RISK ASSESSMENT Lever Hoist Tensioner - RE2LH Reference no.
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RISK ASSESSMENT
Lever Hoist Tensioner
Reference no. Revision. Date. Revision date. Page.
RE2LH 02 07/07/2008 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
Lever Hoist Tensioner
Reference no. Revision. Date. Revision date. Page.
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Safe-T-Pack (Pty) Ltd
1 INTRODUCTION
This supplier’s risk assessment was conducted for Lever Hoist 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 Lever Hoist 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 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 Lever Hoist Tensioner.
1. Productive and safe way to Tension Mono Rope System.
2. Relatively light weight in comparison.
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 Stoltz 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: Lever Hoist Tensioner
Hook Safety Catch Lever Hoist Tensioner
Lever Hoist Hook
RE2 Attachment
Lever Hoist Return Pulley
Rigging Holes
Lever Hoist Handle
Lever Hoist Chain
Safety Chain Attachment
152mm Sheave
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Safe-T-Pack (Pty) Ltd
SECTION 1– (EQUIPMENT - BASED RISK ASSESSMENT) CONDUCTED ON THE: Lever Hoist Tensioner
Risk Risk
Failure effect Recommended controls
Component & Functional Cause of Matrix Supplier’s Strategies or
or to be implemented by the User Matrix
function failure failure No controls With
consequence
control control
1.1Quality assurance from
Incorrect
supplier.
Damaged or assembly and/or
1. Lever Hoist Faulty lever Hoist. 6 1.2 Quality checks with receiving Visual quality checks with delivery. 1
faulty. transportation
and post production.
and storage.
Lever hoist Tensioner 2.1 Attachment bolts permanently
Lever Hoist Incorrect
inoperable. Could cause welded in place. Check that attachment bolts are welded
2. RE2 attachment detached from assembly 6 1
serious injuries during 2.2 Quality Checks after assembly. in place
Return pulley procedure
operation circumstance
Damager or no Could cause serious 3.1 Correct assembly and handling
3. Lever hoist hook, Hook may slip off Check that Safety catch is functioning
Hook safety injuries during operation 9 procedures. 2
safety catch attachment point correctly.
catch circumstance 3.2 Quality checks after assembly.
1.1Quality assurance from
Could cause serious supplier.
Bent and/or Mishandling or Lever hoist Hook to be checked for
4. Lever Hoist Hook injuries during operation 6 1.2 Quality checks with receiving 1
Damaged. negligence deformation.
circumstance and post production.
1.1 Quality assurance from
Porosity and
5 .Rigging Failure of attachment Supplier.
Structural. impurities in 20 Visual quality checks with delivery. 11
attachment points point. 1.2 Improved rigging system.
casting
1.3 Quality checks.
2.1Quality assurance from
Porosity and Supplier.
6. Cast body Structural. impurities in Frame can break. 16 Visual quality checks with delivery 11
2.2 Quality checks after
casting
manufacturing.
3.1 Quality assurance from Visual quality checks with delivery
Porosity and
7. Safety chain Failure of attachment Supplier.
Structural. impurities in 20 11
attachment point point. 3.2 Improved rigging system.
casting
3.3 Quality checks.
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5.1 The adherence of the correct
Structural and Shaft coming code of practice for welding. Check that the sheave wheel rotates
8. Shaft Failure of sheave wheel. 9 2
operational. loose. 5.2 Quality checks after freely.
manufacturing.
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Equipment Base Risk Profile
12
10
8
Value 6
4
2
0
2 3 4 5 6 7 8
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
1.1 Adhere to correct 1.1 Adhere to correct
1. Transport Lever Dropping Lever Hoist Minor injury or damage to
13 transport procedures. procedures. 4
hoist Tensioner Tensioner equipment.
1.2 Wear PPE 1.2 Wear PPE
2.1 Adhere to Mine
Serious injury/or damage to 2.1Making safe
2.1 Fall of ground 20 policies, procedures 16
equipment. procedure
and standards.
2.2 Misalignment 2.2 Mono rope damages the 2.2 Adhere to correct 2.2 Adhere to correct
18 4
Cast Return Pulley installation installation procedures.
2. Installation. 2.3 Under / over 2.3 The rope dislodges 2.3 Adhere to correct 2.3 Adhere to correct
tensioning of mono- from the pulley. 20 installation installation 11
rope. procedures. procedures.
2.4 Not installed to 2.4 Mono rope system is 2.4 Adhere to correct 2.4 Adhere to correct
standard. unsafe and may cause serious installation installation
injuries if the Lever Hoist 20 procedures. procedures. 11
Tensioner breaks free from its
rig position.
Not using the correct Serious injury/or damage to The provided Adhere to correct
3. Attachment points 20 installation procedures. 11
attachment method. equipment. attachment point.
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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 5 6
Risk
Reference no. Revision. Date. Revision date. Page.
RE2LH 02 07/07/2008 July 2010 11 of 12SECTION 3- PROCEDURE FOR USE OF the Lever Hoist Tensioner.
3.1 OPOPERATIONAL REQUIREMENTS
1. Personal protective equipment (PPE) required by the mine standard (Correct
type of gloves, Safety Shoes / boots)
2. Lever Hoist Tensioner.
3. Eyebolts.
4. Rigging Chain.
5. Bolts.
6. Wedges.
7. Necessary tools.
3.2 Operational Procedure
Ensure Lever Hoist Tensioner is in an operational condition.
Installing the Lever Hoist Tensioner
1. Always wear PPE.
2. Install the mono rope around the sheave of the Return Pulley.
3. Hook the lever hoist to an eyebolt and tension to the required tension.
4. Attach two rigging chains to the Return pulley and tension.
5. After the rigging chains have been installed, two separate eyebolts, release the
tension on the Lever Hoist.
6. Install a 16mm safety chain from the safety chain attachment point to a
separate eyebolt in the sidewall or hanging wall.
7.
Note: At end of shift, always remove all equipment from work area and store
in safe place.
Reference no. Revision. Date. Revision date. Page.
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