Guideline: Plant (equipment) risk assessment

guidelines
Purpose
To support the Universitys plant (equipment) management policy and procedure
to achieve a safe and healthy workplace.

Guideline

Scope
1. This guidance material is to support the Universitys Plant management
policy and procedure to achieve a safe and healthy workplace where plant is
involved in endeavours associated with undertaking University business.

Risk Management Process

2. A risk management approach is used in this guideline. This is a four-step
process:

Step One Identify Hazards

Step Two Assess risks

Step Three Determine risk controls

Step Four Monitor & review risk control

3. Specialist technical advice and assistance is available from Occupational

Health and Safety (OHS) and other advice on risk assessment and
management is available through the regulator, Comcare.

4. The risk management process at the University is developed around the life
cycle stages of plant. Use of the Plant Risk Assessment and Management
Summary (PRAMS) and Plant pre-purchase assessment checklist is the
suggested means of documenting the risk assessment, management
decisions and operator guidance. The PRAMS also identifies the hazard level
of an item of plant and its risk category when in use. Once the hazard level
is identified, the required actions to reduce risks are indicated.

5. Risk assessment should be undertaken on new and existing items of plant

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 to achieve safety, compliance and best use of University resources, as far as
is reasonably practicable. The process is best incorporated into the
purchasing and operating procedures and/or associated guidance material
for plant available in a Budget Area.

6. The preferred risk management process for plant involves four (4) steps:

Step One Identify Hazards

7. Identify the hazard/s identify aspects of the plant that may cause harm
(injury or illness) in all aspects of:

the physical plant;

the operation or work practice involving use of the plant; and

the environment in which the plant is used.

8. From this step, the hazard level of the plant can be determined as low,
medium or high.

9. Classes of hazards identified for plant include:

Physical hazards e.g. electrical, hot/cold e.g. boilers, autoclaves, liquid

nitrogen and cold rooms, entanglement; crush; explosion e.g. high pressure
systems, pressure vessels, compressed air; noise and vibration e.g. powered
mobile plant, impact tools;

Chemical hazards e.g. corrosive, toxic, or poisonous substances;

Biological hazards e.g. mould and mildew, vermin, pathogens, viruses;

Radiation hazards e.g. x-ray equipment, infrared or ultraviolet light,

microwaves; and

Ergonomic hazards e.g. A plant operators posture during operation,

machinery controls design; psychosocial environmental hazards e.g. work
targets, workplace relationships.

Step Two Assess risks

10. Assess the risk posed by the identified hazard/s (at least in terms of
likelihood and consequence).

11. For each identified hazard

Determine the likelihood of the identified hazard causing harm to an

operator, people in area, or the environment.

Determine the consequence of injury, illness, damage or harm occurring in

its intended use by operators or its interaction with the environment.

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 Assign a risk level using the matrix as per the PRAMS form or the following
table (other risk assessments models may be applicable).

Table: Risk Matrix

Likelihood Consequences

Insignifican Minor Moderate Major Catastrophic

t

Rare L L M H H

Unlikely L L M H E

Possible L M H E E

Likely M H H E E

Almost H H E E E
Certain

Code:

Risk Rating:

Low risk (L) - managed by routine activities

Moderate risk (M) - management responsibility should be specified

High risk (H) - senior management notified

Extreme risk (E) - immediate action

Likelihood of harm:

Rare May only occur in exceptional circumstances

Unlikely Could occur at some time

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 Possible Might occur at some time

Likely Will probably occur in most circumstances

Almost Certain Expected to occur in most circumstances

Consequence (significance of associated impact)

Insignificant Not worth taking action over

Minor Consequences can be readily absorbed but management effort is

still required to minimise impacts

Moderate Significant event, can be managed under normal procedures

Major Critical event, which with proper management, will be endured

Catastrophic Disaster with potential to lead to collapse

Modified from the Australian / New Zealand Risk Management Standard.

AS/NZS4360: 1999

Consultation
12. Consultation with operators, specialists and management is an
important facet of risk assessment along with consideration of existing risk
controls e.g. regulations, industry standards, operator certification etc.
Specialist advice and resources are available from OHS.

Documentation
13. Consider collecting a Plant Dossier on the Plant or equipment, and
make this available to relevant personnel.

14. Use the Plant Risk Assessment and Management Summary (PRAMS)
form to document risk and actions. The hazard level indicates the extent of
the required assessment of risk for the use of plant in its environment.

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 Refer to existing documented risk assessments for similar plant.

15. The risks associated with the identified hazards are assessed
individually and then collectively, to determine their interaction in the
context of the plants intended use. It is important to differentiate minor
and acceptable operational risk, from major strategic and operational risks.

16. Where a variance in risk assessment occurs between assessors, a

competent person familiar with the plant should undertake a technically
objective assessment to determine risks and appropriate controls.

Risk categories
17. The current ANU workshops procedure for plant allows equipment to
be categorised into the following risk categories:

A. Low risk
B. Medium risk
C. High risk
D. Extreme risk.

18. This category system is also being used in ANUs Maximo system.

19. For Risk Category A plant, complete the recommendations in the table
below. The guidance material may provide some assistance. No formal risk
assessment documentation or registration of plant is needed where the
plant can be identified as low risk i.e. it is not likely to cause injury due to
its inherent low hazards and any consequence, if injury were to occur, is
negligible.

20. For Risk Category B, C and D plant continue with the risk
assessment process. To identify the most appropriate risk controls and
obtain the preferred residual risk, higher category plant needs to be
assessed in detail in the context of its intended use, operators and
environment (using PRAMS).

Table: Examples of common plant and their risk management at the ANU.

Examples of Common Plant at Required Action For Risk Management

ANU

Non-powered hand tools e.g. No formal assessment required beyond pre-

screwdriver, chisel, hammer etc. purchase risk assessment (or similar

documentation for existing equipment)
Small office equipment e.g.
Normal maintenance procedure

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 manual stapler, Computer, No operating procedures beyond that
Table, Chair. provided by supplier

Category A PLANT Consult Ergonomic guidelines for office

based equipment use

No requirement to register

Powered hand tools, bending Plant Pre Purchase assessment

equipment, hydraulic press, Risk assessment documented prior to
bench grinder, power hacksaw, operation
cold saw,
Document operational procedures
Large office equipment e.g.
Consider Registering item of plant (onto
photocopier, printer
Maximo database)
Category B PLANT
Develop maintenance schedule

Drill press, lathes, milling In addition to the above, extreme hazard

machine, welding equipment, level plant (D) requires specialist advice from
bandsaws, router, circular saw OHSIM and management approval prior to
purchase or manufacture.
Tractors, electric vehicles, arc
welding, vehicle hoists.

Category C, D PLANT

Step Three Determine risk controls

21. Take action to eliminate or reduce the risks to a reasonably
practicable level, ensuring that no new hazards are introduced.

22. The overall risk must be reduced to reasonably acceptable levels.

Purchasing and design controls are the most effective to avoid introducing
risk into the workplace (i.e. elimination of the hazard). Budget Area must
take all reasonably practicable steps to ensure that:

risk control measures are maintained and effectively monitored;

effective and safe systems of work are implemented and appropriately

supervised;

training programs support risk management principles.

23. If the plant/equipment is categorised as medium or high risk, then

risk management action by the responsible Budget Area includes:

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 Completion of a Pre-Purchase Risk Assessment and/or PRAMS forms;

Develop a standard operational procedure for use and associated training;

Development of procedures for the safe shutdown in the event of unsafe or

emergency response;

A maintenance schedule; and

Registering the plant item (preferably onto the Maximo system).

All plant categorised as extreme risk requires:

the PRAMS to be completed prior to the plant being purchased or

manufactured, and for existing plant;

Research, planning, senior management approval, and specialist advice from

OHS Branch must support this assessment;

24. Any significant risks must be addressed (ideally) prior to

purchase/manufacture and managed to an acceptable level of risk in
operation.

25. Residual (remaining) risk may be acceptable and the delegate in the
budget area must document recommended risk control strategies and safe
operating instructions.

26. Responsibility for risk controls across the life cycle of the plant should
be clear in operating procedures. Existing systems in use at the ANU (e.g.
job cards, Maximo database, quality systems) can support documentation of
risk control strategies. The ANUs Workshop and Trade Safety Course and
manual may provide further guidance.

27. The risk assessment documents should be supplied to the user if the
budget area is manufacturing or supplying plant.

Step Four Monitoring & review of risk control

28. Review and monitor the effectiveness of the risk reduction measures.

29. The budget area must review the risk assessment upon receipt/
redesign or modification/installation /commissioning of the plant to revise
controls and documentation.

30. Consideration of changes in business practice, external controls

(regulations), and the operating environment is required to ensure the risk is
adequately managed. The frequency of this review is determined as part of
the areas risk management plan or as imposed by external factors. An
annual review is suggested.

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 31. Access to shared ANU knowledge is recommended during this review.
Advice and resources are available from OHS Branch.

[Note quick links to be developed to high hazard plant; FAQs and Plant Procedure]

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