TANKO JM Jet Spray - Installation, Operation, and Maintenan…

OPERATING / INSTALLATION INSTRUCTIONS (Translation)

Container cleaning Device Jet Cleaner TANKO ® JM100/500/800

Armaturenwerk Hötensleben GmbH Schulstr. 5-6 39393 Hötensleben, Germany Telephone: +49 39405 92-0 Fax: +49 39405 92-111 E-mail: info@awh.eu Homepage: http://www.awh.eu

ID no.: 664BAJM0000EN – 2016/12 Rev. 1

A member of Neumo Ehrenberg Group

NOTE

These instructions are an essential part of the device and must be available to operating and maintenance personnel at all times throughout its entire life cycle. The safety precautions they contain must be observed. If the device is resold, the instructions must always be transferred to the new owner.

Translation

The operating instructions must be written in an official European Community language acceptable to the manufacturer of the machinery in which the partly completed machinery will be assembled, or to his authorized representative. If any discrepancies arise in the translated text, the original operating instructions (German) are to be consulted for clarification, or the manufacturer is to be contacted.

These instructions and all illustrations contained therein are protected by copyright. Any use beyond the confines of copyright law is not permissible and liable to prosecution without the prior written approval of the publisher. This applies in particular to reproductions, translations, microfilming, and storage and processing in electronic systems.

© 2016 - Armaturenwerk Hötensleben GmbH. All rights reserved.

Jet Cleaner TANKO-JM

Contents

List of Figures .............................................................................................................................................III

List of Tables.............................................................................................................................................. IV

Abbreviations and Units.............................................................................................................................. V

1 Introduction ............................................................................................................................................. 1 1.1 Means of Presentation .......................................................................................................................... 1 1.1.1 Explanation of Signal Words........................................................................................................ 1 1.1.2 Explanation of the Warnings ....................................................................................................... 2 1.1.3 Pictograms and Symbols ............................................................................................................. 3 1.2 Warranty and Liability............................................................................................................................ 4 1.3 Product Names and Trademarks.......................................................................................................... 4 1.4 Related Documents............................................................................................................................... 4 2 Safety....................................................................................................................................................... 5 2.1 Intended Use.......................................................................................................................................... 6 2.2 Spare Parts, Replacement Parts and Accessories .............................................................................. 8 2.3 Duties of the Operating Company ........................................................................................................ 8 2.4 Requirements for Personnel ............................................................................................................... 10 2.4.1 Personal Protective Equipment ................................................................................................. 12 2.5 Identification Marking ......................................................................................................................... 13 2.5.1 Type Designation........................................................................................................................ 13 2.5.2 Type Plate ................................................................................................................................... 13 3 Construction and Function .................................................................................................................... 14 3.1 Construction......................................................................................................................................... 14 3.1.1 JM100 Construction................................................................................................................... 14 3.1.2 JM500 Construction................................................................................................................... 15 3.1.3 JM800 Construction................................................................................................................... 15 3.2 General Function Description ............................................................................................................. 16 3.2.1 Function of the JM100............................................................................................................... 17 3.2.2 Function of the JM500............................................................................................................... 18 3.2.3 Function of the JM800............................................................................................................... 19 3.3 Technical Data ..................................................................................................................................... 19 3.4 Cleaning Agents ................................................................................................................................... 23 4 Transportation and Storage................................................................................................................... 25 4.1 Packaging............................................................................................................................................. 26 4.2 Transportation ..................................................................................................................................... 26 4.3 Storage ................................................................................................................................................. 27 5 Installation............................................................................................................................................. 28 5.1 Safety Notes for Installation ............................................................................................................... 28 5.2 Installation ........................................................................................................................................... 30 5.2.1 Interfaces.................................................................................................................................... 31 5.2.2 Installation Position ................................................................................................................... 35 5.2.3 Installing the Device................................................................................................................... 35

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6 Commissioning ...................................................................................................................................... 40 6.1 Safety Notes for Commissioning.........................................................................................................40 6.2 Functional Check / Trial Run...............................................................................................................42 6.3 Switch-on Procedure............................................................................................................................43 6.4 Operation..............................................................................................................................................44 7 Maintenance ......................................................................................................................................... 47 7.1 Safety Notes for Maintenance ............................................................................................................47 7.2 Switch-off Procedure............................................................................................................................49 7.3 Removal................................................................................................................................................50 7.3.1 Removing the Device .................................................................................................................50 7.4 Maintenance ........................................................................................................................................52 7.4.1 Maintenance Intervals ...............................................................................................................53 7.4.2 Tools and Tightening Torque Values .........................................................................................57 7.4.3 Disassembling the Device..........................................................................................................59 7.4.4 Assembling the Device...............................................................................................................64 7.4.5 Notes on Cleaning ......................................................................................................................70 7.5 Spare Parts and Customer Service.....................................................................................................71 7.5.1 JM100 Spare Parts ....................................................................................................................72 7.5.2 JM500 Spare Parts ....................................................................................................................75 7.5.3 JM800 Spare Parts ....................................................................................................................78 8 Faults..................................................................................................................................................... 81 8.1 Safety Notes for Fault Clearance ........................................................................................................81 8.2 Faults and Remedial Action ................................................................................................................82 8.3 How to Act in Case of an Emergency ..................................................................................................83 9 Decommissioning .................................................................................................................................. 84 9.1 Disposal ................................................................................................................................................84

Index ......................................................................................................................................................... 86

Appendices ............................................................................................................................................... 88

Notizen ..................................................................................................................................................... 91

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List of Figures

Figure 2.5-1: Type plate position................................................................................................................... 13

Figure 3.1-1: Overview of JM100 .................................................................................................................. 14

Figure 3.1-2: Overview of JM500 .................................................................................................................. 15

Figure 3.1-3: Overview of JM800 .................................................................................................................. 15

Figure 3.3-1: Diagram - Flow JM100-G22, (3 – 10 bar /44 – 145 psi)...................................................... 21 Figure 3.3-2: Diagram - Flow JM100-G22, (10 – 20 bar /145 – 290 psi) ................................................. 21

Figure 3.3-3: Chart - JM500-G22 flow........................................................................................................... 22

Figure 3.3-4: Chart - JM800-G13 flow........................................................................................................... 22

Figure 5.2-1: Installation dimensions of the JM100 device ........................................................................ 31

Figure 5.2-2: Interfaces of the JM100 device .............................................................................................. 32

Figure 5.2-3: Installation dimensions of the JM500 device ........................................................................ 33

Figure 5.2-4: Interfaces of the JM500 device .............................................................................................. 34

Figure 5.2-5: Installation dimensions of the JM800 device ........................................................................ 34

Figure 5.2-6: Interfaces of the JM800 device .............................................................................................. 35

Figure 5.2-7: Assembly of threaded connection (example JM100) ............................................................ 37

Figure 7.4-1: JM100 maintenance points .................................................................................................... 54

Figure 7.4-2: JM500 maintenance points .................................................................................................... 55

Figure 7.4-3: JM800 maintenance points .................................................................................................... 56

Figure 7.5-1: Internal construction of the JM100-G22................................................................................ 72

Figure 7.5-2: Internal construction of the JM500-G22................................................................................ 75

Figure 7.5-3: Internal construction of the JM800-G13................................................................................ 78

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List of Tables

Table 1.1-1: Overview of Signal Words............................................................................................................ 1

Table 3.3-1: Operating parameters of the device ........................................................................................20

Table 7.4-1: JM100 inspection and maintenance work ..............................................................................54

Table 7.4-2: JM500 inspection and maintenance work ..............................................................................55

Table 7.4-3: JM800 inspection and maintenance work ..............................................................................57

Table 7.5-1: JM100 tightening torque values...............................................................................................72

Table 7.5-2: JM100 parts list (standard) ......................................................................................................73

Table 7.5-3: JM100 standard configuration .................................................................................................74

Table 7.5-4: JM500 tightening torque values...............................................................................................75

Table 7.5-5: JM500 parts list (standard) ......................................................................................................76

Table 7.5-6: JM500 standard configuration .................................................................................................77

Table 7.5-7: JM800 tightening torque values...............................................................................................78

Table 7.5-8: JM800 parts list (standard) ......................................................................................................79

Table 7.5-9: JM800 standard configuration .................................................................................................80

Table 8.2-1: Operating faults – cause and remedy......................................................................................82

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Abbreviations and Units

Abbreviations

ATEX

ATmosphère EXplosible; Synonym for the ATEX Directive of the European Union; comprises measures for explosion protection for explosive atmospheres

AWH

Armaturenwerk Hötensleben GmbH

BetrSichV Betriebssicherheitsverordnung (German industrial safety ordinance); ordinance concerning health and safety when using work equipment; German implementation of Directive 2009/104/EC of the European Parliament concerning the minimum safety and health requirements for the use of work equipment by workers at work

AU

Assembly unit

BS

British Standard

BSP

British Standard Pipe; British thread standard for pipe fittings

approx.

Approximately

CIP

Cleaning in Place; a local (automated) cleaning process without dismantling plant parts. Denotes a procedure for cleaning processing plants, predominantly in sectors with particularly critical hygiene requirements, such as the pharmaceutical industry, food and beverage industry or biofuel plants.

DN

DIN-Nennweite (DIN nominal width)

DIN

Deutsches Institut für Normung e.V.; is a national standards organization in the Federal Republic of Germany; The standards of this organization are referred to as DIN standards. Downpipe In the context of these instructions, this colloquial term describes a line or connection in cleaning technology between a media connection [MC] and a cleaning head or cleaning device. This line is generally used to establish the process connection [PC] for connection of the device to the container.

DP

ES

European Standard

IP

Individual part

FDA

Food and Drug Administration (USA food and medication monitor regulation authority)

ISO

International Organization for Standardization

Jet

Cleaning jet In the context of these instructions, this colloquial term describes a cleaning jet from a jet cleaner [JC] using in cleaning technology.

“ JM ” device series: Jet with media actuator

JM

M

Metric

MC

Media connection In the context of these instructions, this colloquial term describes the interface used in cleaning technology for supplying cleaning agent from the supply line to the device.

max.

Maximum

min.

Minimum

NPT

National Pipe Thread; USA thread standard for pipe fittings

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PC

Process connection In the context of these instructions, this colloquial term describes the interface used in cleaning technology for the connection to the process from the device to the container. Système international d’unités; th e most widely used international system of units for physical variables

SI

SN

Serial number

WAF

Width across flats [wrench size]

“ Technische Regeln für Betriebssicherheit ” (German technical rules for operational reliability and safety); these rules put the “ Betriebssicherheitsverordnung ” (BetrSichV) into concrete terms with regard to the identification and assessment of hazards and the derivation of suitable measures.

TRBS

v eff

effective vibration velocity

WP

Wear part

AS

Assembly

JC

Jet cleaner

Terms

Stationary device: The device remains fitted on the container for a long period, even during the production process. Mobile device: The device is mounted on and removed from the container several times in a short period, and can also be used for cleaning several containers.

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Units of Measure

The following indicated factors are for orientation and conversion of the Si units to common units of measures for the American market.

bar

Unit of measure for pressure p [bar] All pressure [bar] specifications stand for positive pressure [bar] [bar g ] unless expressly described otherwise. Conversion: 1 bar = 14.50376… p si [pound-force per square inch] Unit of measure for temperature T [degrees Celsius] Conversion from Celsius to Fahrenheit: °C  1.8 + 32 = °F [degrees Fahrenheit]

°C

h

Unit of measure for time t [hour]

kg

Unit of measure for mass m [kilograms] Conversion:

1 kg = 2.20462 … lb [Latin libra; pound]

l/min

Unit of measure for volume flow rate V [liters per minute] Conversion: 1 l/min = 0.06 m 3 /h [cubic meters per hour]

1 l/min = 0.26417 … gpm (US) [gallons per minute (US)] 1 m 3 /h = 4.40286 … gpm (US) [gallons per minute (US)]

lx

Unit of measure for illuminance E v [Lux]

m

Unit of measure for length l [meters] Conversion: Unit of measure for length l [millimeters] Conversion: 1 m = 3.28083… ft [feet]

mm

1 mm = 1 / 25.40005 in [inches] = 0.03937 in [inches]

Nm

Unit of measure for moment/torque M [newton meters] Conversion: 1 Nm = 0.737 lbft [pound-force + feet] Unit of measure for speed n [revolutions per minute] Conversion: 1 rpm = 1 revolution per minute

rpm

µm

Unit of measure for length l [micrometers]

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1 Introduction

These operating/installation instructions (referred to hereinafter as the instructions) are a component part of the device. They provide you with all the information required for smooth operation of the TANKO ® JM jet cleaner (referred to hereinafter as the device). The instructions must be read, understood, and applied by all persons employed to carry out installation and assembly, maintenance, cleaning and troubleshooting on the device. This applies in particular to the listed safety notes.

After studying the instructions, you will be able to

– assemble, install and operate the device safely,

– clean and service the device correctly and

– take the correct measures if a fault occurs.

In addition to these instructions, generally valid, statutory and other binding regulations in regard of the prevention of accidents and in regard of environmental protection in the country of use must also be observed. The instructions must be kept at the location of use of the device so that it is available in legible condition at all times. If the device is resold, the instructions must always be transferred to the new owner.

Download the instructions if necessary from the http://www.awh.eu/de/downloads Internet page.

1.1 Means of Presentation

1.1.1 Explanation of Signal Words

The warnings are introduced with a signal word which describes the extent of the hazard. The meaning and their classification in case of hazardous situations are explained in the following overview.

Signal Word

Meaning

Consequences of Failure to Observe

DANGER

Hazard with a high level of risk

Death or severe physical injuries

WARNING

Hazard with a medium level of risk Death or severe physical injuries

CAUTION

Hazard with a low level of risk

Minor or moderate physical injuries

NOTE

Hazard with a low risk

Risk of material damage

Table 1.1-1: Overview of Signal Words

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1.1.2 Explanation of the Warnings

Section-related Warnings

The section-related warnings do not just apply for one particular action but rather for all actions within a section. In addition, the pictograms and symbols indicate a general or specific danger.

DANGER

This warning warns of a hazard with a high level of risk. Failure to observe it can lead to death or severe physical injury.  Measure(s) to prevent the danger

WARNING

This warning warns of a hazard with a medium level of risk! Failure to observe it can lead to death or severe physical injury.  Measure(s) to prevent the danger

CAUTION

This warning warns of a hazard with a low level of risk! Failure to observe it can lead to minor or moderate injury.  Measure(s) to prevent the danger

NOTE

This warning warns of a hazard with a minor level of risk! Failure to observe it can lead to material damage.  Measure(s) to prevent the danger

Embedded Warnings

The embedded warnings apply to specific actions and are integrated directly into the action before the specific action step.

The embedded warnings are structured as follows.

SIGNAL WORD Type and source of danger.

Possible consequences in case of failure to observe

 Measure(s) to prevent the danger

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Further Means of Presentation

The “ Info ” symbol provides useful information, additional tips and recommendations.

– Texts which follow this mark, are bulleted lists.  Texts which follow this mark, describe measures for prevention of the danger.

1. Texts which follow this numbering, describe the first step of a task which is followed by further numbered steps which have to be performed in the specified order. (1) Numbers in brackets reflect the item numbers in illustrations or parts lists. “ ” Texts in quotation marks are (direct) quotes from documents (e.g. directives or standards) or words, word groups and parts of a text with a special meaning. Important, significant information is shown with additional bold type, in italics or CAPITAL LETTERS for emphasis of individual words or phrases.

1.1.3 Pictograms and Symbols

The following pictograms and symbols are used as a supplementary measure in these instructions to clarify the sources of dangers and measures. They can appear at all levels of danger.

Warning about electrical voltage

Warning about explosive atmosphere

Warning about hand injuries

Warning about a hot surface

Warning about corrosive substances

Warning about substances which are a water hazard

Unauthorized access prohibited

Wear protective work clothing

Wear safety shoes

Wear protective gloves

Wear safety goggles

Wear a hard hat

Isolate from voltage before work

Wear a welding mask

Obey instructions

Wear hearing protection

Secure against power being switched back on

Return for recycling

Protective grounding connection required

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1.2 Warranty and Liability

The commitments agreed in the contract of supply and delivery, the general terms and conditions and the terms of delivery of Armaturenwerk Hötensleben GmbH Armaturenwerk Hötensleben GmbH (referred to hereinafter as AWH) and the statutory regulations valid at the time the contract was concluded shall apply. Warranty and liability claims in the case of personal injury and damage to property shall be excluded in particular if these can be attributed to one or more of the following causes:

– Improper or incorrect use of the device,

– Improper assembly and installation, commissioning, operation and maintenance of the device,

– Failure to observe the instructions in the instructions regarding assembly and installation, commissioning, operation and maintenance of the device, – Constructional modifications to the device (conversions or other modifications to the device must not be made without previous written approval from AWH. In case of infringement, the device will lose its EC conformity and the operating authorization),

– Use of spare parts that do not meet the specified technical requirements,

– Improperly performed repairs,

– Disasters, the effects of foreign objects and force majeure.

Disclaimer

AWH reserves the right to make alterations to this document at any time and without prior notice. AWH provides no guarantee (neither expressed nor implied) with regard to all information in this document, including but not limited to the implied warranty of merchantability and suitability for a particular purpose. Furthermore, AWH does not guarantee the correctness or completeness of information, text, graphics or other parts in this document.

1.3 Product Names and Trademarks

The product names and trademarks included in these instructions are brands or registered trademarks of the respective owners.

TANKO ® and AWH ® are registered trademarks of Armaturenwerk Hötensleben GmbH.

1.4 Related Documents

The following documents may contain supplementary information for these instructions: – Manufacturer's declaration and/or certificates of conformity – Certificates – Additional documents for any attached or upstream components, e.g. Drawings, technical data, information on accessories etc. – Supplements to these instructions (e.g. special versions) – AWH catalog, product data sheet

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2 Safety

The device has been built in accordance with state-of-the-art technology and the recognized rules of safety. Nevertheless, use of the device may represent a danger to the life and limb of the user and third parties or a risk of impairments to the device and other objects of material value as a result of its function. The following basic safety notes are intended to prevent injury to personnel and material damage. The operating company must ensure that the basic safety instructions are observed and adhered to. These instructions contain basic notes on installation, operation, maintenance and servicing of the device which must be complied with. Anyone involved in installation, operation, maintenance and servicing must have read and understood these instructions.

The safety systems and safety notes described in these instructions must be adhered to.

WARNING

Failure to comply with these instructions, incorrectly performed installation and repair work or incorrect operation could lead to malfunctions on the device and to dangerous situations! There is a risk of death or severe physical injuries.  All work performed on the device must be carried out only by a specialist and in compliance with – the corresponding detailed operating and installation instructions, – the warning and safety signs on the device, – regulations and requirements specific to the plant and – national/regional regulations for safety and the prevention of accidents.  Never install damaged devices or components.

The figures in these instructions are for basic understanding and are primarily representations of the principles involved. They may differ from the actual design of the device.

For maintenance and repair, we recommend a training course provided by the manufacturer or a person authorized by the manufacturer.

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2.1 Intended Use

DANGER

Risk of injuries from fire/explosion when using the device in an explosive atmosphere. Use of the device in an Ex area (potentially explosive atmosphere) is PROHIBITED. There is a risk of death or severe physical injuries.  Adhere to the type plate of the device (see section 2.5.2 Type Plate) and the respective operating instructions .

WARNING

Risk of hazardous situations caused by use going beyond intended use and/or other types of use of the device! There is a risk of death or severe physical injuries.  Only use the device for the intended use. – Only ever use the device in accordance with the specifications contained in these instructions and the specifications on the device’s type plate . – All the specifications in these instructions must be adhered to at all times. – Always keep the operating instructions at the location where the device is used. – Keep all signs on the device in legible condition. – Only use original spare parts.  Modifications or conversions to the device are NOT permitted.

WARNING

Danger from the incorrect use of materials/agents! The materials/agents to be used for the intended operation of the device are procured and utilized by the operating company for the device. If unsuitable materials or agents are selected, strong chemical reactions could lead to fatal injury or (severe) physical injuries.  The proper selection and treatment of these materials/agents is solely the responsibility of the operating company.  When selecting the materials/agents, make sure that the permitted technical parameters of the device are NOT exceeded.  The cleaning agents and media must be approved for all of the materials of the device (e.g. washers, bushings) and for the substances in the container to be cleaned which come into contact with them.  Adhere to the specified chemical limitations for use in the material data sheets.  Adhere to the safety data sheets supplied by the manufacturers of the materials and media, in particular for hazardous substances: – Comply with the hazard and disposal instructions. – Set out protective measures and compile operating instructions for hazardous substances. – This also applies to hazardous substances that may arise during work processes.

Refer to the order confirmation / parts list from AWH for the materials used in the device.

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The TANKO-JM is a rotating cleaning device and belongs to the group of jet cleaners. The device is driven by the cleaning agent. The device is used for cleaning the interiors of containers with and without installed equipment. For the purpose of these instructions, containers refer to enclosed, depressurized tanks, silos, barrels, containers, pipes, etc., which are provided with an outlet that ensures a free outward flow of the supplied cleaning fluid. The pressure in the container to which the device is attached may not exceed a maximum of 0.5 bar (7.25 psi). The device was developed, engineered and built exclusively for industrial and commercial use. It must not be used for private use.

In all cases, operating company must check whether the device is suitable for its application.

The device can be used in containers inside and outside of buildings in compliance with the limitations for use (see section 3.3 Technical Data ). In the process, the following must always be observed:  Only operate the device when installed inside an enclosed container.  Never direct the cleaning jet or torrent from the device at persons.  Protect the device from freezing (e.g. risk of frost from possible residual water).  The device is designed for fixed pipe installation only. Installation on a hose is PROHIBITED.  Use a suitable filter system in the supply line for the cleaning agent.  Operate the container only within the approved parameters, e.g. pressure and temperature, (see section 3.3 Technical Data ).  Only cleaning agents which are compatible with the materials of the device (see section 3.4 Cleaning Agents ) may be used.  The preferred installation position for the device is vertical with the cleaning head pointing downwards. Other installation positions are possible (see section 5.2.2 Installation Position ).  The device may generate vibrations when cleaning the container. Any vibrations going beyond this must be avoided (see section 7.4.1 Maintenance Intervals ).

The device is NOT suitable for the following applications:  The device is NOT suitable for private use.  The device is NOT suitable for ATEX applications.  The device is NOT suitable for use outside of containers.  Holding the device with your hand during operation is PROHIBITED.

 The device must NOT be immersed in the product of the production process (NOT even partially). This could cause the product to enter into the device. The spray boreholes may become blocked. The free movement of the actuator may be obstructed.  The device must NOT by operated with air over a long period as the cleaning agent is used for lubrication of the bearings. The device is intended exclusively for the purpose outlined above. Any other use beyond that described here or alteration of the device without written approval from the manufacturer is considered IMPROPER use.

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The manufacturer accepts NO liability for damage arising from this. The operating company is solely responsible for the risk. The device must not be put into operation until it has been assured that all the safety devices are fully functional and the plant in which the device is installed meets the safety requirements of all relevant European directives (e.g. the Machinery Directive).

2.2 Spare Parts, Replacement Parts and Accessories

WARNING

Risk of damage, malfunction or complete failure of the device! Incorrect or faulty spare/replacement parts and accessories put the functional safety and reliability of the device at risk. There is a risk of death or severe physical injuries. The failure of components or a device malfunction can cause material damage and consequential damages.  Only use the manufacturer's original spare parts. We expressly draw attention to the fact that replacement parts and accessories NOT supplied by AWH have NOT been checked or approved by AWH. The installation and/or the use of such products could therefore under certain circumstances result in changes with negative results to the properties of the device specified by its design and the higher-level plant. AWH is not liable for any damage arising from the use of non-original parts or non-original accessory parts. Standard parts can be obtained from specialist dealers.

Section 7.5 Spare Parts and Customer Service includes a list of spare parts.

2.3 Duties of the Operating Company

The device is used in the commercial sector. The operating company is thus subject to the legal obligations of occupational safety. In the EEA (European Economic Area), the national implementation of the Framework Directive 89/391/EEC on carrying out measures for improving safety and protecting the health of employees during work, as well as the associated individual directives shall be observed and complied with in their current valid versions. Of particular importance in this connection is Directive 2009/104/EC on the minimum specifications for safety and health protection of employees using work equipment in their work.

As a basic rule, in Germany the Industrial Safety Regulation (BetrSichV) must be observed.

In other countries, the respective national directives, statutes and country-specific regulations regarding occupational safety and accident prevention are to be complied with.

At the same time, the following, non-exhaustive instructions apply in particular:

– The operating company must ensure that the device is used only as intended (see section 2.1 Intended Use ). – The operating company must keep informed of the locally applicable occupational health and safety regulations and, in addition, use a risk assessment to determine the hazards resulting from the

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specific working conditions at the location of use of the device. This must then be implemented in the form of operating instructions for the operation of the device. – When using hazardous materials, protective measures must be specified in accordance with the safety data sheets and operating instructions shall be compiled for hazardous materials. Personnel must be appropriately briefed about this. This also applies to hazardous substances that may arise during work processes. – A continuous risk assessment must be carried out for workplaces, including temperature conditions for the medium and the place of use (falling). The measures are to be defined in operating instructions. Personnel must be instructed accordingly.

– Supervisors must monitor compliance with the measures specified in the operating instructions.

– Throughout the entire operating period of the device, the operating company must check whether the operating instructions he has compiled reflect current legislation requirements and adapt them as necessary. – The operating company must clearly regulate and specify the responsibilities of personnel (e.g. for operation, maintenance and cleaning). – The operating company must allow only sufficiently qualified and authorized personnel to work on the device. – The operating company must ensure that all employees handling the device have read and understood the instructions. Furthermore, he must provide personnel with training at regular intervals with certification and inform them about the hazards. – The user must provide sufficient workplace lighting at the plant in accordance with the locally applicable regulations for occupational health and safety in order to prevent hazards occurring as a result of poor lighting. – The operating company must provide personnel with personal safety clothing and equipment and make sure that this is used (see section 2.4.1 Personal Protective Equipment ). – The operating company must make sure that the danger area of the higher-level plant in which the device is installed is not accessible to unauthorized persons. – The operating company must make sure that no one is permitted to work on the device whose ability to react is impaired by drugs, alcohol, medication or similar. – The operating company must take appropriate measures to inform groups of persons who are not intended to come into direct contact with the device (e.g. visitor groups) about the potential dangers involved. – The operating company is responsible for making sure that the device is only ever operated in perfect condition. – Wherever high pneumatic pressures occur, there is a possibility of sudden failure of or damage to the lines and connections. This poses a hazard. The operating company must instruct operating and maintenance personnel at least once a year on the possible hazards. – The constructor of the overall plant must install the switching and safety devices required for setting up, inspection, shutting down (including emergency shutdown), operation, maintenance, cleaning and repair.

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– The operating company must design the disconnection of the energy sources on the higher-level plant technically in such a way that the Switch-off Procedure described in section 7.2 can be adhered to. – The operating company must define and adhere to the intervals for inspections and control measures in accordance with the environment and media used. – The operating company must provide fire safety devices, e.g. the appropriate quantity of suitable hand-held fire extinguishers of the appropriate size, in easily accessible places and provide employees with training on fire safety. – Warnings in the documentation for externally supplied assembly units must be adhered to and incorporated into the risk assessments for the specific workplace.

Connections:

Before operating the machine with the device, the operating company must make sure that the local regulations are observed for assembly and installation and commissioning, if these tasks are performed by the operating company.

2.4 Requirements for Personnel

The device must only be operated, maintained and repaired by persons with the appropriate qualifications. These persons must be familiar with these instructions and act in accordance with them. The respective authorizations for personnel must be clearly defined.

The following qualifications are designated in the instructions for various fields of activity:

Expert/Specialist Personnel

An expert is a person whose professional training, knowledge and experience and knowledge of the relevant standards and regulations enables them to carry out work on the device and identify and prevent potential risks independently.

Instructed Person

An instructed person has been briefed and, if necessary, trained by the operating company or an expert in a briefing on the assigned tasks and possible hazards in the event of improper actions, and instructed on the necessary safety devices and protective measures.

Only personnel with the following expertise are permitted to perform work on the device:

– Assembly/disassembly: Industrial mechanic or similar training, practical experience in the assembly/disassembly of devices The person must be familiar with the construction, mechanical installation, maintenance of the device and fault clearance on the device and have the following qualifications: – Vocational training and final qualification in the field of mechanics (e.g. mechanic or mechatronics technician)

– Welding work: Welder qualification in pipeline engineering or similar qualification.

– Electrical work: Electrician; person with appropriate specialized training, knowledge and experience, enabling them to identify and prevent risks which may be caused by electricity

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The person must be familiar with the electrical installation, commissioning, fault clearance on and repair of the device and have the following qualifications: – Vocational training and final qualification in electrical engineering (e.g. electrician, electronics engineer or mechatronics technician)

– Several years of vocational experience in the field of electrical engineering

– Cleaning: Instructed person

Work performed in other areas transportation, storage, operation and disposal must be performed exclusively by personnel who have received suitable instruction. All of the personnel listed above must wear protective clothing in accordance with their respective activities.

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2.4.1 Personal Protective Equipment

Personal protective equipment must be used in accordance with the respective task when working on the device in order to minimize health hazards. Protective Work Clothing Protective work clothing is tight-fitting work clothing with low resistance to tearing, with close-fitting sleeves and without protruding parts. It is mainly used for protection against getting entangled in moving components. Do not wear any rings, necklaces or other jewelry. Safety shoes Wear slip-resistant safety shoes for protection against heavy, falling objects or for protection against slipping on slippery surfaces. Protective gloves Wear protective gloves to protect your hands against friction, grazes, getting pricked or deep cuts and for protection against coming into contact with hot surfaces or chemical substances.

Protective goggles Wear protective goggles for protection against media escaping at high pressure and against flying objects.

Hard hat Wear a hard hat for protection against falling or flying objects.

Hearing protection Wear hearing protection to protect yourself from an increased sound pressure level (≥ 85 dB(A)). Welding mask Wear a welding mask to protect against damage to the eyes or skin caused by the welding arc and to protect against burns caused by flying particles during welding.

Personal protective equipment must be provided by the user and must meet the valid requirements.

Furthermore, both the national regulations and, if necessary, the internal instructions from the operating company, must be observed.

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