ELECTRICAL

  • All capacitors shall have a method of discharge after being disconnected from their source of supply. (NEC -2002 Art. 460.6 & NFPA 79-2002 #7.10.2)

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  • Equipment has the ability to dissipate or block stored energy (OSHA 1910.147)

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  • There are no hardwire bypass device (jumpers) connected to any part of any safety device or safety circuit. Any other use of any bypass device (jumper) requires explanation per the NAMCs Jumper Guidelines.

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  • E-stop buttons are readily accessible and located at each operators station and other locations where emergency stop is required. (NFPA 79-2002 # 10.7.2.2 .7.4)

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  • All switches, buttons and function control knobs shall have an identifying function legend.(NFPA 79-2002 #10.2.3.1)

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  • Main disconnecting means is mechanically interlocked with the control panel door, or a tool is required to open the door. ( NFPA 79-2002 #5.3.1.4, # 6.2.3)

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  • Maintenance circuits tapped from the "line side" of the main circuit breaker (fuse) shall be Lockout capable, rated for correct short circuit breaker fuse shall be lockout capable, rated for correct short-circuit interrupting capacity of the incoming supply, all contained in their own enclosure ( within the main panel next to the main disconnect or externally mounted adjacent to the main panel) and provided with secondary over current protective devices. (NFPA 79-2002 #16.2.2.2)

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  • All Safety light curtains shall be hard wired thru safety relays or safety PLCs, not normal relays or normal PLCs

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  • All externally fed, ungrounded wiring not switched by the main disconnect must be orange. A label on the panel door must provide a warning.

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  • All motors that may be serviced while other motors controlled by the same machine continue to run, shall have a lockable disconnect switch installed in the motor circuit (NEC -2002 Art. 430.102 & OSHA 1910.147)

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  • Disconnect switches and the motors / systems that they control are clearly labeled with the same identifying information as drawings. And at least one disconnect switch installed in the motor circuit.

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  • All enclosures and terminals boxes which do not clearly show they contain electrical devices shall be marked with a warning label (lightning bolt symbol) on them (NFPA 79-2002 #17.2.6)

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  • All electrical enclosures that contain voltages greater than 50 vac or 60 vdc, must require a tool to be opened and have a warning sign stating "remove power before entering" , unless there is a an interlocked disconnect switch provided. ( NFPA 79-2002#17.2.6)

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  • All maintenance receptacles must have GFCI protection and if external to the control enclosure they must be covered when not in use. (NFPA 79-2002 #14.4.5.7 & # 16.1.2)

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  • Red is used for all ungrounded and white is used for all grounded AC control wires. Blue is used for all ungrounded and white with blue stripes used for all grounded DC control wires. (NFPA 79-2002 # 14.2.3 & # 14.2.4.3)

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EQUIPMENT GUARDING

  • All moving parts or equipment that create pinch points or other potential hazards are guarded by photo eye/light curtain, mat switch, physical barrier or other safety device. This device should be adequate in location, size, and function.

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  • Light curtain location (determined by risk assessment) should be a minimum height = 1400 mm to top and must prevent T/M's from reaching hazard.

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  • The design or location of the guard shall not create a hazard. ( ANSI B11.19-2003)

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  • Perimeter safeguarding around the machine must be designed, designated, and installed to prevent accidental or intentional entry. A combination of walls, fences, photo eyes, safety mats, limit switches, etc. may be used to prevent or detect entry into a machine cell as determined by the risk assessment. This should prevent reaching around, under or climbing into a hazard zone.

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  • The perimeter fence typically should be six feet high and have an opening at the bottom no greater than eight inches and maximum of 40mm openings. The perimeter fence should also be constructed of a material that provides the best visibility of related machinery. All sharp edges must be eliminated. ((ANSI B11.19-2003 and RIA 15.06-1999)

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  • Machine and cell access doors are recommended to be painted yellow.

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  • Access gates, doors and windows that provide full body access to the machine/robot cell must be equipped with an electrical circuit interlock/safety switch that when opened will stop equipment motion as determined by the risk assessment.

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  • An 18inch (450mm) minimum clearance must be maintained between robot movement, "operating space", and any fixed items such as building columns, structures, utilities or other machines and equipment, if teaching occurs inside of the safeguarded space. (ANSI/RIA R15.06-1999 # 10.7.7)

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  • Guards and covers shall require the use of a tool for removal.

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  • All machine guarding at fixed locations is securely mounted.

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WALKING/WORKING SURFACES

  • All elevated work surfaces or walkways 4-feet or higher from the floor are protected by standard guardrail and 4-inch toe board. (OSHA 1910.23)

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  • Stairs should have a standard handrail with a height of 30 to 34-inches and adequate width for expected traffic.

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  • All wall openings shall be guarded (OSHA 1910.23(b))

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  • Fixed ladders are installed per OSHA Standard 1910.27, and ladder cages are installed on all ladders over 20-feet in height.

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LOCK OUT

  • All energy sources must be capable of being locked out to comply with applicable OSHA, ANSI, TEMA, and NAMC lock-out requirements.

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  • Blocking device readily available and tested for stored kinetic energy. Blocking device shall be painted red.

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  • Bleed-off valves shall be readily available for stored pneumatic or fluid energy and tested. They shall be lockable where required.

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ROBOT SAFETY

  • Work envelope drawing reviewed (maximum reach / restricted space)

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  • All pendant that are capable of controlling motion with the operator inside of the safeguard space must have an e-stop device on the pendant. (RIA 15.06-1999 #4.6.2). All pendants must have an enable switch (three position for new equipment manufactured after June 2001 (RIA 15.06-1999 #4.7.3 & #10.3.2)

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CRANE AND HOIST

  • All cranes have been initially inspected and tested by the OEM/Installer or qualified inspector.

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  • Rate load markings are plainly marked on each side of the crane, and where applicable, easily legible from floor level.

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  • Hard stops are at or near ends of each rail to which the crane/hoist is attached.

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  • Safety cables or other effective means are attached as a secondary method of protection from crane hoist falling.

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SAFETY/OPERATIONAL

  • Laser Safety Check
    a) Does the machine have a laser?
    b) Have all laser safeguards been implemented?

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  • Workspace isn't cluttered, cramped or congested. (OSHA 1910.22)

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  • All tripping hazards are eliminated, guarded, or covered.

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  • Where required, has the installation ( machine, structural steelwork, process,,lifting fixtures, etc) been reviewed and approved by a "Professional Engineer", licensed by the local authorities.

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  • Sufficient/adequate lightning for process lighting and control cabinet? (Foot candles, structure, and layout) ( Meets ANSI/IESNA "Recommended Practices" of 50 foot candles for welding area, 150 foot candles for parts inspection stations, and 200 foot candles for final assembly, measured at 30 inches from the floor). (Ref: ANSI/IESNA RP -7-01, "Recommended Practice for Lighting Industrial Facilities), copyright 2001)

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  • General area ventilation is acceptable for work performed.

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  • Process specific ventilation systems are completed and function for production trials, or alternate temporary monitoring and systems are in place.

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  • Designed-in noise reduction systems are completed and functioning for production trials, or alternate temporary monitoring and systems are in place.

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  • Any Confined Spaces have been identified according to plant policy.

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ERGONOMICS

  • Principle working height is between 880mm and 1080mm with horizontal reach less than 700mm (measured from the hip) and a maximum vertical reach of 1820mm.

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  • All equipment push buttons are recommended to require 1kg or less to operate. (TEMA Ergo Guideline # 49 & # 50, July 2003)

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  • There are no sharp edges or points at the t/m operating area that would cause contact stress.

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FINAL SAFETY CHECKLIST

  • Manual Operations Check

  • Automatic Operations Check

  • Activating any safety device immediately stops equipment motion. If machine has multiple zones, interlocks in hard wiring end PLC circuits must be confirmed.

OTHER

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PUNCHLIST

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SIGNATURES

  • PE ENGINEER

  • Safety

  • CONTRACTOR

  • PILOT

  • PRODUCTION

  • TEMA ENGINEER

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