lifting of heavy resources industry master control unit is also available that machinery. offers daisy chain control of up to 16 The EVO system is the evolutionary EVO systems, giving a maximum of 192 result of Enerpac’s 25 years of lifting points.

Enerpac experience in specialised hydraulic 02 9743 8988 engineering and lifting technology www.enerpac.com.au using digitally controlled hydraulics to

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gas detectors in underground mines whilst reducing cost of ownership. Mario Moura, Marketing Director for Honeywell Life Safety, said, “Mining applications represent some of the most challenging environments for portable gas detectors; temperature and relative humidity can fluctuate dramatically as workers move from external locations into hot and humid mining environments, and pressure shocks can occur during mine shaft lift descent – sometimes resulting in incorrect oxygen readings; these aspects can make nuisance alarms a prevalent and costly issue.”

City Technology www.citytech.com

Confined spaces air management improves work atmosphere FANQUIP provides a confined spaces management service and product supply for all industrial sectors, including mining.

This confined space speciality can be applied across the industry spectrum, including the likes of aluminium smelters, dust control in food processing, mining, vapour-rich processes, fuel tank cleaning, sewerage cleaning – just about anywhere air quality could be compromised in a confined space.

It can provide explosion proof motors for applicable situations where a spark could ignite the air; for example, when enamels are being used so the fresh air route versus the contaminated air route coming through is reduced.

Fanquip provides consultation and design on how to choose the most appropriate technologies and where to position them in confined spaces that may suffer not just from explosive and noxious air but also from heat, cold, humidity and general contaminants.

Fanquip 1800 224 308 www.fanquip.com.au

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Understanding Functional Machine Safety Standards To ensure you’re ahead of the game, NHP has developed a white paper to help you understand the transition from Safety Categories to the probabilistic measurements of ISO 13849-1:2006.

It also explains how these probability methods build on the proven architectures of safety categories – and it’s yours for FREE!

NHP ELECTRICAL ENGINEERING PRODUCTS PTY LTD

Sales 1300 NHP NHP | nhp.com.au |

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A major challenge for those in the Australian electrical industry is the transition of international machine safety standards towards probability based design methods.

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MATERIALS HANDLING

High-rise storage shelving maximises expensive footprints

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CTISAFE, an industrial occupational health and safety specialist, has expanded into the area of bulk storage.

It has released its Australian made high-rise storage shelving for warehouses, components and parts processes, food manufacturers and other general industrial companies.

The ‘Defence Preferred Supplier’ added this technology to its growing list of stocks as a way of facilitating those companies in need of a certain level of customisation to their storage and shelving requirements.

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Heavy-duty steel panel and framework construction.

priced at a premium – companies looking to lock into particularly in metropolitan lease agreements. areas – a high-rise storage Made of heavy-duty steel option is considered a panels 1 2 0 1 4 - 0 2 - 0 6 T 1 5 : 0 2 :and 2 4framework, + 1 1 : 0 0 strategic investment for most Actisafe high-rise storage

EDGES NEW

Safepad has introduced a new range of edge protection products. Safepad Edges are designed to cover protruding or hazardous edges with a soft yet durable EVA foam strip. Each Safepad edge product is highly visible, and is supplied in various profiles applicable to most edges, including cornices, flanges, ducting, braces, stairways and beams. Contact Safepad for cost effective solutions to worksite impact hazards.

www.safepad.com.au sales@safepad.com.au (+61) 8 9474 6886 6

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shelving can be powder coated to a specific colour required by the end user.

Designed with reinforced edges, the customised technology is durable enough to withstand a certain degree of impact from items such as forklifts, palette tracks and other industrial materials handling equipment.

Actisafe high-rise storage shelving optimises the use of warehouse spaces which, in the current market where industrial space is near cost prohibitive, is a very positive outcome for the end-user.

Actisafe 1300 852 397 www.actisafe.com.au

Pallet jack for improved safety LENCROW has just lunched its latest pallet jack on the market. The EPT20-15EHJ is a pump to lift with power drive which offers a much safer alternative to hand pallet jacks. The unit has a capacity of 1500kgs and is designed Total self weight of the unit is only 150kg. with 4.5mm ribbed forks and made with a high strength frame to give many years of operation.

The unit works in the same area as The unit offers increased safety with a standard pallet jack and the total self less operator strain than pushing or weight of the units is only 150kg. This pulling pallets and with the automatic makes this unit ideal for use in shops brake the unit will not roll away on and bulky goods outlets. The price for slopes when the pallet is elevated. The these units are a fraction of a standard unit has been fitted with an anti skid power pallet jack. drive wheel and auto reversing safety The unit is self contained with built switch on handle. in charger that can be charged at any Ross Grassick, managing director, power point. As with all of the EP green Lencrow, said, “We have looked for range of equipment they are pollution a low cost unit that will improve the free and work with a reduced carbon safety in the workplace. This unit was foot print.

Lencrow Materials Handling not designed to replace heavy duty 1300 536 276 power pallet jacks that have much www.lencrowgroup.com.au longer duty cycles.”

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NEW PB49 BOOTS. Calling all women! The struggle to find comfortable work shoes is finally over.

Oliver’s new women’s footwear range is a triumph of safety, comfort and style. www.oliver.com.au Love your feet more

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BODY PROTECTION

Over 25,000 products including PPE and workwear.

Staples Safety Solutions launched

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TAPLES, a business products and services supplier, has launched a new division: Staples Safety Solutions.

The Staples Safety Solutions range features over 25,000 products including Personal Protective Equipment (PPE), workwear and site safety products suitable for a range of industries including mining, construction, manufacturing, food service, transport, government and warehousing.

“The gap we saw in the market, combined with an increase in demand

from our customers for a single source solution for all their PPE and workwear, led us to launch Staples Safety Solutions,” said Joe Taylor, Head of Facility Solutions, Staples Australia and New Zealand.

“Our team of Safety Specialists can help ensure that there is product consolidation across an organisation and that they’re only ordering necessary equipment and clothing, reducing overhead costs and excess deliveries,” added Taylor.

The Staples Supply Chain model has

22 warehousing and distribution points offering next day delivery in metro regions, and the Staples Spot service means with the correct authority, orders can be delivered to a secure nominated location within a premises without the need for a signature.

To support the launch of Staples Safety Solutions, Staples has released a 180-page standalone catalogue (see below link).

Staples Australia and New Zealand 13 26 44 www.staplesadvantage.com.au

Protecting tradies’ health TRADIES National Health Month is this month. Its aims are boosting and transforming the health and safety of Australian tradies.

Safe Work Australia recently reported $8.7 billion in compensation costs for trips, slips and falls relating to 26,705 claims and with research showing that 80% of injured workers in Australia are tradesmen and labourers, this initiative is a must.

Tradies rely on their physical and mental health to do their jobs and ignoring aches, pains and body stress could result in disability and debilitation in the future.

Steel Blue and the Australian Physiotherapy Association are providing tradies with the right tools to help them move well, stay well and assist in reducing

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the risk and severity of injuries. Throughout August, there will be events at work sites Australia wide with physiotherapists and Steel Blue representatives spreading the word.

All tradies are encouraged to register their support online and will enter a $4,000 prize draw to win the ultimate outdoor adventure and choose from the ultimate surfing, camping or fishing trip.

Bigger and better each year as we reach more tradies - this year, Tradies National Health Month is also launching an online game featuring an Australian celebrity. More details to be revealed soon.

National Health Month www.tradieshealthmonth.com.au

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BODY PROTECTION

New women’s workwear OLIVER’s new PB 49 Series of women’s safety footwear offers protection, comfort and style.

A long established manufacturer of safety and industrial footwear, Oliver Footwear identified the need to create a range of safety and industrial footwear specific to the safety needs of women in the workplace.

The shoes are suitable from the resources sector to manufacturing to the services and hospitality sector.

The PB 49 Series offers six different styles including a lace up, slip on, elastic sided, jogger and the stylish cross strap.

An important consideration was the need for slip resistance hence the choice of a dual density rubber outsole with a polyurethane midsole.

The excellent slip resistance not only meets the SRC slip standards but exceeds them.

SF 0 8 1 4 _ 0 0 0 _ I NF 1 And having an anti-static sole, any

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Hardwearing rubber outsole resists mineral and organic oils and acids.

build up of electrostatic activity is The outer sole has superior cut, slip and minimised. crack resistance and is also heat resistant The Oliver comfort footbed has to 300°C of surface contact.

Oliver Footwear perforated air channels to promote natural airflow and is treated with AEGIS Microbe 03 5320 0200 2 0 1 4 - 0 6 - 3 0 T1 3 : 1 8 : 1 6 + 1 0 : 0 0 www.oliver.com.au Shield solution to help maintain freshness.

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PRODUCTION LINE

Robot safety courses

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USTRALIA is seeing a significant growth in the use of robots, especially in non-traditional industries, as the relative cost of robots decrease and companies search for improvements in operational costs and efficiencies.

As a result, Pilz has seen a rising demand for robotic safety systems and has recently designed a new robot safety training course to provide those who integrate robotic systems with a comprehensive understanding of the essential requirements of robot safety.

Pilz’s one-day course examines how the risks associated with the use of robotic systems should be assessed and how to achieve safety while maintaining productivity.

Designed for technical personnel responsible for ensuring robotic system compliance, the course covers best practice standards

Assessing risks while maintaining productivity.

including ISO 10218 and AS 4024.3301 – Robots for Industrial Environments – Safety Requirements.

Participants will learn about risk assessment in robotic cells, common hazards and controls

and robotic safeguarding techniques and leave with the knowledge to apply the correct strategy to ensure right first time engineering.

The Robot Safety course will take place in:

Melbourne – 13 August 2014 Sydney – 24 September 2014 Brisbane – 3 March 2015 Adelaide – 18 June 2015 Machine Safe 1300 723 334 www.machinesafe.com.au

Easy-to-use safety solution

Configured through through Connected Components Workbench (CCW) software.

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THE new Allen-Bradley Guardmaster 440C-CR30 is a flexible, cost-effective and easy-to-use configurable safety relay ideal for applications requiring 4 to 10 safety circuits and control of up to 5 zones.

The Guardmaster 440C-CR30 is configured through Connected Components Workbench (CCW) software – the same “free” programming environment used by the Micro 800 family of controllers, PanelView component HMIs and PowerFlex drives – for simple and seamless programming of standard and safety logic in separate devices.

The distinct graphical user interface and drag-and-drop capabilities of CCW help guide users through a simple process of selecting certified safety function blocks for the 440CCR30. This means users can create, control and

monitor a safety system in the same software environment as their standard control, resulting in increased productivity and reduced programming time.

According to Paul Costantin, business manager, components – South Pacific, Rockwell Automation, “The free CCW safety application enables users to deploy complex safety functions quickly and simply through an intuitive logic editor that uses TUV certified function blocks.

While the compact hardware design and IO flexibility means that the 440C can be used in standalone safety functions as well as applications requiring multiple safety functions and zones.”

Rockwell Automation 1300 319 741 www.rockwellautomation.com/aus

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OH&S

ENPAC smarter stronger safer

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Pictured above: SharpDrive chief executive officer, Ryan Balemi.

Programmed signs up Kiwi driver training company

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ROGRAMMED, a facilities management company, has signed up Kiwi online driver training outfit SharpDrive to help pursue its Zero Harm goal.

SharpDrive is an online fleet driver training programme with content developed by driver training guru and former rally driver Graham Sharp, whose career highlights include winning the World Cup 3 Rally to the Sahara Desert in Morocco.

Programmed, which employs 10,000 staff and has more than 1200 drivers on the roads throughout Australia, is upfront about its Zero Harm health and safety goal. It was recognised for its ongoing commitment to health and safety, winning the Impact on

Organisation and Workplace Award at the Facility Managers Association Industry Awards for Excellence late last year.

Programmed Group General Manager of Health and Safety and Environment Malcolm Deery believes SharpDrive training will not only increase employee safety, reduce fleet incidents and infringements but also lead to reduced insurance premiums and improved fuel economy.

“While we have not had any major driver incidents, recent minor incidents and infringements tell us that we cannot ignore the possibility of a serious event in the near future,” Mr Deery said.

SharpDrive 1800 680 187 www.sharpdrive.co

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OH&S

Safety through standards and regulations SICK is represented on numerous national and international standard and committees. SICKinsight spoke to Otto Gornemann, Manager Machine Safety & Regulations at SICK about current trends.

SICKinsight: Mr Gornemann, which committees and working groups are you currently actively working with?

Otto Gornemann: We are working in national and international standards groups for safety principles (e.g. safety distances, risk assessment), applications for protective devices (e.g. electrosensitive protective devices), functional safety (safety controllers), industrial and nonindustrial robotics (e.g. classic industrial robots, collaborative robot systems, service robots, machines tools (e.g. presses) and packaging machines. I am also a member of the “Machines” section of the international Social Security Association. One of their aims is to spread knowledge regarding machine safety and its applications especially in newly industrialized countries and developing countries.

SI: Who are the members of such types of working groups? Who is represented in these working groups?

OG: The classic working groups, which develop safety standards, are made up of representatives from interested groups. These are authorities or research institutes machine and product manufacturers or the associations, and occupational health and safety organizations.

SI: How are the requirements of machine manufacturers taken into account?

OG: As one of the main driving forces in the German economy, the machine building industry must consider technical and economic feasibility. Occupational health and safety authorities and representatives are focused on the social demands for product safety and a safe working environment.

As product manufacturers, we have to take all these aspects into account and find a balance. Each interested party brings their own requirements to the table, however standards are always the result of a consensus. In Germany, machine building has been represented extremely well for a number of

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years by the VDMA. However, it would be better if there was an increased collaboration from machine manufacturers in some industries. Unfortunately, it seems to me that some are more focus on short-term aims than securing future business.

SI: How much time and effort does SICK invest in standardisation work?

OG: SICK invests a great deal of time and effort in standardization work. I can’t put a precise figure on it as standardisation work is highly varied. Redacting a draft standard or processing comments can take several days alone. The effort, in particular when it comes

In addition, our “Six steps to a safe machine” guidelines contain additional and more in-depth information regarding standards and their application.

SI: What are you currently working on?

OG: Our main priority at the moment is to support our customers as they adapt to the new EN ISO 14119. The most common protective devices in machine building are interlocking devices used in connection with physical guards. The new standard doesn’t represent a technological revolution, but it does require careful consideration due to the number of changes and additions.

to international standards, is not just important for us as a company, but also for our customers. To operate successfully on the global technical market, you need to have a firm grasp of the technical “rules of the game”. This is another area in which we are able to make a difference for our customers.

SI: How does SICK inform its customers about the latest developments?

OG: The German Institute for Standardization (DIN) provides regular updates via its DIN Announcements (DINMitteilungen) and the DIN Gazette of Technical Rules (DIN-Anzeiger fur technische Regiein). Interested parties can view and comment on the latest draft standards on the relevant DIN web pages.

A lot of information form the ISO, IEC, CEN, and CENELEC standards at customer events e.g. at the SICK safety days. Our customer magazine, SICKinsight, also features regular articles on safety standards and their usage.

SI: What is new in this standard and what has changed?

OG: First, it is important to note that as an ISO document the new standard will be more widely recognised than the purely European standard EN 1088. The new standard contains specific requirements for selecting and using interlocking devices. It takes into account improved, modern technologies such as noncontact position detection, RIFD and electromagnetic guard locking.

The bypassing of interlocking devices is systematically evaluated and the standard stipulates requirements to prevent this. It also defines requirements for correct incorporation into the controller and the evaluation of fault masking.

SI: What exactly is fault masking?

OG: When electro-mechanical safety switches or reed position switches are connected in series to a single safety module, it is possible for a fault detected by a safety module to be overwritten

by the foreseeable actuation of another switch. This phenomenon reduces fault detection for the position switch in question and the reliability of the entire safety function.

SI: What effect do the changes in this standard have on machine manufacturers?

OG: As mentioned, the changes are not revolutionary. The new standard enables machine manufacturers to use existing technologies in a flexible manner, however it demands careful selection and design and a bit more effort in preventing foreseeable manipulation and integration in the controller (functional safety) SI: What is the best way to deal with these changes?

OG: Not all existing solutions will need to be revised, however I would advise machine manufactures to have these carefully inspected and adjusted accordingly. Hardly and o the new requirements are absolutely new in terms of technology, they are simply laid down for the first time in a standard. Product manufacturers such as SICK have been taking these requirements into account for years, for example, through the use of RFID technology in T4000 transponder safety switches. To address the well-known problem of fault masking in series connections, SICK developed the Flexi Loop safe sensor cascade, which completely prevents fault masking, among other things. Flexi Loop can also be retrofitted.

SI: What important changes can we expect to see in the near future?

OG: in the case of standards which deal with basic safety requirements (A and B type standards), there will be hardly any changes. These requirements and the described safety solutions can generally be regarded as consolidated state-ofthe-art. Work is currently being carried out to combine the control standards ISO 13849 and IEC 62061, however we should not expect to see any specific results before 2016.

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WASTE HANDLING

A “big picture” compressed air system

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OMPRESSED air management systems have long played an important role in the efficient operation of compressed air systems.

They are able to recognise, for example, when the compressor needs something, if excessive temperatures arise and if human intervention is required.

The drive toward efficiency, reliability and – most importantly – sustainable resource usage and energy savings, is increasingly compelling developers and users to optimise existing solutions ever further. Modern installations are comprehensive systems, including compressors, cooling systems, dryers and filters.

Complex systems such as these require

Capable of coordinating multiple compressors with different internal control systems.

an organising principle of sorts – this is where master control systems come into play. By monitoring the individual components and optimally co-ordinating the interaction between them, these

YOU WON’T PAY EXTRA FOR EXTRAS AT SPECSAVERS.

controllers transform the individual ‘players’ into a truly cohesive team that operates reliably and efficiently.

In the past, use of such systems has yielded a certain degree of optimisation.

For instance, master controller systems such as the SAM with 3D-Control have for some time been capable of coordinating multiple compressors with different internal control systems, ensuring that they supply the required and set working pressure with maximum energy efficiency.

Kaeser Compressors Australia 03 9791 5999 www.kaeser.com.au

Our AS/NZS1337.6:2012 certified prescription safety glasses come complete with frames, lenses, lens cloth, case & certification. Other companies might consider these optional extras and charge additionally.

So if you’re looking for AS/NZS1337.6:2012 certified prescription safety glasses without the hidden extras (from just $199 for one pair), you simply can’t look past Specsavers.

ANS/NZS1337.6:2012 Personal Eye Protection

All products in the Specsavers Safety Eyewear range are fully certified and covered by the AS/NZS 1337.6:2012 Standards Licence No: SMKH25349 Issued: 30 May 2012.

August 2014 | Safety First |

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