Safety Design & Construction

• Audit Title

• Client / Site

• Conducted on

  Date

• Prepared by

• Location
  Address

• Personnel

Machine Safety Checklist

• Machine Name:

• Person completing Checklist at Design Phase:

• IHE resource confirming the Checklist Accuracy and Machine Safety:

Declaration of Conformity is available and includes:

• DESIGN COMPLETE AUDIT:

• Declaration of Conformity is available and includes

  Yes

  No

  N/A

• List of regulations (Directives for CE) applicable to the machine.

  Yes

  No

  N/A

List of the applicable standards, plus other standards and technical specifications used to achieve the overall design of the machine.

• Instructions/Drawings/Lists are available for safe:

• installation/de-installation

  Yes

  No

  N/A

• operation (in the language of the machine operator)

  Yes

  No

  N/A

• maintenance & inspection (including spare part lists, electrical / pneumatic / hydraulic drawings, control circuit and safety circuit drawings)

  Yes

  No

  N/A

• Safety device listing and inspection schedule

  Yes

  No

  N/A

• If CE compliance required, CE label is on equipment in case of stand-alone machine

  Yes

  No

  N/A

• Drawings, calculations; test results necessary to check conformity with health & safety requirements, applicable regulations/directives and any other validation tests.

  Yes

  No

  N/A

• Machine Manufacturer's risk assessment available assuming delivery was agreed in purchasing contract

  Yes

  No

  N/A

• Safety report of 3rd party inspection(s) available assuming delivery was agreed in purchasing contract

  Yes

  No

  N/A

• Functional validation check completed and documented covering all hazardous energy safety devices and circuits of Hazardous Energy Control and Islolation

  Yes

  No

  N/A

• Inspection list and inspection procedures of all hazardous energy safety devices documented per CBA 2050.

  Yes

  No

  N/A

• Safety Map(s) for each machine showing energy isolation and control devices.

  Yes

  No

  N/A

• Hazardous energy control and isolation procedures complete.

  Yes

  No

  N/A

Electrical Engineering Review

• General

• A P&G PC&IS engineer checked cable/wiring sizes and circuit protection coordination. Spot checking of a large design is sufficient if no errors are found.

  Yes

  No

  N/A

• Control, instrument and I/O supply voltage is 24VDC, 0 VDC conductor grounded

  Yes

  No

  N/A

• All circuit breakers rated min. 10 kA. acc. IEC 60 947.2

  Yes

  No

  N/A

• Separate PE circuit / copper grounding bar with individual wires to equipment and metal parts

  Yes

  No

  N/A

• Components in cabinets are labelled on the backplane, as per circuit diagrams.

  Yes

  No

  N/A

• All components in a cabinet are touch-safe (IP20).

  Yes

  No

  N/A

• All exposed equipment > 48 VDC and power circuits not isolated by main disconnect have lexan cover + hazard label

  Yes

  No

  N/A

• All Circuits not isolated by main disconnect (lighting, outlets, and PLCs) are identified by color (ORANGE) or labeled inside the control enclosure. In addition, a label shall be placed next to the main disconnect outside the panel indicating that it does not de-energize all conductors.

  Yes

  No

  N/A

• No automatic restart possible after fault or emergency stop.

  Yes

  No

  N/A

• Warning text on VFDs and Servo drives for residual voltage that is 60V or more 5 seconds after power is removed.

  Yes

  No

  N/A

• Transformers have proper overload protection and the secondary side is grounded.

  Yes

  No

  N/A

• Plugs and sockets are color coded or non-interchangeable (such as keyed to prevent improper connection)

  Yes

  No

  N/A

• Sufficient access and working space shall be provided and maintained about all electrical equipment to permit ready and safe operation and maintenance of such equipment. This applies only to panels likely to require examination, adjustment, servicing, or maintenance while energized

  Yes

  No

  N/A

Cabling & Wiring

• Power, instrumentation and communication cabling is installed with distance separation (30cm is suggested) or with a grounded metal separator. All insulation of cables in the same raceway are rated for the highest voltage in the raceway.

  Yes

  No

  N/A

• Cables entering and leaving closed cable trays by means of cable glands

  Yes

  No

  N/A

• Cables protected against mechanical damage where needed.

  Yes

  No

  N/A

• Only 1 wire per terminal allowed unless the terminal is specifically designed for that

  Yes

  No

  N/A

• Ground wire to cabinet door separate from wire bundle, as large as the largest power conductor on the door, and min 6 mm2

  Yes

  No

  N/A

• For EU, stranded wires need to be crimped with a ferrule unless the nature of the termination point of that wire excludes the reasonable use of ferrules.

  Yes

  No

  N/A

• Moving cables (e.g. telescope arms, flexible cable trays, …) need to be highly flexible and made for that purpose.

  Yes

  No

  N/A

• Cables need adequate stress relief where required

  Yes

  No

  N/A

• Cables/ wires will be labelled on both ends with the same unique numbering and match circuit diagrams and cable lists

  Yes

  No

  N/A

• Wire colors: <br>Under power when main power isolator is off : Orange<br>Power : Black , Neutral : White (U.S. and global) or Lt. Blue (EU Only), Ground : Green-Yellow<br>AC Control (not recommended) : Red<br>DC Control : Blue, DC Common : White w/Blue Stripe

  Yes

  No

  N/A

Cabinets & enclosures

• If enclosure temp exceeds 40 degree C ventilation is required.

  Yes

  No

  N/A

• Cabinets must be accessible from ground floor or fixed platforms.

  Yes

  No

  N/A

• All field equipment min. IP 54 or Nema 12

  Yes

  No

  N/A

• Cabinets outside building min IP 44

  Yes

  No

  N/A

• Enclosures with voltages > 48 V marked with voltage level and flash sign.

  Yes

  No

  N/A

Indicators and controls

• Acoustic and/or visual warning on machine before start-up

  Yes

  No

  N/A

• Colors of lamps and push buttons are according EN 60204.1/NFPA 79 :<br>Color General Specific<br>Red Emergency, Critical condition Emergency stop, Immediate action req'd.<br>Yellow Caution, abnormal condition Hazardous condition or impending shutdown<br>Green Normal Start, run, normal<br>Blue Auxiliary Reset, mandatory action<br>White Auxiliary Power on, standby, etc...<br>Black Auxiliary Stop/Off

  Yes

  No

  N/A

Electrical Power Isolation

• Isolator (disconnect) height between 0.6 m and 1.7 m above the floor, and is padlockable in the off position only.

  Yes

  No

  N/A

• Location (convenience) of disconnects facilitate the expected lockout behavior

  Yes

  No

  N/A

• Acceptable verification method is provided. Options: Green light and Pilz voltage sensing safety relay per PCP 345, Push to start per PCP 345, Voltage vision systems (only for mechanical maintenance), visible blade disconnect. Where IEC 60 947.3 standard is followed (i.e. EU), disconnect handle position in off position is an acceptable verification method.

  Yes

  No

  N/A

• Electrical power isolators (disconnects) are properly rated and listed for use as disconnects. For EU requirements, disconnects shall be marked utilization category AC-23B acc IEC 60 947.3, and rated for nominal power and/or stalled motor current of largest motor. For U.S. requirements, disconnects shall be UL listed for use as a disconnect (see NFPA 79 Chapter 5.3.2 for allowed types) and be rated for the application per the requirements of NFPA 79 Chapter 5.3.3.

  Yes

  No

  N/A

• Electrical power isolator is red on a yellow background if it has an emergency stop function, otherwise must be black on grey.

  Yes

  No

  N/A

Pneumatic Power Isolation

• Isolator (disconnect) height between 0.6 m and 1.7 m above the floor, and is padlockable in the off position only.

  Yes

  No

  N/A

• Location (convenience) of disconnects facilitate the expected lockout behavior

  Yes

  No

  N/A

• Acceptable verifcation method is provided. Options: Preferred method is visual verification of 0 pressure such as using a pressure gauge mounted immediately downstream of the pneumatic isolator. Also will accept audible exhaust combined with visual verification that the shaft that blocks supply air and exhausts downstream air is in off position (example: Versa Valve).

  Yes

  No

  N/A

• The pneumatic isolator relieves the pressure downstream of the isolator when in the off-position (air dump valve).

  Yes

  No

  N/A

Main Electrical Power Isolation

• Machine is equipped with a main power isolator to isolate all electrical power to the equipment

  Yes

  No

  N/A

• The electrical panel cannot be opened unless the power is isolated (Mark will update this item)

  Yes

  No

  N/A

• Main isolator is labelled as such.

  Yes

  No

  N/A

Individual isolator devices (maintenance disconnects)

• Disconnects are directly interrupting the power to the device (motor, heater)

  Yes

  No

  N/A

• Disconnects for VFD driven motors have a early break auxiliary contact wired in the VFD enable.

  Yes

  No

  N/A

• Disconnects are unambiguously identified to the equipment that they serve (via placement and / or labelling)

  Yes

  No

  N/A

Electrical Power Safety Circuit

• Power to all hazardous motion is removed on fault (failsafe)

  Yes

  No

  N/A

• Main power isolated via 2 contactors (non solid sate / semiconductor) in series or via an approved safe-off function in Servos' and drives.

  Yes

  No

  N/A

• Power isolation contactors have positive guided contacts.

  Yes

  No

  N/A

• Contactors are controlled via a Category 3 + monitoring Safety System

  Yes

  No

  N/A

• Power is only restored when e-stop, LOTO, Guard fault is removed, and separate reset signal sent to safety relay

  Yes

  No

  N/A

• Machine does not automatically restart when safety circuit is reset

  Yes

  No

  N/A

• Safety relay/controller is identified inside panel and is protected from tampering by signage and guarding

  Yes

  No

  N/A

• Guard locking is fail-safe, i.e. power required to unlock

  Yes

  No

  N/A

• Machine stops as fast as possible on fault

  Yes

  No

  N/A

• Additional wiring to PLC input to identify which safety device opened. (NOTE:This is not necessary if a Safety PLC is used and the information about individual interlock devices can be gathered from there. In case of daisy-chained safety devices, the additional contact should be wired to the PLC for monitoring.)

  Yes

  No

  N/A

• If a safety PLC it is used, a validation plan with safety signature is developed and completed.

  Yes

  No

  N/A

Pneumatic Power Safety Circuit

• Air is isolated and vented via an air dump valve certified by third party as category 3/4.

  Yes

  No

  N/A

• There is no hazardous air retained in the system after isolation

  Yes

  No

  N/A

• Vented air is muffled if needed to prevent noise hazard, and positioned to eliminate eye hazard from air or dispersed particles.

  Yes

  No

  N/A

E-Stop Circuits

• Machine has at least one e-stop method … either an e-stop circuit or a disconnect device designed for e-stop function.

• All hazardous motion stops as fast as possible when e-stop pressed

  Yes

  No

  N/A

• All e-stops meet category 3 requirements unless MRA shows otherwise and HS&E concurs

  Yes

  No

  N/A

• Additional wiring to PLC input to identify which safety e-stop opened. (NOTE:This is not necessary if a Safety PLC is used and the information about individual e-stops can be gathered from there. In case of daisy-chained safety devices, the additional contact should be wired to the PLC for monitoring.)

  Yes

  No

  N/A

• All e-stops are red mushroom button on a yellow background or tension style pull cords.

  Yes

  No

  N/A

• All e-stops are identified with the equipment they stop, need local manual reset and are labelled with an identifying number.

  Yes

  No

  N/A

• Pull cords have a red plastic covered cord and initiate an e-stop both if pulled or if not tensioned.

  Yes

  No

  N/A

• Blue reset push button for emergency stop relay on main control or power panel

  Yes

  No

  N/A

• E-stops are mounted so that inadvertant actuation is prevented, while still allowing easy actuation.

  Yes

  No

  N/A

SLS systems

• SLS system is installed, as per circuit diagram and as per manufacturer's (or P&G PCP345) requirements, and sealed.

  Yes

  No

  N/A

• SLS system is checked functionally and documented

  Yes

  No

  N/A

Mechanical Engineering Review

• Guards

• Guards are designed to make access to mechanical hazards impossible to reach

  Yes

  No

  N/A

• Gaps or openings in guards comply with the safety distances in table from CBA 2051

  Yes

  No

  N/A

• For barriers guards, the height and position of the barrier complies with table from (CBA 2051)

  Yes

  No

  N/A

• All mechanical hazards below 2.7m are guarded.

  Yes

  No

  N/A

• All fixed guards require tool to remove.

  Yes

  No

  N/A

• All non fixed guards (called movable guards) are interlocked with all sources of hazardous energy that are exposed when guard is opened.

  Yes

  No

  N/A

• All guards that are opened or removed daily comply with movable guard requirements (including interlocking, attachment to machine with tamper resistent fasteners)

  Yes

  No

  N/A

• Guard locking exists on movable guard where stopping time exceeds approach time. (reference stopping distance formula in CBA 2051, ANSI B11.19, or EN ISO13855)

  Yes

  No

  N/A

• Guards are durable for foreseeable machine life and conditions (consider hinges, slides, handles, latches, environment, etc.).

  Yes

  No

  N/A

• Guards are of sufficient strength for foreseeable loading. Consider unintended forces such as someone falling against or stepping onto the guard.

  Yes

  No

  N/A

• Guards are of adequate fastening and rigidity to prevent deformation that could violate guard safety distance tables. Consider the number and position of supports and guard material.

  Yes

  No

  N/A

• Guards do not create new hazards (consider pinch points, gap at door hinge, risk of falling (avoid guards that raise/lower), sharp edges or corners, bump hazards, ease and safety of opening or removal.)

  Yes

  No

  N/A

• Guards are designed to accommodate all product sizes; while providing adequate protection.

  Yes

  No

  N/A

• Guards allow necessary observations and essential work tasks while in-place. (Consider critical and frequent adjustments, gage and process observations, etc.) Expanded metal (mesh) guards should be darker than the background and matte finish for optimal observation.)

  Yes

  No

  N/A

• Temperature and chemical hazards are assessed and protected.

  Yes

  No

  N/A

• Lighting is sufficient for the routine work tasks inside the guarded area

  Yes

  No

  N/A

Individual Safety Zones /Integrated Equipment

• A risk assessment and reduction completed on the points of interface between machines or between cells or zones within a machine.

  Yes

  No

  N/A

Machines with openings for Material/Product Handling & Conveying

• Material infeed/outfeed stations prevent access to machine hazards and accommodate all product sizes.

  Yes

  No

  N/A

• Material outfeed station control circuit prevent(s) hazards from materials exiting unexpectedly (example: impact or pinching hazard from material movement)

  Yes

  No

  N/A

Light Curtains, Scanners, Pressure Sensitive Mats

• For safety devices with approach reaction time, position the device following distance formula. (reference stopping distance formula in CBA 2051, ANSI B11.19, EN ISO13855)

  Yes

  No

  N/A

• Positioned to ensure protection from hazard (Safe distance formula )

  Yes

  No

  N/A

Labelling

• Disconnects/isolators/valves shall be labelled in the language of the users. Label shall unambiguously identify the device(s) that it affects

  Yes

  No

  N/A

• Equipment is labelled with signs to warn operators about hazards, which could not be eliminated by design (e.g. hot surface, laser, hazardous chemicals, electrical hazard, etc.)

  Yes

  No

  N/A

• Equipment is labelled with signs for required PPE (e.g. gloves, goggles, ear plugs,…)

  Yes

  No

  N/A

• Is the machine intended to use AMEC? If yes: AMEC risk assessment is completed, AMEC label is applied (according to CBA 2050)

  Yes

  No

  N/A

• Safety related labelling must be in the language of the operator

  Yes

  No

  N/A

Robotics -

• Definition: Robot: An automatically controlled, reprogrammable multipurpose manipulator programmable in three or more axes which may be either fixed in place or mobile for use in industrial automation applications.

• Robots meet requirements of RIA 15.06 /ISO 10218, including risk assessment following standard.

  Yes

  No

  N/A

• The robotic envelope is sized to accommodate entire extension of robotic arms and end of arm tooling, or utilizes safety rated robot limiting.

  Yes

  No

  N/A

• The minimum control circuit for robotics is Category 3 with monitoring and also includes lockout capability.

  Yes

  No

  N/A

• Access to the envelop is controlled such that only one person can be in the envelop with robot energized. Person must have pendant with hold-to-run controls.

  Yes

  No

  N/A

• While envelope is occupied by personnel it can only be operated by pendant at less than 250 mm (10in) per second

  Yes

  No

  N/A

• Non mechanical limiting devices (programmable) are to be avoided, but where necessary, must be isolated from general maintenance access

  Yes

  No

  N/A

• Robotic reset / start control panel(s) required verification that robotic envelop is clear. The entire hazardous zone must be viewable from the reset position or from multiple and sequenced reset positions.

  Yes

  No

  N/A

• If P&G is the integrator, P&G Engineering completes a third party inspection to confirm compliance with standard.

  Yes

  No

  N/A

Other Selected HS&E Competencies

• Laser radiation

• Laser hazards are guarded according to source classification per CBA130 and local reg. ( ANSIZ136, EN 60825)

  Yes

  No

  N/A

• Verify laser manufacuter plate includes the classification of the laser power source and that appropriate hazard warning labels are affixed

  Yes

  No

  N/A

• For Class 3b/4, apply the following:

  Yes

  No

  N/A

• Class 3 plus monitoring interlocked to power supply of laser, or redundant/monitored control to shutter

  Yes

  No

  N/A

• Accessible stations within Nominal Hazard Zone (NHZ) protected to Class 3 plus monitoring (as above)

  Yes

  No

  N/A

• Installation is reviewed by a qualified Laser Safety Officer (for Class 3b, 4), and, if required, appropriate action completed.

  Yes

  No

  N/A

Noise

• Machine meets noise targets in contract at VAT and when installed at site.

  Yes

  No

  N/A

Fall Prevention and Protection

• Machines having routine tasks (routine definition: at least once every two weeks or duration of >4hrs total in any sequential 4 week period) which require access greater than 1.2 m (4 ft.) have a fixed platform or HS&E leader approves moveable platform approach. Non-routine tasks have Fall Protection system design with certified anchor point.

  Yes

  No

  N/A

Ergonomics

• All lifting tasks that exceeds 5 kg (10 lbs) conform to the recommended weight limit determined using the NIOSH Lifting Calculator (or other prominent industry standard). Include calculations in machine safety documentation.

  Yes

  No

  N/A

• A risk assessment is conducted (typically using BRIEF survey) on repetitive tasks and the risk factors reduced to an acceptable level.

  Yes

  No

  N/A

Miscellaneous Hazards

• Machine parts and components are checked and verified to ensure there are no sharp edges, corners that could create a cut.

  Yes

  No

  N/A