Breweries and distilleries information and checklists

Introduction
In 2009 WorkSafe conducted an inspection campaign in the

August 09

Manual tasks
What are manual tasks? Manual tasks means any activity requiring the use of force exerted by a person to lift, lower, push, pull, carry or otherwise move, hold or restrain a person, animal or thing. Manual tasks also include any activity involving repetitive and/or forceful movements (eg. keying data into a computer; using a screwdriver) and any activity where the person must maintain constrained or awkward postures (eg. lifting items such as full beer kegs or bags). What is the current legislation on manual handling? The Occupational Safety and Health Act 1984 contains general duties and responsibilities placed upon employers and workers to ensure their own safety at work, and that of others who might be injured by the work. These duties extend to the prevention of manual task injuries. The Act also requires employers to investigate matters reported to them by employers, determine the action to be taken (if any), and notify the worker who made the report of the action to be taken. The Occupational Safety and Health Regulations 1996 require the employer to identify each hazard that is likely to arise from manual tasks at the workplace and to assess the risk of injury or harm. How can manual task hazards be identified? Manual task hazards can be identified by: reviewing hazard/injury reports; consulting with workers and safety and health representatives; and by observing tasks being performed. What is a safe weight to lift? There is no safe weight. The risk of injury increases as the weight of the load increases. Evaluating the risk posed by the weight of the object needs to take into account: how long the load is handled; how often the load is handled and: the physical characteristics of the individual. Is it expensive to implement manual handling solutions? There are a wide range of ways to control the risk of manual handling injury, ranging from simple procedural changes to state-of-the-art machinery and equipment. The costs of solutions are justified when you consider the costs associated with injured workers requiring time off work. What type of products could I use to address manual handling problems? The type of products depend on the work being done include: trolleys; castors and wheels.; drum handling; hand trucks; lift tables; work stands; and pallet lifters.
Westcentre 1260 Hay Street West Perth WA 6005 Telephone: 1300 307 877 Facsimile: (08) 9321 8973 Email: safety@commerce.wa.gov.au

brewing and distillery industry aimed at improving safety and health issues within the industry. The checklists used by WorkSafe inspectors during this campaign are included in this newsletter. Please use the checklists to ensure your workplace meets the occupation safety and health legislation.

Safety priorities for working with hazardous substances

Lost time at work, illness and sometimes death are all outcomes of failing to store, use or dispose of hazardous substances properly. Great care is essential and following the information below will help reduce the risk of such serious outcomes. Hazardous substances are any chemicals or other materials that may put people at risk. They include pesticides, acids, alkalis solvents, cleaners, paints, asbestos, wood dust and welding fumes. Some substances may cause allergic reactions and other medical conditions of varying severity. Other substances may be corrosive, harmful or toxic. Employers must identify any hazardous substances being used in their workplace and should question whether their use is essential. Material Safety Data Sheets (MSDS) must be provided for each hazardous substance, identifying the ingredients, and giving health information and precautions for safe use and handling. Continual vigilance is essential. Because of the high potential for hazardous substances to cause lost time injuries, disease and even deaths, WorkSafe has designated their use in industry as one of seven areas to be given priority when our inspectors visit your workplace. During their inspection, the department's inspectors will be looking for the six key elements. These deal with many of the common problems affecting the handling of hazardous substances that WorkSafe has found in workplaces. The elements of the checklist do not cover all mandatory requirements under workplace safety and health laws. However, following the same checklist yourself will assist you to identify any shortcomings in your procedures or training and to correct or update them, thus getting you started on meeting your safety and health responsibilities. In looking at safety in relation to hazardous substances and all workplace safety matters, please remember the three ThinkSafe steps: spot the hazard; assess the risk; and make the changes.

Dangerous incidents
Confined space work
A cellar-hand was overcome by carbon dioxide after entering a 4,500 litre wine vat through a 380 mm opening at the top of the wine vat containing crushed grape skins and seeds. The juice of the crushed grapes had been drained off through the drainer at the bottom of the tank. The atmosphere was inert due to the presence of a large amount of carbon dioxide. Carbon dioxide is added to the process as an antioxidant to displace oxygen during the winemaking process. Factors Lack of scientific monitoring equipment to test the internal atmosphere in the wine vats. (Non-scientific methods such as the sniff test are not satisfactory and expose workers to harmful gasses). The worker appeared to have a lack of appreciation of the risks associated with carbon dioxide, that is the rapidity of symptoms, the onset of euphoria, loss of muscle control and death within four (4) minutes.

Slips, trips and falls

Slips and trips can result in serious injury and lengthy amounts of time off work. The factors that contribute to the risk will depend on the type of workplace. Common factors include: unstable, loose, or uneven floor surfaces; obstacles blocking walkways; slippery floor surfaces from spilt substances, fluid, mud, oil; type of flooring or surface texture like wood, concrete or vinyl; carrying boxes etc that obscure the view of the floor; inadequate lighting; and inadequate footwear.

How can I reduce the risk of slips in wet areas?

A risk assessment should be undertaken at the workplace to determine the specific hazards, level of risk, and appropriate controls, and all staff should be provided with appropriate information and training. Controls may include safe work practices such as: keeping floors, ramps and stairs clean and dry; following procedures for cleaning up spilled substances; decanting fluids away from common areas; and wearing footwear suitable to the task and surface.

Recommendations Procedures and systems of work must be developed and implemented for all confined space entry. The system of work must include training and provision of satisfactory equipment for oxygen measurement and personnel rescue. The wine industry develop and implement a code of practice to ensure that there is a greater awareness, and following training, a greater understanding of hazards, risks and the management of these hazards and risks. Australian Standard 2865-1995 "Safe Working in a Confined Space" is to be used when determining the suitability of a confined space entry system. Consideration must be given to a regime of safety inspections and audits with a view to ensuring safety requirements are adequately adhered to and implemented.

Other controls include providing: anti-slip mats; adequate drainage; restricted access to areas that are potentially hazardous; the right floor surface for the type of work; adequate and well directed lighting; and

warning signs.

ThinkSafe Small Business Assistance Program

If you are a small business owner or manager (employing less than 20 full-time employees) and want to make your
workplace safe, the ThinkSafe Small Business Assistance Program can help you. The good news is that the help you get is: free (up to three hours assistance); easy to obtain; provided by an independent and qualified osh consultant; and is a simple process with clear and immediate outcomes. To apply download and complete the online form from www.worksafe.wa.gov.au or call 1800 429 273.

Regular updates on OSH

WorkSafe has a service that provides information on occupational safety and health direct to your email. To subscribe to receive this service go to www.worksafe.wa.gov.au servicesmailing lists

Frequently asked questions

Confined space
1. What is a confined space?
Regulation 3.82 of the Occupational Safety and Health Regulations 1996, defines a confined space as an enclosed or partially enclosed space which: a. b. c. is not intended or designed primarily as a workplace; is at atmospheric pressure during occupancy; and has restricted means for entry and exit;

and which either: a. b. c. has an atmosphere containing or likely to contain potentially harmful levels of contaminant; has or is likely to have an unsafe oxygen level; or is of a nature or is likely to be of a nature that could contribute to a person in the space being overwhelmed by an unsafe atmosphere or contaminant.

2. Is there a maximum size area that can be classed as a confined space?

The size of a space is not one of the factors used to define a confined space. Therefore, there is no specified minimum or maximum size.

3. What risks might I be exposed to whilst working in a confined space?

A person working in a designated confined space may be at risk of exposure to: electrical shock or electrocution; oxygen deficiency; toxic gases or fumes; engulfment/Suffocation by solids; fire and/or explosion; drowning in liquids; falls from height; and environmental factors such as noise, extremes of temperature, poor lighting, manual handling and radiation.

4. Do I always need an observer?

Yes. A person should be on standby in the immediate vicinity outside the designated confined space.

5. Does the person on standby need to have the person working in the confined space in sight at all times?
As the person on standby has to remain outside the confined space it is not always possible for them to keep the person/s working inside the confined space in sight at all times. Continuous communication with the worker/s inside the confined space must be maintained. Dependent upon the location, communications may be achieved using: voice; radio (intrinsically safe one if used in flammable conditions); mobile phone (not to be used if flammable gas or vapour is present in sufficient concentration to cause explosion or fire); or hard wired communications.

Locking out and tagging equipment

1. What is locking out and tagging?

Locking out of equipment or machinery is the most effective way of preventing it becoming operational during maintenance. Its effectiveness lies in the "one key per lock, one lock per person" procedure. If there is only one key per lock, the key has to be with the person carrying out the maintenance. Where more than one person is working on equipment or machinery a multi-lock system should be followed, ensuring that each person has attached a "personal" lock to the equipment or machine's multi-lock switch. All workplaces must have a system unless the equipment or machinery is fully inoperative and then disconnected from the energy source. Essentially, there are two types of tag, the "DANGER" tag and the "OUT OF SERVICE" tag.

2.

Danger Tags

Danger tags are used for a variety of hazards that may be involved in equipment and machinery maintenance, such as moving parts, electricity, steam, gas, liquid or toxic substances. If any work is to be carried out on a particular piece of machinery or equipment and there is a possibility of somebody inadvertently turning it on, the person carrying out the work must personally fasten a red and black "DANGER" tag or lock to the main isolating switch or valve. As with locking out, if more than one person is undertaking the work, each person must fit their own personal lock or tag to the machine. Each tag must be printed with the person's name and their section, and give the date and time it was attached to the switch or valve. No one must operate a switch or valve that has been locked or tagged "DANGER" until the lock or tag has been removed, and only the person who attached the lock or tag is allowed to remove it.

3.

"Out of Service" Tags

Yellow and black "OUT OF SERVICE" tags are to be used to prevent accidents or damage to machinery that is out of service for repairs or alterations. These tags are used in the same way as "DANGER" tags, except that only a supervisor can remove an "OUT OF SERVICE" tag. If possible, both tags AND locks shall be used. This will provide both visual and physical protection. As a further precaution, a portable sign can also be placed in front of the equipment or machine, or it can be cordoned off with a barrier or rope. Once a locking-out and tagging system has been introduced, it must be strictly enforced. If the system is not always followed, it becomes ineffective and dangerous. Safety locks and tags are readily available from most distributors of industrial safety products.

4.

Colour Coding

Australian Standard 1318 - 1985 recommends specific colours for the marking of physical hazards and the identification of certain equipment in industry. Colours used are red, yellow, green and blue. RED AND WHITE: Signifies danger and prohibition, fire protection equipment, stop buttons for electrical switches and emergency stop controls for machinery. YELLOW AND BLACK: Signifies caution: draws attention to such hazards as unfastened or removed machinery guards. GREEN AND WHITE: Denotes safety and location of safety or first aid equipment. BLUE AND WHITE: Is for information signs where there is no specific hazard.

Electricity safety checklist

check
Electrical installations are installed, constructed, maintained, protected (cover) and tested to minimise the risk of electric shock or fire. Evidence of maintenance and testing in place. Components clearly marked and switchboard free from obstructions. Hand held portable equipment is protected by RCD (not construction) Switchboard or fixed sockets marked whether RCD protected.

yes

no

n/a

Maintenance program in place. Flexible cords and extension cords are used in a safe manner Connection moulded or transparent plug Plugs, sockets and extension leads in good condition and protected from damage Electrical installations are protected from damage that would increase the risk of electrical shock or fire The work is organised for the safety of workers and others at the workplace. Work in the vicinity of power lines and plant

Hazardous substances safety checklist

check
Register of hazardous substances is complete (contents list and MSDS) Register is readily available Hazardous substances are properly labelled: manufacturers labels on container Decanted containers labelled with name, risk & safety phrases Risk assessment has been completed for all substances and recorded in register Report is available where risk is significant Practical control measures have been implemented and maintained Hierarchy of control is taken into account People who may be exposed or work with hazardous substances have been provided with adequate information, instruction and training Record of training includes health effects, controls, safe work methods, PPE Health surveillance is undertaken where appropriate

yes

no

n/a

Manual tasks-lifting safety checklist

check
Practical control measures have been implemented and maintained to eliminate or reduce risk associated with manual handling work activity: hazard identification, risk assessment conducted, worker feedback Accident or hazard investigation is conducted Everyone involved in organising and implementing manual tasks where manual task hazards have been identified have been provided with adequate instruction and training (induction and ongoing training)

yes

no

n/a

Mobile plant safety checklist

check
Mobile plant is maintained to minimise risks. Log book/records, pre-start checks Evidence of training/instruction. License if high risk work. The plant is a safe condition, Eg Plant registration, access to cab, seat & seat-belt, FOPS/ROPS as reqd, loadchart as reqd, operators manual, controls labelled, guarding dangerous parts. Work is organised for the safety of employees and others. Pedestrian control, traffic mgt, 2-way communication as reqd, high-visibility clothing as reqd. Site hazards are identified, assessed and controlled (ramps, slopes, rough ground, power lines, excavations, ground load limits, underground services)

yes

no

n/a

New and young workers safety checklist

check
Induction, information, instruction & training emergency/evacuation procedures Induction, information, instruction & training in hazard and accident reporting Induction, information, instruction & training in how to reduce the risk of injury or harm for hazards new/young workers may be exposed to in the course of their work Induction, information, instruction & training in use, maintenance & storage of PPE Supervision: ensure that new & young workers are working in accordance with safety instructions including instructions re. skylarking, initiation ceremonies, bullying Employers ensure the risk of injury or harm to (young) visitors is reduced by means appropriate for the workplace and the type of work activity

yes

no

n/a

Working from heights safety checklist

check
Practicae control measures have been implemented and maintained to eliminate or reduce the risk associated with work at heights Hazard identification, risk assessment conducted? Elimination of hazard considered? Would a fall be arrested before contact with the ground or a structure? Edge protection required if could fall > 2 metres from scaffold, fixed stairs, landing, suspended slab, formwork, false-work. In any other case > 3 metres: FIPS (catch platform, scaffold, safety nets, safety mesh, fall arrest system) or edge protection provided. There is safe means of access and egress to the work being performed at heights Stairs, walkways, ladders, mechanical lifts, obstruction free People required to work at height have been provided with adequate information, instruction and training for the work being performed.

yes

no

n/a

Slips trips and falls safety checklist

check
Floor or any stair or ramp has unbroken and slip resistant surface. Special provisions for slip resistance provided in wet areas Floor or any stair or ramp is free from any obstruction that may cause a person to fall (eg. electrical leads, hoses, floor mounted power boxes in walkways, etc.) Access to egress from workplace safe and at all times kept free from obstructions Safe systems of work (eg. clean as you go policy) in place Warning signs available and erected near spills Guard rails or other safeguards provided on ramps and stairs Appropriate PPE, such as slip resistant footwear, provided Ramps in areas where height of floor levels change and trolley access required or items are carried regularly

yes

no

n/a

Machine guarding safety checklist

check
Is every dangerous part of fixed, mobile or hand held powered plant (machinery) securely fenced or guarded in accordance with Regulations 4.37 and 4.29, except where the plant is so positioned or constructed that it is as safe as it would be if fenced or guarded? Are adequate safe work procedures provided and documented to set, test and use machinery during all cycles of production and maintenance? Look for: Pre-operational checks? Presence sensing system: safe system of work documented and a clearly identified warning provided when guard is muted? Presence sensing system: inspection and maintenance records maintained? Appropriate isolation and lock-out procedures provided for maintenance? Where setting, testing and start-up of machinery is required with the final means of safeguarding removed, have interim safeguards been provided? Where fixed physical guards are provided is adequate provision made for cleaning, maintenance, adjustment and repair? Where it is not practical to guard machinery is a safe system of work in place for persons operating or passing in close proximity?

yes

no

n/a

Are operators and maintenance personnel properly trained, familiar with the operation and set up of the machinery and able to demonstrate safety features? Are manufacturers decals, manuals and operator instructions readily available and in the English language? Is the highest level of guarding that is practical being provided?

Hoses safety checklist

check
Hoses should have identification marked on the outside that indicates the maximum working pressure of the hose There should be no damage that affects the structural integrity of the hose eg. Broken wires or kinking Bubbles or blisters in the outer covering that indicate leakage are reasons for discarding End fittings and crimping should be examined for cracks, damaged threads or other evidence for damage

yes

no

n/a

Pressure vessels safety checklist

Pressure equipment categorized as hazard level A, B, C or D according to the criteria set out in AS 4343, but not pressure piping must be registered with WorkSafe

Other issues safety checklist

check
Notifiable accidents reported to WorkSafe LTI/LTD accidents and notified hazards investigated Workers have received induction and on the job training Passages/walkways kept free of obstructions Access and egress (emergency exits) kept free of obstructions Emergency egress enable safe egress in event of emergency / exit signs provided Portable fire extinguishers provided and maintained Evacuation procedures & diagram available and displayed and practised and training in the use of fire extinguishers provided Warning signs provided Cleanliness and removal of debris Surface and floors are unbroken and slip resistant to prevent slips and falls Seating provided and maintained Workplace facilities provided Portable ladders according to AS 1892.1 (metal) or AS 1892.2 (wooden) Gas cylinders secured Flash back arrestors are fitted (oxy-acetylene or oxy-LPG) PPE provided where necessary Instruction, information, maintenance, storage of PPE, sign Noise Noise assessment conducted Control measures in place / avoid noise above exposure standard Provision of personal hearing protection (PHP) Instruction fitting, use, selecting, testing, maintenance and storage PHP Training on noise Signage PPE according to AS 1319 First Aid box or facilities available and first aid trained person available No smoking in enclosed workplaces Location of any asbestos on site identified and the risk assessed A2332334

yes

no

n/a