1.0 - General

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

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

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

  • Could materials or liquids be ejected from the equipment?

  • 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.

  • Are any very hot surfaces accessible?

  • Are any very cold surfaces accessible?

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

  • Does the equipment include a pressure vessel?

  • Could a blockage cause over pressure in the equipment?

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

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

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

2.0 - Guarding

  • Is it possible to access hazardous machine parts?

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

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

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

  • Can settings & adjustments be carried out safely?

  • Can the machine be loaded and unloaded safely?

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

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

  • Have all sharp edges been removed?

3.0 - Safety / System Controls

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

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

  • Are single channel safety devices used in safety circuits?

  • Are dual channel safety devices used in safety circuits?

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

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

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

  • Do all guard switches fail safe?

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

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

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

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

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

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

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

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

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

  • 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?

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

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

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

  • Are all push buttons in good condition and operational?

  • Are all indicator lamps in good condition and working?

  • 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

  • Can the equipment be started from only one position?

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

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

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

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

4.0 - Electrical System

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

  • Is the main Earth clearly identified?

  • Earth Sizing

    no label
  • Based on the Phase Conductor size, is the incoming Earth correctly sized?

  • Does each Earth wire have its own dedicated terminal?

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

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

  • Is the main Neutral clearly identified?

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

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

  • Is the isolator easily defeated?

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

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

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

  • Is over current circuit protection fitted?

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

  • Are all permanently live circuits appropriately marked?

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

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

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

  • Are there any unconnected wires in the electrical panel?

  • Is the Power Supply Unit bonded to Earth?

  • Is the armor from all armored cables properly connected?

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

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

  • Is the panel door free from mains voltage components?

  • Are all electrical panels located outside the guarding?

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

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

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

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

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

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

  • Are the electrical panel voltages segregated and clearly identified?

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

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

  • Is the electrical panel free from debris?

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

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

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

5.0 - Pneumatic System

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

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

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

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

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

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

  • Is the equipment free from air leaks?

  • Are all pneumatic exhaust ports fitted with silencers?

6.0 - Hydraulic System

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

  • Are all hydraulic hoses in good condition?

  • Is there a pressure relief valve in working condition?

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

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

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

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

7.0 - Process Liquids and Gases

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

  • Do all pipes have the direction of flow marked?

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

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

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

  • Are all liquid and gas supplies free from leaks?

8.0 - Pressure Systems

  • Is the pressure vessel name plate readable?

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

  • Is the Pressure Relief Valve secured against unauthorised adjustment?

  • When was the Pressure Relief Valve last tested?

  • When was the Pressure Relief Valve last overhauled?

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

9.0 - Documentation, Instruction & Identification

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

  • Are all warning labels in appropriate languages?

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

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

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

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

10.0 - Training

  • Are all operators trained to use the equipment safely?

  • Is the delivered training documented and recorded?

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

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

11.0 - Maintenance

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

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

  • Is there suitable access for maintenance?

  • 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?

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