Observations
322 observations
A — Reduce dangerous substances to a minimum
Whole row
Types and quantities do not exceed activity requirements
High standard of housekeeping
A maximum of 250 litres of flammable liquids only is stored in one workroom, of which 50 litres may be highly flammable
Periodically review necessity of using flammable solvent borne spray paints and thinners to reduce risk ALARP
Confirmation of maximum flammable substances input to be sought from manufacturer’s information
Review inventory of legacy hazardous substances and remove redundant stocks
Not in use containers of flammable liquids to secure, spill containing, fire resistant cabinets / chests
Bins emptied regularly
B — Avoid or minimise release
Whole row
Substances stored appropriately in single layers within storage enclosures
Press equipment placed on critical items register and recorded service contracts arranged with specialist sub-contractor
VOC and over temperature alarms shut-down the heating system but keep the ventilation system operating, and that they are to level PL d
Minimum exhaust flowrate of 469m3 /h for drying tunnel
Spill containing safety containers at usage areas
Ductwork maintained in good condition
Flange guards to pressurised pipework
Overcharging under fault conditions is prevented
Storage cage for aerosols
Filters are fitted within airflow alarms
Gas equipment placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Vehicle impact protection barriers to roadway side of diesel tank
Review maintenance and leak prevention for pumps, rotating, and process equipment
Corrosion to pipework, fittings and tank
Small solid fuel heater placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Oil fired heater placed on critical items register and recorded inspection and service contract arranged with specialist sub-contractor
UV equipment placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Review effectiveness of dust extraction systems
Tank and dispenser placed on critical items register and ensure recorded inspection and service contract arranged with specialist sub-contractor
Pipework correctly coloured and/or identified
Biomass plant placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Satisfactory operation of excess high / low condition switches and alarms
Alarm switches placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Dust collector equipment placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Maximum flammable substances throughput of drying tunnel as less than 4,250g/h
Transport methods for larger containers prevent spillage of flammable liquids
Heating oil tank placed on critical items register and recorded inspection and service contract arranged with specialist sub-contractor
Cell terminals effectively guarded against inadvertent short circuits
Trays / lipped edges to mixing tables and benches
Review maintenance and leak prevention for equipment connections and access hatches
Spray equipment placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Flexible dust and hoses are correctly installed and replaced if damaged
Corrosion to gas pipework
Gas pipework sleeved where it enters buildings or passes between building compartments
Covers are in place and hatches are closed so that loss of containment is minimised for process equipment
Pipework sleeved where it passes through walls
Woodworking machinery placed on critical items register and recorded service contracts arranged with specialist sub-contractor
C — Control release at source
Whole row
AIVs to gas incoming supplies to buildings
Use of top mounted dispensing pumps for medium and large containers
Receiver tanks and distribution system placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Drying tunnel placed on critical items register and recorded service contracts arranged with specialist sub-contractor
Remote indication for dust collection plant status and alarms
Decanting: Flammable solvent inventory within the area should be minimised / controlled at all times
Only required materials are moved from storage locations
Battery using equipment on critical items register and ensure recorded service contracts arranged with specialist sub-contractor
Heating system shut-down in event of control system failure
Decanting: Limit the flow rate
Decanting: Avoid splashing where possible
Dust extraction and collection systems are interlocked to functioning of required machinery
Use metallic funnels and static dissipative hoses as required
Decanting: Avoid open containers / faulty containers and subsequent vapour potential at all times
Decanting: Ensure adequate earthing for dispensing / decanting of flammable solvents.
Temperature and air flowrate achieved prior to charging operations
Confirmation of drying ranges to be sought from manufacturer’s information
Isolation valves are identified and operable
Mechanical extract ventilation system interlocked with the drying tunnel controls
Shut-down sequence function implemented to drying tunnel operations
Extract duct valves that are capable of controlling airflows satisfactorily
Satisfactory operation of control system inputs and outputs and associated control equipment
Equipment functions as designed, so as to minimise loss of containment at cutting / trimming / MEV / extraction equipment
Decanting: Utilise secondary containment / bunded trays or similar for holding flammable containers
Purging sequence function implemented to drying tunnel operations
Mechanical extract ventilation system interlocked with the spray equipment controls
Hazardous liquids stood on secondary spill containing pallets / trays
Battery charging equipment on critical items register and ensure recorded service contracts arranged with specialist sub-contractor
All storage enclosures are locked when not in use
Decanting: Use only metallic containers
Decanting: Ensure adequate ventilation for dispensing / decanting of flammable solvents.
D — Prevent formation of an explosive atmosphere, including ventilation
Whole row
VOC and over temperature alarms shut-down the heating system but keep the ventilation system operating, and that they are to level PL d
8 – Strengthening of critical ductwork to resist over-pressure and contain it so that the relief vents operate as designed
The exhaust air ducts feature adequate access for inspection and maintenance
Rapid cycling ignition scenarios are added to operating manual and training material
Differential air-flow detection and alarm across filter unit
Adequate fresh air inlets from exterior provided
Extraction from low level available to collect heavier than air vapours
Spray booth ventilation systems are placed on critical items register and service contracts arranged with competent specialist sub-contractor
Ventilation louvres kept clear
Ventilation to enclosed store rooms and open stores is adequate and achieves 0.1m/s and 5ACH
10 – Exhaust heights to meet local authority guidelines
2 – Anti-static filters to replace standard units
4 – Differential pressure monitoring, alarm, and shutdown on filter controllers
Ventilation rates around forklift batteries under charge are adequate
Suitably EX rated mechanical extract ventilation systems (MEV) implemented to extract the dust and collect it in external units, or the features below to be verified or installed to existing systems. The MEV to feature:
Dust MEV systems are placed on critical items register and service contracts arranged with competent specialist sub-contractor
6 – Overpressure relief vents relieving to a place of safety away from personnel routes or critical equipment
Ventilation measures periodically reviewed for adequacy as regards process and production activities
7 – Shut-off damper on ductwork to prevent dust explosion passing back into building
Failed ignition scenarios are added to operating manual and training material
Implementation of VOC monitoring system to internal mixing and use areas
Smoke clearance test required to be carried out as part of thorough written scheme of examination
The ventilation system recirculates warm air throughout the total volume of the drying tunnel
Dust extraction to woodworking activities is adequate and achieves required rate
MEV systems do not automatically re-start after a power failure
1 – All metallic parts earthed in such a manner that the earth path back to reference point can be measured. Usually by use of earth bonds across joints, with two paths being specified, so that when one is disconnected for testing the other still functions
Sufficient inspection frequency
Visual and audible airflow alarm indication is present and adequate for the extent of the booth
Ventilation to open spray booth is adequate, and that the average of measured air velocities is at
Ventilation to workshop activities is adequate and achieves 0.5m/s and 12ACH
Induced draft fan interlocked to operation of biomass unit
Manual intervention scenarios included in existing operating manual and training material
EX rated MEV systems to flammable substances storage and use areas
Drying tunnel ventilation system is placed on critical items register and service contracts arranged with competent specialist sub-contractor
Adequate ventilation in place in at bottom shed press heater
Hazardous waste stored in external well-ventilated location
MEV systems interlocked to functioning of required process equipment
Input of flammable substances is monitored
Vapour MEV systems are placed on critical items register and service contracts arranged with competent specialist sub-contractor
3 – Temperature detection, alarm, and shutdown on critical rotating parts
Extraction points to process equipment connected to vapour extract systems using fixed ductwork
5 – Use of materials and methods to offer inherent mitigation of likelihood of production of sparks, such as greater clearances, brass rubbing strips on shafts
9 – Provision of explosion isolation device at outlet (rotary valve) if required
E — Collect, contain or remove any release
Whole row
Minimum exhaust flowrate monitoring devices installed to drying tunnel
Fans and ducts thoroughly cleaned of paint residues
Forced ventilation system run-on in event of safety system failure
Ventilation louvres are kept clear
For releases of a dangerous substance, ensure measures to contain or collect or remove to a safe place are documented, and reviewed periodically
All biomass boiler incidents are reported
Investigate whether interceptor installed to collect fuel spillages
Use vacuum cleaner as required to ensure surfaces and ledges are regularly cleaned to remove dust accumulations
Areas are kept free of obstructions
Filters are changed when differential pressure readings cross thresholds
Periodically review and ensure satisfactory performance of dust extraction and collection systems
Vapour extract vents are at least 3 metres above ground level, and 3 metres from sources of ignition and building openings
Heating system shut-down in event of forced ventilation failure
Spill kit available in area
Heating system interlocked to monitoring device
Forced ventilation system run-on in event of heating failure
F — Avoid ignition sources
Whole row
All lighting is of sealed type
Alternatively, implement ventilation failure alarms and gas detection alarms, and install a safety isolating contactor to remove power to the UV equipment in event of alarm
Dust extraction flexible ducts feature metal filaments, and that these are earth bonded at both ends
Earth resistance of circuit protective conductors for any electrical equipment
Spray booth floor resistance does not exceed 1006 Ohm
EX equipment on critical items register and ensure recorded service contracts arranged with specialist sub-contractor
If dryer operates in Range 3, ensure equipment and installations meet ATEX category 2G
Electrical switches, contactors and relays remove power from both phase and neutral conductors
Adequate identification of main isolation points
Where vacuum cleaners are used in dusty environments, ensure these are suitably EX rated
Electrical and mechanical equipment within Hazardous Areas is suitably EX rated
Vapour extract LEV/MEV system will require suitably EX rated fan assemblies
Robust barriers installed to cable and pipework routes between Hazardous Areas and non-Hazardous Areas
Electrical circuits adequately identified
Delivery tanker earthing point
Earthing system for EX electrical installation is TN-S, IT or TT, not TN-C, TN-C-S
Battery powered equipment is isolated prior to charging
Potential hot surfaces of the tunnel are prevented from contacting the drying items
Where earth connections exist, these should be on a recorded schedule of earth resistance measurement
EX equipment is installed as per the X conditions on accompanying ATEX certificates
If dryer operates in Range 2, ensure equipment and installations meet ATEX category 3G
Biomass feed system to be suitably EX rated
Static dissipative footwear and clothing, mats, and floor coatings
Large lead-acid batteries are separated from sources of ignition by at least 1 metre
Vehicle ignition systems switched off during refuelling
Install suitably EX rated lighting, fans and power and alarm circuits to flammables storage and mixing areas
Electrical and mechanical equipment properly maintained so as to prevent being a source of ignition
Implementing lightning protection system to tall external structures (exhaust vents)
No sources of ignition within separation distances of flammable substances storage and use locations
The MEV fan features spark minimizing bearings and anti-static blades
All plant, equipment and structures adequately earthed
Rigorously control / separate flammables from personal sources of ignition
Auto-ignition cannot occur by provision of temperature monitoring and shutdown controls
Electrical installation within area is approved by EX certified electrical supervisor
Overheating cannot occur by provision of temperature monitoring and shutdown controls
G — Avoid adverse conditions causing harmful physical effects
Whole row
Robust metal baffle plates around internal bag dust collectors to deflect flame away from occupied areas
VOC/gas monitoring to drying tunnel
Electrical and electronic equipment competently installed so as to prevent external influences adversely affecting safety performance of equipment
VOC/gas monitoring system equipment on critical items register and ensure recorded service contracts arranged with specialist sub-contractor
Eye wash stations present at battery charging areas
The equipment within the spray booth or drying tunnel that is reachable by operatives is correctly installed and maintained in good working order, and there is no possibility of contact with hot parts
Employee exposure limits are not exceeded by use of appropriate barriers, ventilation and if necessary, PPE
Flammable liquids containers shielded from sunlight if stored externally
Adverse conditions are avoided by use of appropriate detection, isolation, ventilation and if necessary, PPE
Electrical equipment competently installed so as to prevent being a source of ignition or electric shock
RPE fits correctly and is periodically checked for satisfactory functioning
The lighting level meets 750 lux
Implementing portable gas monitoring equipment
Implementing carbon monoxide (CO) gas detection and alarms at fired appliance areas
H — Segregate incompatible substances
Whole row
Different waste types are effectively managed to separate waste streams
Hazardous waste disposed using licenced waste carrier with consignment note received
Safe working instructions for mixing and use of different classes of hazardous substances are followed
Structural steelwork protected from spill of corrosive fluids
Minimum separation distances between different classes of hazardous substances are observed
I — Reduce number of employees exposed
Whole row
Review and minimise personnel attendance at hazardous substances locations
J — Avoid propagation of fires or explosions
Whole row
Excess combustible material removed from storage and production areas
Excess combustible material removed from gas incomer and metering and appliance areas
Combustible material not stored in compressor areas
Combustible material and vegetation removed from around heating oil tank area
Bins are suitably fire resistant
Partitions are suitably fire rated such that propagation of fires or explosion is contained as required for the facility
Combustible material removed from spray areas
The spray booths meet the criteria for fire safe construction, including materials of construction of the filter cartridges
Excess combustible material removed from drying tunnel area
Excess combustible material removed from biomass plant area
Annual review of Fire Risk Assessment
The drying tunnel meets the criteria for fire safe construction, including materials of construction of the filter cartridges
Where not fitted, seriously consider implementing rotary valves to assist with explosion isolation
Combustible material removed from around diesel fuel tank area
Replacing spiral wound ductwork with smooth walled type
Stores are located such that propagation of fires or explosion is contained as required for the facility
Minimum separation distances for external storage locations are implemented
BS EN 14470 flammables cabinets as required
Excess combustible material removed from dust collector areas
Excess combustible material removed from woodwork machining areas
2 hour fire barrier along boundary fence
Combustible material removed from battery charging areas
Seriously consider relocating internal dust collectors to external locations, away from occupied work areas
K — Explosion relief
Whole row
Review explosion relief arrangements for the dust extraction equipment
Explosion relief vents are placed on critical items register and service contracts arranged with competent specialist sub-contractor
Explosion relief vents to dust extraction equipment
Explosion relief vents relieve to a place of safety away from personnel routes or critical equipment
Pressure relief valves on critical items register and checked by specialist sub-contractor at appropriate interval
Non-EX rated safety devices with suitably EX rated items
L — Explosion suppression
Whole row
Water quench system placed on critical items register and recorded service contracts arranged with specialist sub-contractor
M — Plant built to withstand explosion pressure
Whole row
N — Personal protective equipment
Whole row
Correct PPE provided and worn by personnel
O — Raise alarm and shut down from a safe place
Whole row
Remote emergency shutdown controls at least 3 metres from dust collector
Emergency shutdown and alarm systems are placed on critical items register and service contracts arranged with competent specialist sub-contractor
Means of shutting down systems from a safe place provided and readily identified
Means of raising alarm from a safe place provided and readily identified
P — Means of escape
Whole row
Fire-fighting equipment placed on critical items register and service contracts arranged with competent specialist sub-contractor
Emergency lighting placed on critical items register and service contracts arranged with competent specialist sub-contractor
Adequate fire-fighting equipment provided in area
Adequate illumination provided for non-daylight hours or emergency evacuation
Sufficient fire water capacity available
Q — Signage
Appropriate warning signage at hazardous locations
Specific EX signage present at entrances to or around Hazardous Areas
R — Information, instruction and training
Whole row
Procedures for safe operation and maintenance
Staff in COSHH & DSEAR risks
S — Information for emergency services
Whole row
Inventories of dangerous substances
Hazardous locations on site emergency response plan
Gas distribution schematic
T — Organisational measures
Review flammable gases, liquids and dusts delivery offloading and handling procedures
Review site materials SDS, and minimise inventories
Review site emergency response plan and include DSEAR risks
Review DSEAR arrangements & controls after a significant plant change and/or a period of THREE years has elapsed
Review Management of Change procedures
DSEAR training at appropriate levels
Review work instructions for DSEAR activities
Review work instructions (PTW) and hot work permit arrangements
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