Machinery Safety Assessment - #342v2

• Equipment Details

• Document No.

• Site

• Department

• Date

  Date

• Assessment completed by

• Comments

1.0 - General

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

  Yes

  No

• Are there work instructions in place for operating this machine?

  Yes

  No

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

  Yes

  No

• Could materials or liquids be ejected from the equipment?

  No

  Yes

• 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.

  No

  Yes

• Are any very hot surfaces accessible?

  No

  Yes

• Are any very cold surfaces accessible?

  No

  Yes

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

  No

  Yes

• Does the equipment include a pressure vessel?

  No

  Yes

• Could a blockage cause over pressure in the equipment?

  No

  Yes

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

  No

  Yes

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

  No

  Yes

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

  Yes

  No

2.0 - Guarding

• Is it possible to access hazardous machine parts?

  No

  Yes

• Where there are gaps in the guarding for product flow, is it possible to reach through to hazardous machine parts?

  No

  Yes

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

  Yes

  No

• Can the guarding be easily defeated with out the use of tools?

  No

  Yes

• Can settings & adjustments be carried out safely?

  Yes

  No

• Can the machine be loaded and unloaded safely?

  Yes

  No

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

  Yes

  No

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

  Yes

  No

• Have all sharp edges been removed?

  Yes

  No

3.0 - Safety / System Controls

• How is the safety circuit designed to ensure reliable operation?<br>1: Hard wiring<br>2. Safety relay<br>3: Safety PLC

  1

  2

  3

  None

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

  No

  Yes

• Are single channel safety devices used in safety circuits?

  Yes

  N/A

  No

• Are dual channel safety devices used in safety circuits?

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

• Do all guard switches fail safe?

  Yes

  N/A

  No

• Are guards constructed such that however it is opened the guard switch activates?

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  No

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

  Yes

  No

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

  No

  Yes

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

  Yes

  N/A

  No

• Where two hands are required to operate equipment, if both buttons are not pressed within 0.5 seconds of each other, does the equipment still operate?

  Yes

  N/A

  No

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

  Yes

  No

• 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

  N/A

  No

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

  Yes

  No

• Are all push buttons in good condition and operational?

  Yes

  No

• Are all indicator lamps in good condition and working?

  Yes

  No

• 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

• Can the equipment be started from only one position?

  Yes

  No

• 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

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

  Yes

  No

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

  Yes

  N/A

  No

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

  Yes

  No

4.0 - Electrical System

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

  Yes

  No

• Is the main Earth clearly identified?

  Yes

  No

• Earth Sizing

  

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

  Yes

  No

• Does each Earth wire have its own dedicated terminal?

  Yes

  No

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

  Yes

  No

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

  Yes

  No

• Is the main Neutral clearly identified?

  Yes

  No

• Does the incoming electrical supply terminate at a lockable isolator?

  Yes

  No

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

  Yes

  No

• Is the isolator easily defeated?

  No

  Yes

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

  Yes

  No

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

  Yes

  No

• Is earth leakage, Residual Current Device, detection fitted?

  Yes

  No

• Is over current circuit protection fitted?

  Yes

  No

• Are all terminals above 50V ac or 120V dc protected from fingertip access/ ⌀12mm probe?

  Yes

  No

• Are all permanently live circuits appropriately marked?

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  N/A

  No

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

  Yes

  No

• Are there any unconnected wires in the electrical panel?

  No

  Yes

• Is the Power Supply Unit bonded to Earth?

  Yes

  N/A

  No

• Is the armor from all armored cables properly connected?

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  N/A

  No

• Is the panel door free from mains voltage components?

  Yes

  No

• Are all electrical panels located outside the guarding?

  Yes

  No

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

  Yes

  No

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

  Yes

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  No

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

  Yes

  No

• Are the electrical panel voltages segregated and clearly identified?

  Yes

  No

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

  Yes

  No

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

  No

  Yes

• Is the electrical panel free from debris?

  Yes

  No

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

  No

  Yes

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

  Yes

  N/A

  No

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

  Yes

  No

5.0 - Pneumatic System

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

• Is the equipment free from air leaks?

  Yes

  N/A

  No

• Are all pneumatic exhaust ports fitted with silencers?

  Yes

  N/A

  No

6.0 - Hydraulic System

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

  Yes

  N/A

  No

• Are all hydraulic hoses in good condition?

  Yes

  N/A

  No

• Is there a pressure relief valve in working condition?

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

7.0 - Process Liquids and Gases

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

  Yes

  N/A

  No

• Do all pipes have the direction of flow marked?

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

• Are all liquid and gas supplies free from leaks?

  Yes

  N/A

  No

8.0 - Pressure Systems

• Is the pressure vessel name plate readable?

  Yes

  N/A

  No

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

  Yes

  N/A

  No

• Is the Pressure Relief Valve secured against unauthorised adjustment?

  Yes

  N/A

  No

• When was the Pressure Relief Valve last tested?

  Date

• When was the Pressure Relief Valve last overhauled?

  Date

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

  Date

9.0 - Documentation, Instruction & Identification

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

  Yes

  No

• Are all warning labels in appropriate languages?

  Yes

  No

• Is their a machine manual available in the language of the user?

  Yes

  N/A

  No

• If the machine is from Europe and/or in Europe: Is the machine CE marked?

  Yes

  N/A

  No

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

  Yes

  N/A

  No

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

  Yes

  N/A

  No

10.0 - Training

• Are all operators trained to use the equipment safely?

  Yes

  No

• Is the delivered training documented and recorded?

  Yes

  No

• Is a Pre-Use or Start-Up Safety checklist available for every operator?

  Yes

  No

• Has a Job Safety Analysis been carried out for the use of this equipment?

  Yes

  No

11.0 - Maintenance

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

  Yes

  No

• Do the tasks instructions detail all of the potential hazards and provide instructions on how to work safely?

  Yes

  No

• Is there suitable access for maintenance?

  Yes

  No

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

  Yes

  No