Coats Machinery Safety Assessment

• Unit/ Location:

• Department:

• Machinery name:

• Model:

• Serial # (if available):

• Manufacturer:

• Checked by:

• Conducted on:

  Date

• Purpose:

  Select Purchasing Commissioning Inspection

  • Purchasing
  • Commissioning
  • Inspection

1.0 - General

• 1.1 Has the equipment been designed for the task it is performing?

  YES

  NO

  N/A

• Details

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  Media

• 1.2 Are there clear and comprehensive work instructions in the language of the user in place for the safe operation of this machine?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 1.3 Are the START, STOP, RESET and E-Stop controls clearly identified?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 1.4 Could materials or liquids be ejected from the equipment?

  YES

  NO

  N/A

• Details

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• 1.6 Are any very hot surfaces accessible?

  YES

  NO

  N/A

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• 1.5 Is there any possibility of fire or over heating? e.g. excessive friction, electric motor burning out, naked flame or spark, thermostat or cooling system failure.

  YES

  NO

  N/A

• Details

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• 1.7 Are any very cold surfaces accessible?

  YES

  NO

  N/A

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• 1.9 Does the equipment include a pressure vessel?

  YES

  NO

  N/A

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• 1.10 Could a blockage cause over pressure in the equipment?

  YES

  NO

  N/A

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• 1.11 Is there a risk of flammable vapours creating a potentially explosive atmosphere?

  YES

  NO

  N/A

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• 1.8 Is there any possibility of hazardous liquids or gases escaping?

  YES

  NO

  N/A

• Details

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• 1.12 Is there a risk of dust or fine fibres creating a potentially explosive atmosphere?

  YES

  NO

  N/A

• Details

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• 1.13 Are sufficient and appropriate fire extinguishers located within easy access to the machinery?

  YES

  NO

  N/A

• Details

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2.0 - Guarding

• 2.1 Is it possible to access any moving and/or hazardous parts or materials? These may be behind unsecured covers or guards.

  YES

  NO

  N/A

• Details

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• 2.3 Are all FIXED guards secured with suitable fixings that require a tool not kept in the workplace?

  YES

  NO

  N/A

• Details

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• 2.4 Can the guarding be easily defeated without the use of tools?

  YES

  NO

  N/A

• Details

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• 2.5 Can settings & adjustments be carried out safely?

  YES

  NO

  N/A

• Details

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• 2.6 Can the machine be loaded and unloaded safely?

  YES

  NO

  N/A

• Details

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• 2.5 Can settings & adjustments be carried out safely?

  YES

  NO

  N/A

• Details

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• 2.8 Are the guards made from a suitable material? e.g. shatterproof, sufficient strength

  YES

  NO

  N/A

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• 2.9 Have all sharp edges been removed?

  YES

  NO

  N/A

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• 2.7 Is guarding positioned so that it does not restrict the operators view?

  YES

  NO

  N/A

• Details

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3.0 - Safety / System Controls

• 3.1 How is the safety circuit designed to ensure reliable operation?<br>a) Hard wiring<br>b) Safety relay<br>c) Safety PLC

  YES

  NO

  N/A

• Details

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• 3.2 Are standard electrical switches, relays or other non-safety rated components used in safety circuits?

  YES

  NO

  N/A

• Details

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• 3.3 Are single channel safety devices used in safety circuits?

  YES

  NO

  N/A

• Details

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• 3.4 Are dual channel safety devices used in safety circuits?

  YES

  NO

  N/A

• Details

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• 3.5 Does the machine stop immediately after the E-stop is activated?

  YES

  NO

  N/A

• Details

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• 3.6 Are guards secured shut until the machine comes to a complete standstill after the E-stop has been activated?

  YES

  NO

  N/A

• Details

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• 3.7 Are guard switches fitted to all guards that can be opened without a tool?

  YES

  NO

  N/A

• Details

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• 3.8 Are the guard switches 'Positively acting'?

  YES

  NO

  N/A

• Details

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• 3.9 Are the guard switches positioned so it is not possible to open the guard without activating the safety device?

  YES

  NO

  N/A

• Details

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• 3.10 Do all of the guard switches stop the machine in the same way as activating the E-Stop?

  YES

  NO

  N/A

• Details

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• 3.11 Does the STOP control bring the equipment to a safe condition in a safe manner?

  YES

  NO

  N/A

• Details

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• 3.12 Is all stored energy (compressed air, hydraulic, springs) automatically released when a guard is opened?

  YES

  NO

  N/A

• Details

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• 3.13 Is there immediate access to an E-Stop or similar device at the operator's working position?

  YES

  NO

  N/A

• Details

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• 3.14 Do all the E-Stops on the machine operate in the same way?

  YES

  NO

  N/A

• Details

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• 3.15 Are the emergency stops suitable for the work area? e.g. Red mushroom button, pull cable, kick board

  YES

  NO

  N/A

• Details

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• 3.16 Could an operator activate the equipment with one hand while exposing their other hand to a hazard?

  YES

  NO

  N/A

• Details

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• 3.17 Where two hands are required to operate equipment, are two hands required continuously to operate the equipment?

  YES

  NO

  N/A

• Details

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• 3.18 Where two hands are required to operate equipment, does the equipment require both buttons to be pressed within 0.5 seconds of each other?

  YES

  NO

  N/A

• Details

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• 3.19 After activating a guard switch or E-Stop, does the machine require a RESET before restarting?

  YES

  NO

  N/A

• Details

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• 3.20 Where light curtains are used, are they positioned at a suitable distance to safely stop the machine before contact with hazardous parts is possible?

  YES

  NO

  N/A

• Details

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• 3.21 Are the controls positioned and designed to prevent accidental operation?

  YES

  NO

  N/A

• Details

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• 3.22 Are all push buttons in good condition, and operational?

  YES

  NO

  N/A

• Details

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• 3.23 Are all indicator lamps in good condition and working?

  YES

  NO

  N/A

• Details

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• 3.24 Are all push buttons and indicator lamps clearly labelled in the local language or with a universally understood format? e.g. O - Off, I - On

  YES

  NO

  N/A

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• 3.26 The machine should only start moving after the RESET button has been activated and then the START button. Does the machine operate this way?

  YES

  NO

  N/A

• Details

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• 3.25 Can the equipment be started from only one position?

  YES

  NO

  N/A

• Details

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• 3.28 If there is a delayed start or remote starting on the equipment, is there an appropriate warning system?

  YES

  NO

  N/A

• Details

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• 3.29 Is the equipment stable under its own weight or bolted securely to the floor?

  YES

  NO

  N/A

• Details

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• 3.27 Is there good visibility around the machine from the position where the machine can be started?

  YES

  NO

  N/A

• Details

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  Media

4.0 - Electrical System

• 4.1 Is the incoming Earth correctly and securely terminated, with measured resistance < 1Ω?

  YES

  NO

  N/A

• Details

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• 4.2 Is the main Earth clearly identified?

  YES

  NO

  N/A

• Details

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• 4.3 Based on the Phase Conductor size, is the incoming Earth correctly sized?

  YES

  NO

  N/A

• Details

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• 4.4 Does each Earth wire have its own dedicated terminal?

  YES

  NO

  N/A

• Details

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• 4.5 Is Green & Yellow coloured insulation only used on Earth cables?

  YES

  NO

  N/A

• Details

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• 4.6 Is all of the equipment and associated metalwork earthed or suitably earth bonded?

  YES

  NO

  N/A

• Details

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• 4.7 Is the main Neutral clearly identified?

  YES

  NO

  N/A

• Details

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• 4.8 Do the mains supply terminate at a lockable isolator?

  YES

  NO

  N/A

• Details

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• 4.9 Does the isolator have to be switched off before the panel can be opened?

  YES

  NO

  N/A

• Details

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• 4.10 Is the isolator easily defeated?

  YES

  NO

  N/A

• Details

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• 4.11 Are electrical panels locked and require a tool, not kept in the workplace, to be unlocked?

  YES

  NO

  N/A

• Details

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• 4.12 Is the highest voltage clearly identified on the electrical panel?

  YES

  NO

  N/A

• Details

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• 4.13 Is short circuit protection fitted?

  YES

  NO

  N/A

• Details

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• 4.14 Is over current circuit protection fitted?

  YES

  NO

  N/A

• Details

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• 4.15 Are all terminals above 50V AC or 75V DC protected from fingertip access/ ⌀12mm probe?

  YES

  NO

  N/A

• Details

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• 4.16 Are all permanently live circuits appropriately marked?

  YES

  NO

  N/A

• Details

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• 4.17 Do all electrical terminations have identification which corresponds with the electrical diagram?

  YES

  NO

  N/A

• Details

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• 4.18 Are all multi-strand wires fitted with ferrules before termination?

  YES

  NO

  N/A

• Details

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• 4.19 Do all wires run continuously from terminal to terminal or terminal to component with no joints?

  YES

  NO

  N/A

• Details

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• 4.20 Are there any loose wires in the electrical panel?

  YES

  NO

  N/A

• Details

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• 4.21 Is the Power Supply Unit bonded to Earth?

  YES

  NO

  N/A

• Details

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• 4.22 Is the armour from all armoured cables properly connected?

  YES

  NO

  N/A

• Details

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• 4.23 Can all electrical panel doors be opened beyond 90 degrees?

  YES

  NO

  N/A

• Details

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• 4.24 Are all metal electrical panel doors fitted with Earth straps to the main panel?

  YES

  NO

  N/A

• Details

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• 4.25 Is the panel door free from mains voltage components?

  YES

  NO

  N/A

• Details

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• 4.26 Are all electrical panels located outside the guarding?

  YES

  NO

  N/A

• Details

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• 4.27 Are all electrical cables free from damage, in good condition and clear of moving parts?

  YES

  NO

  N/A

• Details

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• 4.28 Do all electrical components have a suitable ingress protection (IP) rating for the environment?

  YES

  NO

  N/A

• Details

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• 4.29 Where equipment is in an area where a potentially explosive atmosphere could develop, is all of the electrical equipment suitably rated?

  YES

  NO

  N/A

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• 4.30 Do all external electrical cables have suitable physical protection for the environment?

  YES

  NO

  N/A

• Details

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• 4.31 Do all electrical panels have a suitable ingress protection (IP) rating for the environment?

  YES

  NO

  N/A

• Details

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• 4.32 Are all control panels ventilated or temperature controlled where necessary?

  YES

  NO

  N/A

• Details

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• 4.33 Are the electrical panel voltages segregated and clearly identified?

  YES

  NO

  N/A

• Details

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• 4.34 Is there a circuit diagram available in each control panel?

  YES

  NO

  N/A

• Details

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• 4.35 Are there pneumatic or hydraulic components in the electrical panels?

  YES

  NO

  N/A

• Details

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• 4.36 Is the electrical panel free from debris?

  YES

  NO

  N/A

• Details

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• 4.37 Are there any High Voltage cables in ducts with Low Voltage cables?

  YES

  NO

  N/A

• Details

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• 4.38 Where electrical sockets are fitted, do they have their own protection?

  YES

  NO

  N/A

• Details

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• 4.39 Is the available lighting sufficient for working in the electrical panels?

  YES

  NO

  N/A

• Details

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5.0 - Pneumatic System

• 5.1 Can the compressed air supply be isolated and locked out at the machine?

  YES

  NO

  N/A

• Details

• Photos

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• 5.2 Is the compressed air isolation valve outside of the guarding?

  YES

  NO

  N/A

• Details

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• 5.3 Is all of the compressed air exhausted whilst in an emergency stop state?

  YES

  NO

  N/A

• Details

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• 5.4 Are all pneumatic valves / solenoids clearly identified, accessible and secure?

  YES

  NO

  N/A

• Details

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• 5.5 Do all pneumatically powered moving parts immediately return to a safe position when the compressed air is isolated?

  YES

  NO

  N/A

• Details

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• 5.6 Is there a pneumatic circuit diagram available in the control panel?

  YES

  NO

  N/A

• Details

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• 5.7 Is the equipment free from air leaks?

  YES

  NO

  N/A

• Details

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• 5.8 Are all pneumatic exhaust ports fitted with silencers?

  YES

  NO

  N/A

• Details

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6.0 - Hydraulic System

• 6.1 Can the hydraulic pump be isolated and locked out in the work area?

  YES

  NO

  N/A

• Details

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• 6.2 Are all hydraulic hoses in good condition?

  YES

  NO

  N/A

• Details

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• 6.3 Is there a pressure relief valve in working condition?

  YES

  NO

  N/A

• Details

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• 6.4 Do all hydraulically powered moving parts immediately return to a safe position when the hydraulic pack is isolated?

  YES

  NO

  N/A

• Details

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• 6.5 Are hose burst valves fitted to cylinders used in lifting and lowering?

  YES

  NO

  N/A

• Details

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• 6.6 Is there a hydraulic circuit diagram available in the control panel?

  YES

  NO

  N/A

• Details

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• 6.7 Is the work area free from oil and the equipment free from oil leaks?

  YES

  NO

  N/A

• Details

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7.0 - Process Liquids and Gases

• 7.1 Are all pipes appropriately colour coded and have their contents marked?

  YES

  NO

  N/A

• Details

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• 7.2 Do all pipes have the direction of flow marked?

  YES

  NO

  N/A

• Details

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• 7.3 Can the steam supply be isolated and locked out in the work area?

  YES

  NO

  N/A

• Details

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• 7.4 Can the water supply be isolated and locked out in the work area?

  YES

  NO

  N/A

• Details

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  Media

• 7.5 Can all other liquid or gas supplies to the equipment be locked out in the work area?

  YES

  NO

  N/A

• Details

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• 7.6 Are all liquid and gas supplies free from leaks?

  YES

  NO

  N/A

• Details

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  Media

8.0 - Pressure Systems

• 8.1 Is the pressure vessel name plate readable?

  YES

  NO

  N/A

• Details

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  Media

• 8.2 Is a unique Pressure Relief Valve or similar safety device fitted to the each pressure vessel?

  YES

  NO

  N/A

• Details

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• 8.3 Is the Pressure Relief Valve secured against unauthorised adjustment?

  YES

  NO

  N/A

• Details

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• 8.4 When was the Pressure Relief Valve last tested?

  YES

  NO

  N/A

• Details

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• 8.5 When was the Pressure Relief Valve last overhauled?

  YES

  NO

  N/A

• Details

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• 8.6 When was the Pressure Vessel last checked by an approved inspector?

  YES

  NO

  N/A

• Details

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  Media

9.0 - Documentation, Instruction & Identification

• 9.1 Are all warning labels in place and suitable for the hazards identified?

  YES

  NO

  N/A

• Details

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  Media

• 9.2 Is the machine Technical File available?

  YES

  NO

  N/A

• Details

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  Media

• 9.3 Is the Technical File in the language of the user?

  YES

  NO

  N/A

• Details

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• 9.4 For CE marked equipment, is a Certificate of Conformity in the Technical File?

  YES

  NO

  N/A

• Details

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• 9.5 For CE marked equipment, are the relevant BS/EN Standards listed in the Technical File?

  YES

  NO

  N/A

• Details

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10.0 - Training

• 10.1 Are all operators trained to use the equipment safely?

  YES

  NO

  N/A

• Details

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  Media

• 10.2 Is the delivered training documented and recorded?

  YES

  NO

  N/A

• Details

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  Media

• 10.3 Is a Pre-Use checklist available for every operator?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 10.4 Has a Job Safety Analysis been carried out on this equipment?

  YES

  NO

  N/A

• Details

• Photos

  Media

11.0 - Maintenance

• 11.2 Do the task instructions detail all of the potential hazards?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 11.1 Is there a Planned Maintenance schedule for this piece of equipment?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 11.3 Is there reasonable access for maintenance?

  YES

  NO

  N/A

• Details

• Photos

  Media

• 11.4 Are all protective devices (Circuit Breakers, E-Stops, Pressure Relief Valve and Safety Switches etc.) subject to routine functional testing, with the results recorded?

  YES

  NO

  N/A

• Details

• Photos

  Media

• Recommendation:

• Conclusion:

• Signature:

  Sign