TANKO® S & TANKO® RB_IOM_Rev0

OPERATING/INSTALLATION INSTRUCTIONS (Translation)

Container cleaning devices

Spate cleaner TANKO ® EX-S

Spray cleaner TANKO ® EX-RB

Type series

TANKO-EX-S20

TANKO-EX-RB30

TANKO-EX-S30

TANKO-EX-RB40

TANKO-EX-S40

TANKO-EX-RB64

TANKO-EX-S50

TANKO-EX-RB90

II 1 GD c T(X)

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.: 664BA010706ENX - 2017/10 Rev. 0

A member of the 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 contained therein 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) must be consulted for clarification, or the manufacturer must be contacted.

This manual and all figures 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.

ATEX Spate Cleaner TANKO-EX-S and ATEX Spray Cleaner TANKO-EX-RB

Contents

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

List of Tables..............................................................................................................................................III

Abbreviations and Units............................................................................................................................ IV

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 ....................................................................................................... 9 2.4 Requirements for Personnel .............................................................................................................. 11 2.4.1 Personal Protective Equipment............................................................................................... 13 2.5 Labeling............................................................................................................................................... 14 2.5.1 Type Designation...................................................................................................................... 14 2.5.2 Type Plate ................................................................................................................................. 15 2.5.3 Labeling for Explosion Protection ........................................................................................... 15 3 Construction and Function ................................................................................................................... 17 3.1 Structure ............................................................................................................................................. 17 3.2 General Function Description ............................................................................................................ 18 3.3 Technical Data .................................................................................................................................... 19 3.4 Cleaning Agents .................................................................................................................................. 25 4 Transportation and Storage.................................................................................................................. 28 4.1 Packaging............................................................................................................................................ 29 4.2 Transport ............................................................................................................................................. 29 4.3 Storage................................................................................................................................................ 30 5 Installation............................................................................................................................................ 31 5.1 Safety Instructions for Installation .................................................................................................... 31 5.2 Installation .......................................................................................................................................... 34 5.2.1 Interfaces.................................................................................................................................. 35 5.2.2 Installation Position ................................................................................................................. 35 5.2.3 Installing the Device ................................................................................................................ 36 6 Commissioning ..................................................................................................................................... 40 6.1 Safety Notes for Commissioning ....................................................................................................... 40 6.2 Functional Check / Trial Run ............................................................................................................. 43 6.3 Switch-on procedure........................................................................................................................... 44

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6.4 Operation.............................................................................................................................................45

7 Maintenance ........................................................................................................................................ 49 7.1 Safety Instructions for Maintenance .................................................................................................49 7.2 Switch-off Procedure ..........................................................................................................................52 7.3 Removal...............................................................................................................................................53 7.3.1 Removing the device................................................................................................................54 7.4 Maintenance .......................................................................................................................................55 7.4.1 Maintenance Intervals .............................................................................................................56 7.4.2 Tools and Tightening Torque Values .......................................................................................59 7.4.3 Notes on Cleaning ....................................................................................................................61 7.5 Spare Parts and Customer Service....................................................................................................63 7.5.1 Spare Parts ...............................................................................................................................64 8 Faults.................................................................................................................................................... 65 8.1 Safety Instructions for Troubleshooting ............................................................................................65 8.2 Faults and Remedial Action ...............................................................................................................66 8.3 What to Do in Case of an Emergency ................................................................................................67 9 Decommissioning................................................................................................................................. 69 9.1 Disposal...............................................................................................................................................70

Index ........................................................................................................................................................ 71

Appendices .............................................................................................................................................. 73

Notes ....................................................................................................................................................... 77

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List of Figures

Figure 2.5-1: Type Plate Position................................................................................................................... 15

Figure 3.1-1: Overview of designs ................................................................................................................. 17

Figure 3.2-1: Actuator structure (example TANKO-S)................................................................................... 18

Figure 3.3-1: Spray pattern............................................................................................................................ 19

Figure 3.3-2: External dimensions ................................................................................................................ 19

Figure 3.3-3: Consumption data S20............................................................................................................ 23

Figure 3.3-4: Consumption data S30............................................................................................................ 23

Figure 3.3-5: Consumption data S40............................................................................................................ 24

Figure 3.3-6: Consumption data S50............................................................................................................ 24

Figure 5.2-1: Interfaces of the devices (similar to picture).......................................................................... 35

Figure 5.2-2: Weld-on design......................................................................................................................... 36

Figure 5.2-3: Installation threaded connection ............................................................................................ 37

Figure 5.2-4: Dimensions clip-on................................................................................................................... 38

Figure 5.2-5: Clip-on Installation ................................................................................................................... 39

Figure 7.4-1: Maintenance Points................................................................................................................. 57

List of Tables

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

Table 2.5-1: Type series................................................................................................................................. 14

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

Table 3.3-2: Operating parameters of the device TANKO-EX-RB ................................................................ 21

Table 3.3-3: Material combinations body - balls .......................................................................................... 22

Table 3.3-4: Material pairings device - locking pin (examples) ................................................................... 22

Table 5.2-1: Recommended Filler Materials ................................................................................................ 37

Table 5.2-2: Dimensions clip-on.................................................................................................................... 38

Table 7.4-1: Inspection and Maintenance Work .......................................................................................... 58

Table 7.5-1: Spare part wire locking pin for clip-on ..................................................................................... 64

Table 8.2-1: Operating Faults – Cause and Remedy ................................................................................... 66

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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

approx.

approximately

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

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. 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.

DIN

Head diameter

European Standard

ISO

International Organization for Standardization

Length

L EX,8h

Daily noise exposition level

L PA

Emission noise pressure level at workplace

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

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; the most widely used international system of units for physical variables

Serial number

Width across flats [wrench size]

TRBS

“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.

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TRGS

“Technische Regel für Gefahrstoffe” (German technical rules for hazardous materials); these rules reflect the state of the art, occupational medicine and occupational hygiene as well as other sound scientific knowledge for activities involving hazardous materials, including their classification and labeling.

up / down

Spray template up / down

v eff

effective vibration velocity

Units of Measure

The following indicated factors are intended for orientation and the conversion of the SI units to common units of measure 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… psi [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

Unit of measure for time t [hour]

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)]

Unit of measure for illuminance E v [Lux]

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

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

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 U/min = 1 rpm [revolutions per minute]

rpm

µm

Unit of measure for length l [micrometers]

Contents

Translation-Operating/Installation Instructions 2017/10

ATEX Spate Cleaner TANKO-EX-S and ATEX Spray Cleaner TANKO-EX-RB

Translation-Operating/Installation Instructions 2017/10

Contents

ATEX Spate Cleaner TANKO-EX-S and ATEX Spray Cleaner TANKO-EX-RB

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 ® EX-S/TANKO ® EX-RB cleaning system (referred to hereinafter as the device). The instructions must be read, understood, and applied by all persons employed to carry out installation and assembly, commissioning, maintenance, cleaning and troubleshooting on the device. This applies in particular to the listed safety instructions.

After studying the manual, you will be able to

– Assemble, install and operate the device safely

– Clean and service the device correctly

– Take the correct measures if a fault occurs.

In addition to these instructions, generally applicable, 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 they are 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 injury

Hazard with a medium level of risk

WARNING

Death or severe physical injury

CAUTION

Hazard with a low level of risk

Minor or moderate physical injury

NOTE

Hazard with a low risk

Risk of material damage

NOTE ON EXPLOSION PROTECTION

Important note on explosion protection

Loss of explosion protection and resulting hazards.

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 apply not only to one particular action, but rather to 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

NOTE ON EXPLOSION PROTECTION This note contains instructions regarding explosion protection. Non-compliance results in the explosion protection being removed, thus leading to hazards.

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, 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

Operating equipment for Ex zone

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 (referred to hereinafter as AWH) and the statutory regulations valid at the time the contract was concluded shall apply. Warranty and liability claims in 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 comply with 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 instructions 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 assembly, operation, maintenance and servicing must have read and understood these instructions.

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

WARNING

Failure to comply with this manual, 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 injury.  All work performed on the device must be carried out only by a specialist and in compliance with

– the corresponding detailed operating and installation instruction(s),

– the warning and safety signs on the device,

– the regulations and requirements specific to the plant and

– the national/regional regulations for safety and the prevention of accidents.  Never install damaged devices or components.

The figures in this manual are intended to provide 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, UNLESS the device is expressly intended for said purpose. There is a risk of death or severe physical injury.

 Adhere to the type plate of the device and the relevant 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 injury.

 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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2 Safety

ATEX Spate Cleaner TANKO-EX-S and ATEX Spray Cleaner TANKO-EX-RB

The TANKO-EX-S is a cleaning device without an external actuator and is a member of the spate cleaners group. The TANKO-EX-RB is a cleaning device without an external actuator and is a member of the spray cleaners group. 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 device was developed, engineered and built exclusively for industrial and commercial use. It must not be used for private use. Operation may also be carried out if an explosive dust or gas atmosphere is present, or can develop, inside the tank that is to be cleaned. The TANKO-EX-S or TANKO-EX-RB device is suitable for use in explosion protection areas classified as Zone 0 (in which an explosive gas atmosphere is continuously present or present for prolonged periods; can also be caused by the cleaning agent used) or Zone 20 (in which an explosive dust atmosphere is continuously present or present for prolonged periods).

The use of devices in device group II, category 1G is enforced for Zone 0.

The use of devices in device group II, category 1D is enforced for Zone 20.

Please note the additional information on the type plate for the Ex labeling (see Section 2.5.3 Labeling for Explosion Protection ).

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

NOTE ON EXPLOSION PROTECTION The area of application of the device must always be adjusted to the relevant operating conditions and the materials in contact with the product. These materials must be selected to ensure that they do not react with the cleaning agent or the substances in the container to be cleaned in any way that could impair the explosion protection. Non-compliance can result in the loss of the explosion protection.

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 device 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 ).

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 The preferred installation position for the device is vertical with the cleaning head pointing downwards. Other installation positions are possible.  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 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 holes may become blocked. The free movement of the actuator may be obstructed.  The device should NOT be used to blow dry air, gases or vapors over containers or over the device itself, 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. The manufacturer accepts NO liability for damage arising from such use. 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 injury. The failure of components or a device malfunction can cause material damage and consequential damages.

 Use only the manufacturer's original spare parts.

We expressly draw attention to the fact that spare parts and accessories NOT supplied by AWH have NOT been checked or approved by AWH. The installation and/or 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 7.5.1 Spare Parts includes a list of spare parts.

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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 regarding 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 guidelines, statutes and country-specific regulations regarding occupational safety and accident prevention must 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 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 briefed accordingly. 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 only allow 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, it must provide personnel with training at regular intervals with certification and inform them of the hazards.

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– The operating company 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 protective 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 there is nobody whose ability to react is impaired by drugs, alcohol, medication or similar substances is allowed to work on the device. – 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. – 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 in fire safety. – Warnings in the documentation for externally supplied assembly groups must be adhered to and incorporated into the risk assessments for the specific workplace. – The operator must ensure that the permitted operating parameters (see section 3.3 Technical Data) are not exceeded.

Connections:

Before operating the machine with the device, the operating company must make sure that the local regulations are observed for assembly, installation and commissioning, if these tasks are performed by the operating company. – The hydraulic connections must meet the requirements of DIN EN ISO 4413 and the pneumatic connections must meet the requirements of DIN EN ISO 4414.

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– The grounding measures must be implemented and checked prior to commissioning of the device and the container. NOTE ON EXPLOSION PROTECTION Any person working in a hazardous area must be regularly instructed with regard to the necessity of grounding measures and they should also be made aware of typical grounding faults (e.g. subsequent grounding of objects or devices that are already charged)

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 this manual and act in accordance with them. The respective authorizations for personnel must be clearly defined.

The following qualifications are designated in the manual 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 comparable vocational qualification, practical experience in the assembly/disassembly of devices. The person must be familiar with the construction, mechanical installation, maintenance and troubleshooting of 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 apprenticeship

– Electrical work: Electrician; person with appropriate specialized apprenticeship, knowledge and experience, enabling them to identify and avoid the risks that may arise from working with electricity The person must be familiar with the electrical installation, commissioning, troubleshooting 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.

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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

NOTE ON EXPLOSION PROTECTION Persons working in potentially explosive atmospheres must not be dangerously charged. The personal protective equipment must satisfy the requirements of explosion protection. Non-compliance can result in the loss of explosion protection.  Observe TRGS 727 “ Prevention of ignition hazards due to electrostatic charge ” Chapter 7 “ Electrostatic charging of persons and personal protective equipment (PPE) ” .  DIN EN 1149-5 Protective clothing - Electrostatic properties - Part 5: Observe performance requirements for material and design. 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 becoming 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.

Hardhat Wear a hardhat for protection against falling or flying objects.

Hearing protection Wear hearing protection to protect yourself from an increased noise pressure level (≥ 85 dB(A)). Welding hood 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 operating company in accordance with 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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