RISK ASSESSMENT Mono Winch Tensioner - WT
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RISK ASSESSMENT
Mono Winch Tensioner
Reference no. Revision. Date. Revision date. Page.
WT 01 15/01/2009 July 2010 1 of 12
Safe-T-Pack (Pty) Ltd
CONTENTS
1. INTRODUCTION
2. SCOPE OF THE ASSESSMENT
3. OBJECTIVES
4. METHODOLOGIES
5. RISK MEASUREMENTS
6. EXCECUTIVE SUMMERY
7. SECTION 1- EQUIPMENT-BASED ASSESSMENT
8. SECTION 2- TASK-BASED ASSESSMENTS
9. SECTION 3- PROCEDURE FOR USE OF THE
Mono Winch Tensioner
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1 INTRODUCTION
This supplier’s risk assessment was conducted for Mono Winch Tensioner.
2 SCOPE OF THIS ASSESSMENT
The scope of this risk assessment is to identify and evaluate all activities and equipment
that could lead to injuries, production loss or property damage as a result of poor
manufacturing, incorrect storing, transporting and using the Winch Tensioner.
3 OBJECTIVES
To identify, evaluate and risk rank the hazards and associated risks and to identify the
required controls to eliminate or reduce the severity of the outcomes should an incident
occur.
4 METHODOLOGY
In general, a risk assessment involved identifying the hazards present in some work activity
or associated with the layout of premises, the construction of machinery or the failure of
critical parts. This is followed by an evaluation of the extent of the risk involved taking
into account those precautions already being taken. In this guidance the following
definitions will apply.
a) A HAZARD is something that has the potential to cause HARM. This
includes substances, machines, and methods of work or other aspects of
work organisation;
b) RISK is the PROBABILITY that the harm from a particular hazard will occur;
c) The extent of the risk depends on not only the severity of the harm to a
person but also the number of people who will be harmed and the
severity of a possible incident or production loss.
Risk therefore reflects both the probability that the harm will occur and it’s severity in
terms of the degree of harm and the number of people harmed.
Bottom-up risk assessment Techniques
In this case the approach is one of breaking down the system or problems into small
components and then seeing how they or others may fail building up to a major event.
Examples of this type of technique include hazard and operability studies (HAZOP)
which may address both hardware and people-ware systems. Failure Modes Effects
Analysis and its extension in terms of Criticality Analysis (FMECA) will be applied.
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5 RISK MEASUREMENTS
Once hazards have been identified, it is necessary to prioritise them so that action can be
programmed and so that they can be dealt within a way, which will satisfy the
REASONABLY PRACTICABLE requirement in the Mine Health and Safety Act. The
aim of risk assessment is to enable management to make decisions based on the information
reflected in the assessment and identify possible training needs. Risk assessment itself does
not make decisions, it only provides the basis for the decision making process. The setting
of priorities is an important way to change employee understanding and to build hazard
awareness. It also sets the direction for management.
The matrix below was used to determine the criticality and risk ranking of the hazards
and associated risks identified.
RISK MATRIX
PROBABILITY
A B C
D E
SEVERITY Common or Is known to Could occur or“
Not likely to Practically
Frequent occur or “it has heard of it
occur impossible
occurrence happened” happening”
1
Fatality or 25 23 20 16 11
permanent
disability
2
Serious loss time 24 21 17 12 7
injury/illness
3
Moderate loss time 22 18 13 8 4
injuries/illness
4
Minor loss 19 14 9 5 2
time
injuries/illness
5
No loss
15 10 6 3 1
RISK RANKING
Between 1 and 10 is a LOW risk
Probability C with Severity 3 = Risk
Between 11 and 19 is a MEDIUM risk Ranking Of 13 which falls in the MEDIUM
RISK Range
Between 20 and 25 is a HIGH risk
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When assessing the risk the one with the highest risk ranking with regard to people, equipment or
production loss will be used to rank that particular hazard and associated risk
CONSEQUENCE / SEVERITY ASSESSMENT
Here consequence will relate to the POTENTIAL SEVERITY or degree of harm / injury or losses
that could result of an event taking place.
PROBABILITY
This is a compound of two separate factors the one being EXPOSURE which gives an
indication of how often and how long employees are exposed to the hazard, the second includes
the PROBABILITY that a person or a number of persons will be harmed or production may
suffer and property damaged may occur.
6 EXECUTIVE SUMMARY
SUMMARY OF ALL THE HIGHEST RISKS (BETWEEN 20–25)
Nil
DISCUSSION
The following advantages can be gained from using the Mono Winch Tensioner.
1. Easy instillation.
2. Increase the staging area behind the winch.
3. Cost Effective.
Position. Name. Experience
1 Technical Director .............. Clive W Holleran 28 years
2 Sales Director..................... Andre Human 31 years
3 National Sales Manager... Brian Stolz 22 years
4 Area Sales Manager ............ Christo Rudman 24 years
5 Technical Manager……… Paul Brown 21 years
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SECTION 1–(EQUIPMENT - BASED RISK ASSESSMENT) CONDUCTED ON THE: Mono Winch Tensioner.
Mono Winch Tensioner
Tensioner Safety Guard
M24 Threaded Bar
M24 Bolt
200mm Sheave Wheel
Tensioning Handle
Guide Bar
Safety Chain Attachment
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SECTION 1– (EQUIPMENT - BASED RISK ASSESSMENT) CONDUCTED ON THE: Mono Winch Tensioner.
Failure effect RR Recommended controls
Component & Functional Cause of Supplier’s Strategies or
or No to be implemented by the User RR With
function failure failure controls control
consequence control
1.1. The adherence of the correct
Visual quality checks with delivery.
1.Safet Guards Incorrect welding code of practice for welding.
Structural. Material can Bend 6 Door to be kept closed, only to be 1
and door practices 1.2. Quality checks after
opened during rope loading.
manufacturing.
1.1. The adherence of the correct
2. Chain Incorrect welding Attachment can break code of practice for welding.
Structural. 6 Visual quality checks with delivery. 1
Attachment practices 1.2. Quality checks after
manufacturing.
1.1. The adherence to the correct
assembly procedure. No additional equipment or tool used to
3. Handle Structural. Over tensioning. Handle may break. 6
1.2. Quality checks after extend the tensioning handle.
1
manufacturing.
1.1. The adherence of the correct
Incorrect welding Faulty threaded. code of practice for welding.
4. M24 Nut Structural. 6 Visual quality checks with delivery. 1
practices 1.2. Quality checks after
manufacturing.
1.1. The adherence of the correct
5. M24 Threaded Incorrect welding code of practice for welding.
Structural. Faulty threaded 6 Visual quality checks with delivery. 1
Rod practices 1.2. Quality checks after
manufacturing.
1.1. The adherence to the correct
Not rotating
6. 200mm Sheave Worn or damage assembly procedure.
freely Secede sheave wheel 6 Visual quality checks with delivery. 1
Wheel bearings 1.2. Quality checks after
manufacturing.
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Equipment Base Risk Profile
25
24
23
22
21
20
19
18
17
16
15
14
Value 13
12
11
10
9
8
7
6
5
4
3
2
1
0
1 2 3 4 5 6
Risk
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SECTION 2– TASK BASED RISK ASSESSMENT
Risk Recommended Risk
Suppliers
Matrix Control to be Matrix
TASK HAZARD UNDESIRED EVENT Strategies or
No implemented by With
Controls
control the User control
Not adhering to Adhere to make safe
1. Instillation of the Making safe
policies and Fall Of Ground 25 policy, procedures and 16
Tensioner procedure
procedures. standards.
2.1 Adhere to correct 1 Adhere to correct
If the rope dislodges from
2. Mono-rope Under/over transport and transport and
the pulley, injuries may
incorrectly tensioned. tensioning of mono-
occur.
14 installation installation 2
rope procedures. procedures.
2.2 Wear PPE 2.2 Wear PPE
Failure to rig properly
and to utilise the The tensioned rope may
Adhere to correct Adhere to standard 12
3. The Tensioner fails. safety attachment on release if the Tensioner fails, 24 instillation procedures. procedure
the Mono Rope serious injury is possible.
Tensioner
Failure to close and If the rope dislodges from Provision made for a Keep the door locked
4. Not closing the the pulley, injuries may with a bolt or pad
lock the safety guard 24 locking device on 12
safety guard door. occur. Exposed moving parts lock at all times.
door. door.
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Task Base Risk Profile
25
24
23
22
21
20
19
18
17
16
15
14
13
Value 12
11
10
9
8
7
6
5
4
3
2
1
0
1 2 3 4
Risk
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WT 01 15/01/2009 July 2010 10 of 12SECTION 3- PROCEDURE FOR USE OF the Mono Winch Tensioner.
3.1 OPOPERATIONAL REQUIREMENTS
1. Personal protective equipment (PPE) required by the mine standard / COP.
(Correct type of gloves, Safety Shoes / boots)
2. Mono Rope Tensioner
3. Rigging Chain
4. Bolts and Nuts
5. Eyebolts
3.2 Operational Procedure
Ensure Mono Rope Tensioner is in an operational condition.
Installing the Mono Rope Tensioner
3.2.1 The Mono Rope Tensioner is installed directly behind the Mono Winch.
3.2.2 Pin the front two feet to the Mono Winch bed.
3.2.3 If the bed has been made large enough the rear pining hole should also be used.
3.2.4 Attached a safety chain to the Mono winch Tensioner and rig directly behind the
direction of pull.
3.2.5 Crank the sheave wheel all the way to the front (closes to the Mono Winch).
3.2.6 The instillation of the mono rope will pass over the Chimes wheel of the mono winch
and around the Mono Rope Tensioner sheave back to the Chimes wheel, making one
full turn around the Chimes wheel before leaving the Mono winch.
3.2.7 After the instillation of the Mono Rope, the safety Guard door must be closed and
locked in the closed position with the bolt provided or a pad lock.
3.2.8 Make sure that the threaded rod and guide bar are free from dirt and is greased on
weekly bases.
3.2.9 When the instillation requires tensioning the handle is cranked clock wise to tension
the rope.
3.2.10 When the Tensioner sheave wheel riches the end of its reach, release the tension by
cranking the sheave all the way forward. The instillation is then tensioned at the front
of the instillation.
Reference no. Revision. Date. Revision date. Page.
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