Engineering Inspection Guide from Sun Alliance

7/30/2019 Engineering Inspection Guide from Sun Alliance

1/45

[Engineering

Inspection Guide]


2/45

[C

ontents]

Engineering Customer Centre: 0845 074 0704

Lines are open Monday to Friday

8.30am to 5.30pm.

Calls may be recorded for security

and t raining purposes.


3/45

[4] Our b usiness is prot ect ing p eople

Our business is all about protect ing people and

providing peace of mind. Leave engineering inspection

to us and we can help you look af ter the safety of yourworkforce and comply with your legal obligations,

secure in the knowledge that your plant and machinery

are safe to operate.

As a nationally accredited and independent inspection body,

w e w i ll w ork w i th you to pu t t he r igh t t ype o f inspect ionservice in place. All our inspection activities are accredited

by UKA S or N ICEIC. W e also h ave capabil it ies in equ ipm ent

certif ication and m anagem ent system certif ication, as w ell as

being a not if ied bo dy fo r th e M achinery, Lift s and Pressure

Equipment Directives. A founder member of SAFed, all our

w ork is carr ied ou t to industry standard.

Of course, no t all our custom ers are the sam e, so w e believe

in being flexible. Whether the requirement is for single or

multiple inspections, or the provision of detailed technical

[Our business is

protect ing people]


4/45

[ 6] Our b usiness is pro tect ing p eople

W e inspect a w ide range o f equ ipment and w i th the suppor t

of laboratory and research equipment, we also provide arange of exam ination and analysis procedu res. M ore details

on the type of equipment we inspect can be found later

in this guide.

To ensure com m un ication w ith u s is alw ays clear and

stra ightf orw ard, w e offer you a single point of contactfo r all your safet y inspection needs.

Such a refreshing appro ach is hardly surprising fo r a

bu siness th at grew ou t o f Nat ional Vulcan and British Eng ine.

For g enerations, both w ere acknow ledged as the leading

inspect ion com panies in the w orld. Com bining t hese

bu sinesses created a w ealth o f t echnical skill and exp ertise.

This Engineering Inspection Guide is just one part of our

added value service. It has been design ed t o help you

und erstand t he m andatory and recom m ended inspect ion

frequencies for different types of plant and machinery.


5/45

[8] Our b usiness is prot ect ing p eople

To ensure safety d uring th e exam ination process ou r

eng ineer w ill carry ou t a site-specific risk assessm ent .

A copy of this assessment is available on request.

W here act ions are required you w i l l be not i f ied.

Informat ion at your f ingert ips

This guide cont a ins a w ealth of usefu l in form ation

in an easily accessible and readily digestible format.

There are def in i t ions for a num ber of d i f ferent

categories of plant including lift ing equipm ent, p ressure

systems, local exhaust ventilation systems, electrical

equipm ent, po w er presses and process machinery.

The guide contains details on the relevant legislation

applicable to each of these catego ries, tog ether w ith

notes on the types of examinations required, and the

frequency w ith in w hich th ey need to b e carr ied out .

W e have also inc luded a nu m ber of l ine draw ings in

each section to give a simple i l lustration of the

dif ferent types of equ ipm ent w e inspect.


6/45


7/45

Definitions

Lifting equipment is work equipment used for l i f t ing

and low ering loads. It includes th e att achm ents used for

anchoring, f ix ing or supporting equipment such as cranes,

l if ts, excavators and lift tru cks.

Accessories for lifting includes any chain, rop e, sling, o r

component kept for at taching loads to machinery for l i f t ing.

Examination scheme m eans a suitable scheme draw n up by

a com petent person f or the th orough exam inat ion of l if t ing

equipm ent at such int ervals as m ay be app ropriate for t he

purp ose described w ithin t he regulations.

Work equipment means any machine, appliance, apparatus,

too l or insta l la t ion fo r use at w ork.

Relevant Legislation

The requirements for the exam inat ion of l if t ing equipm ent

are foun d w ith in th e Li f t ing O perat ions and Li f t ing

Equ ipm ent Regu latio ns 19 98 (LOLER). LOLER applies over

and above the more general requirements of the Provision

and Use of Work Equipment Regulations 1998 (PUWER).

Unlike previous legislation, w hich app lies to specif ic industry

secto rs, PUW ER and LOLER app ly to all places of w ork .

[12] Li f t ing Equipm ent


8/45

Different catego ries of exam ination are ident ified w ithin LOLER:

Examinations should be carried out:

[ ] Init ial ly, before equipment is taken into service (there

are some except ions for CE marked new equipment)

[ ] Post installation, where safety is dependent on

correct installation

[ ] W here li f t ing equ ipment is exposed t o cond it ions w hich

cause deter iorat ion that could lead to a dangerous

si tuat ion , p er iod ic examinat ions are required

[ ] Follow ing any except ion al event s such as an accident

or long per iod wi thout use

[14] Li f t ing Equipm ent


9/45


10/45

[Lifting Equipment ]


11/45

[22 ] Li f t ing Equipm ent

Welding may in fact do further harm by mismatching of

metals, localised heating and lack of heat treatment.

Q. How often is a ' thorough exam ination' required on

lift ing plant?

Und er LOLER a 't ho roug h exam ination ' is typically required every

12 months. Lift ing attachments, accessories and machines

for l i f t ing persons need examination every six months.

Q. Can I l ift a person on m y lift tru ck?

It is not advisable to l i f t a person using a l if t truck. A more

appropriate m ethod o f w orking at heights should b e em ployed

such as a ladder, permanent/temporary scaffold or mobile

elevat ing work p lat form. A person should not be l i f ted on

the forks, pal le t or bucket on the front of a l i f t t ruck under

any circumstances.

The only acceptable use of a l i f t truck l if t ing a person is by

using a specif ically designed and t ested carrier or w orkin g

platform. These purpose built units are normally available

f rom the m anufacturer o f the t ruck .


12/45

6

36

*

6

26

6

Inspection is required/implied in law . The num ber

indicates the typical frequency in m onths.

Inspection is required in law . The num ber indicates

likely inspection f requ ency w hich is variab le according

to usage or risk assessme nt.

Inspection is recomm ended at the indicated initial

frequencies by gu idance no te 3 t o BS7671:2001

Requirements for Electrical Installations. Frequency of

inspection may also be determined by local licensing

authority f or some locations

Inspection is recom me ded by t he IEE* Code of practice

for in service inspection and testing of electrical

equipment. Inspection frequencies vary considerably

depending upon the type of equipment andenvironment.

M ost a ir pressure plant is inspected every 26 mon ths,

how ever, w ell maintained w elded air receivers built to

suitable standards may be inspected every 48 mont hs.

Inspection is required unde r Regulation 33 of PUW ER

1998 part IV. The num ber indicates frequency in mont hs.

* IEE Institution of Electrical Engineers

This chart is int ended as a guid e only, and deals w ith categories

of p lant in general use w hich are com m only found in the

industries or locations specif ied. Whilst correct to the best of our

kno w ledge, no legal l iabil i ty or respo nsibil i ty can be accept ed fo r

the inf orm ation cont a ined. The chart is not legal ly autho r i ta t ive

and in cases of doubt, reference should be made to the relevant

legislation or the appropriate enforcing authority.

[24]

[ Lifting Equipment ]


13/45


14/45

Definitions

Relevant f luids include steam, gases under pressure and

fluids that are artif ic ially kept under pressure and become

gases up on release into th e atm osphere.

Pressure system means a system comprising one or more

rigid p ressure vessels w ith associated pip ew ork and

protective devices.

W ritten Schem e of Examination is a docum ent th at

identif ies the extent of th e pressure system and out l ines th e

examination requirements.


Inspection requirements for pressure systems are consolidated

w ith in Th e Pressure System s Safet y Regu latio ns 20 00 (PSSR).

The regu lation s apply to users and o w ners of system s

containing 'relevant f luids'.

They require the w ho le system to be inspected in accordan ce

with i ts 'Wri t ten Scheme of Examinat ion ' .

A Writ ten Scheme of Examinat ion is drawn up fo l lowing a

risk assessment of the system.

It m ust:

[ ] Clear ly def ine the extent o f , and i tems of p lant inc luded

in, the pressure system

[32] Pressur e System s


15/45

[Pressure System s]

Horizont al M ult i tu bu lar Steam Boi ler

[34]

Horizontal M ult i tubular Steam Boi ler

Horizontal M ult i tub ular Steam Boi lers are

som etimes referred t o as a package

bo iler or shell bo iler. These items can

range f rom 1 m t o 4m in d iameter and

are typically used for generating steam

or high-pressure hot water to be used in

various process/manufacturing processes.


16/45

[ Pressure Systems]


17/45

[40] Pressur e System s

The other components of the air compressor set

(i .e. comp ressor and m oto r) do no t n eed a statut ory

inspection . If an air com pressor h as no receiver it d oes not

need an inspection. Hydrovane manufacture compressors haveno receivers and are consequently exempt from the legislation.

Q. W hat is the diff erence betw een an air receiver and

an a ir com pressor? Do th ey b oth need an inspection?

An air compressor has three component parts:

[ ] Dr iv ing m oto r

[ ] Com pressor - w hich com presses th e air

[ ] A ir receiver - a pressur e vessel, w hich sto res th e

com pressed air

The air receiver is th e on ly part o f t he air com pressor u nit

that needs a statutory examination. The air compressor and

driv ing motor do not need an inspect ion - but should be

regularly serviced and m aintained by t he u ser.

Some air compressors only have two components - a driving

m ot or and an air com pressor. The d elivery of com pressed air

is im m ediate and th e need t o store air in a pressure vessel is

no t required. Because th ese com pressors do no t have an air

receiver th ey do n ot need exam inat ion.

The term 'compressor' is also used for refrigeration

compressors on fridges, cold stores, freezers and air


18/45

[42]

6

36

*

6

26

6




likely inspection f reque ncy w hich is variable a ccording


Inspection is recomm ended at t he indicated initial

frequencies by g uidance n ote 3 t o BS7671:2001








M ost air p ressure plant is inspected every 26 mon ths,


suitable standards may b e inspected every 48 mon ths.

Inspection is required under Regulation 33 of PUW ER



This chart is int ended as a gu ide on ly, and deals w ith categories

of p lant in general use which are commonly found in theindustries or locations specif ied. Whilst correct to the best of our

kn ow ledge, no legal l iabil i ty or respo nsibil i ty can b e accepted f or

the inform ation cont a ined. The chart is not legal ly autho r i ta t ive



[ Pressure Systems]


19/45


20/45

Definitions

System m eans an electrical system in w hich all th e electricalequipm ent is, or m ay be, electr ical ly connected to a comm on

source of electrical energy and includes such source and such

equ ipment .

Danger m eans r isk of ' in jury ' w hich in turn m eans death or

personal injury from any part of the 'electrical system'.


The Electr ic ity at W ork Regulat ions 198 9 cont a in a

comprehensive l ist of legal requirements designed to prevent

the risk o f d eath or person al injury from th e use of electricity at

all places of work, regardless of size or number of employees.

The regulations require all system s to b e m aintained so as to

prevent d anger. Furt herm ore HSE gu idance stat es th at regu lar

inspection and testing is an essential part of any maintenance

programme. Regulation 6 of PUWER also requires that work

equipm ent, w hich may be subject to d eterioration l iable to

result in a d angerou s situat ion, requires inspection at

suitable intervals.

[50] Electrical


21/45

[Electrical]

DISTRIBUTOR

COIL

TEMPS.U.

OILS.U.

STARTER

Y.R.

FIREWALLPLUG

BALLASTBATTERY

ALTERNATOR

Wiring circuit

[52]

W iring circuit

It is hard to imagine any location t hat

does not incorp orate an electrical w iring

installation of som e form . Even a storage

w arehou se w ill have some basic electrical

power requirements such as l ight ing,

heating and a security system. Larger

locations will have a comp lex distribut ion

netw ork required to del iver the dem andsof electrically driven plant and equipm ent.


22/45

[ Electrical]


23/45

[58]

6

36

*

6

26

6





to usage or risk assessm ent .

Inspection is recomm ended at t he indicated initial

frequencies by g uidance note 3 t o BS7671:2001








M ost air pressure plant is inspected every 26 mont hs,


suitable standards may be inspected every 48 mon ths.





of p lant in general use which are commonly found in theindustries or locations specif ied. Whilst correct to the best of our


the inf orm ation cont a ined. The chart is not legal ly author i ta t ive



[Electrical]


24/45


25/45

Definitions

Local Exha ust Ven tilatio n (LEV) is equipm ent th atcontrols, captures or contains airborne releases at or close

to the po int of emission by m eans of vent i la t ion and

conveys the p ol lu tant to a point w here it can be safe ly

collected or released.


The Control of Substances Hazardous to Health Regulations

20 02 (COSHH) apply to all w ork activit ies w here sub stances

hazardous to health are produced. The regulations state that,

'every employer shall ensure that the exposure of his

em ployees to sub stances hazardou s to h ealth shall be

prevented, or w here it is no t reason ably practicable,

adequately contro l led. ' W here a cont ro l needs to be appl ied,

local exhaust vent i lation is em ployed.

The following regulations also impose duties to provide and

m ainta in LEV equipm ent t o cont ro l a irborn e cont aminant s:

[ ] The Cont rol of Asbestos at W ork Regulat ion s 20 02

[ ] The Control of Lead at Work Regulat ions 2002

[66] Local Exhaust Ventilat ion


26/45

[Local Exhaust Ventilation ]

LEV System

[68]

LEV System

An LEV System uses extract ventilation

to p revent o r reduce the level of

airborne hazardous substances from

being breathed in by people in the

workplace. I t draws pol lutants away

from a process or operat ion that is

likely to release a hazardous substance

into the workplace and consists of aninlet such as a hoo d, slot, b oot h or

cabinet placed aroun d or close to the

point of release of the substance.

The inlet is connected to a fan o r air

m over and the extracted air is usual ly

discharged into the atmosphere or

re turned to the w orkp lace a f ter hav ing

being cleaned to make it safe fo r release.


27/45

[ ]


28/45

[72]

6

36

*

6

26

6






Inspection is recomm ended at the indicated initial

frequencies by g uidance no te 3 t o BS7671:2001








M ost air pressure plant is inspected every 26 mon ths,





*IEE Institution of Electrical Enginee rs


of p lant in general use which are commonly found in the


kno w ledge, no legal l iabil i ty or respo nsibil i ty can b e accepted f or

the inf orm ation cont a ined. The chart is not legal ly autho r i ta t ive



[ Local Exhaust Ventilation ]


29/45


30/45

Definitions

Pow er Presses are pow er driven m echanical presses w hichhave a f lyw heel and c lutch and are used w hol ly or part ly to

w ork co ld m etal .

Interlocking Guard Systems prevent actuation of the p ress

until the guard screen is fully closed or, in the case of a photo-

electric gu ard, th e screen h as been cleared o f any ob stru ction .


Examinat ion requ irement s fo r Pow er Presses are w ithin th e

Provision and Use of Work Equipment Regulations 1998

(PUW ER). Part IV of PUW ER deals specif ically w ith th ese

requirement s and is supp orted b y an Ap proved C ode

of Practice.

The regulat ion s requ ire users of Pow er Presses to app oin t a

person to set tools and carry out a simple inspection of the

press du ring every w orkin g shift . There is l i t t le diff erence

betw een PUW ER part IV and th e Pow er Presses Regulatio ns

196 5 & 197 2, w hich PUW ER 199 8 Part IV revoked.

[80] Pow er Presses

[P P ]


31/45

[Pow er Presses]

Pow er Press

[82]

Pow er Press

Pow er Presses are pow er driven

m echanical p resses or press brakes,

which have a f lywheel and clutch and

are whol ly or part ly used to work

m etal. Pow er Presses are amo ng t he

m ost dangerou s machines used in

industry. Am put at ion or serious injury

usually results from accidents caused by

t rapp ing betw een the too ls o f a Pow er

Press. The varied w ork d em and s on

Pow er Presses and the w ear to w hich

the g uarding m echanisms are subject

means that the in tegr i ty o f the

guarding is constant ly un der threat.


32/45


33/45

[86] Pow er Presses

Regu latio n 32 of PUW ER requ ires Pow er Presses and Press

Brakes to be exam ined by a com petent person and t h is

examinat ion shou ld be com pleted at in tervals dependent on

the type of guards fitted to the press. As a general rule the

frequ ency is every 12 m on th s fo r presses w ith f ixed gu ards,

and at six monthly intervals for all others.

The examination and tests completed primarily seek to identify

serious defects l ikely to cause an in jury to person s using th e

m achine or w orkin g in close vicinity. They w il l also p ick up

on less serious defects w hich left un checked could create a

danger, along with a series of observations and comments.

Q. Do I have to disma ntle th e clutch on my Pow er Press

for every examination?

No. The competent person wil l require you to dismantle parts

of the press but the f requency for t h is w ork is dependent

upo n m any factors inc luding the p ress duty, th e operat ing

environm ent and the g eneral condit ion of the p ress. The

engineer wi l l not i fy you in p lenty of t ime when any

dismantling is required but he wil l not be able to complete

the th orough exam inat ion un t i l the w ork has been done.

[Pow er Presses]


34/45

[88]

6

36

*

6

26

6






Inspection is recomm ended at the indicated initialfrequencies by g uidance no te 3 t o BS7671:2001

















kno w ledge, no legal l iabil i ty or respo nsibil i ty can b e accepted f or

the inform ation cont a ined. The chart is not legal ly autho r i ta t ive



[Pow er Presses]


35/45


36/45

Definitions

W ork equipment means any machine, appliance,

apparatus, too l or insta l la t ion f or u se at w ork.

Inspection is that t ask w hich determines if the w ork equipm ent

can be operated, adjusted and maintained safely and that

any deterioration can be detected.


The Provision and Use of Work Equipment Regulations 1998

(PUW ER) covers the u se, m aintenance and inspection of all

w ork equip m ent. PUW ER Regulation 6 requires th at w here

the work equipment can deteriorate to a dangerous level

it m ust be inspected at suitable int ervals. The int ervals w illdepend u pon the risk and the rate of deterioration. The extent

of the inspect ion w i ll a lso d epend o n t he po tent ia l r isks and

m ust b e carr ied o ut by a person com petent for t he task.

The def in i t ion of w ork equipm ent is very w ide and covers

almo st everyth ing u sed du ring w ork activity. The inspection

required u nd er PUW ER Regulatio n 6 w ill also vary con siderablyfrom a simp le user check, w hich w ould ver i fy funct ional i ty,

to a mu ch m ore involved inspect ion by an independent th ird

party such as Royal & SunAlliance.

[96] Other Work Equipment

[O ther W ork Equipm ent ]


37/45

[O ther W ork Equipm ent ]

Do ck Leveller

[98]

Dock Leveller

Dock levellers are design ed t o

accom mo date a w ide variety of lorry

tailboard heights and as such are, in

effect, adjustable loading ramps. Hinged

to and fo rming an in tegral part o f the

loading bay f loor, the free end o f th e

dock leveller/ramp is adjusted to suit t he

height of the incoming lorry tai lboard.

This allows goods to be loaded/unloaded

w i th the use o f fo rk l if t t rucks or

pal let t rucks.

[ Ot her W ork Equipm ent ]


38/45



39/45



40/45

[106]

6

36

*

6

26

6






Inspection is recomm ended at t he indicated initialfrequencies by g uidance note 3 t o BS7671:2001







depending upon the type of equipment and

environment.











the inf orm ation cont a ined. The chart is not legal ly author i ta t ive





41/45


42/45

[114]

Q. W hat is a compet ent p erson?

Different levels of competency are defined in HSE regulations.

These can cover training, o peration of m achinery and d aily

inspect ion of w ork ing p arts.

In term s of t horoug h exam inat ions of m achinery and p lant

to f ind defects l ikely to cause dam age, the com petent

person is generally defined as:

A p erson w ho h as th e approp r iate pract ical and t heoret ical

knowledge and actual experience of the plant he is examining

to enable him to detect defects or weaknesses and to assess

their importance in relat ion to the safety and cont inued use

of the p lant .

In som e regulation s th e academ ic qualifications of a com petent

person are clearly def ined. In ot her regu lations it is stressed t hat

the competent person must be sufficiently independent and

impartial to allow objective decisions to be made.

This def in i t ion o f com petency for p lant examinat ions has

been tested following numerous court cases. It is not

suff icient t hat you have used the i tem of p lant for m any

Frequen t ly Asked Quest ions


43/45

[116]

Examples of serious or safety related defects include:

[ ] Defective safet y com po nen ts such as safety vales or

overspeed go vernors

[ ] W orn o r w asted structural com po nent s such as fo rks,

chassis or pressure envelopes

[ ] Damaged l i f t ing ropes or chains

[ ] Incorrect or b r idged f uses

Other 'defects' may also be identif ied during an examination,

w hich are not con sidered t o p resent any dang er to p ersons.

These ot her def ects and o bservatio ns w ill norm ally receive

attent ion at th e next rout ine maintenance of the equipm ent

and because they are not felt to provide an imminent r isk ofinjury they are not reported t o local enforcing auth orit ies.

Q. The en gineer sent a copy o f t he serious defect

report t o H SE. Does he have t o do this?

Yes. As the com petent p erson h e is dut y bound und er the

relevant regulat ion t o send a copy report to the enf orc ing

autho r i ty w ith in a specif ied t im e l im it i f , in h is opin ion, t he

defect is l ikely to cause imminent danger to the person using

the machine or persons working in the vicinity.

Frequent ly Asked Q uest ions


44/45

[118]

The Declaration lasts for the l ifespan of the machine unless

major alterations are made. It must be passed to any new

owner when the i tem is sold.

For l i f t ing equipm ent th e declarat ion a l low s new plant a

short per iod of exempt ion fo r thorou gh examinat ion. This is

norm al ly 12 m ont hs provid ing safety does not depend up on

installation conditions.

Q. I have a b rand new i tem of plant . Does this require

an inspection p rior to b eing p ut into service?

If it is pressure plant, for example an air receiver or steam

bo iler, th e answ er is yes. If i t is li f t in g p lant an d safety does

not depend upon insta l la t ion condit ions - when the

declaration of conformity init ial period has expired - an

inspection is no rm ally required tw elve mo nt hs after being

purchased.

Q. Can thorough examinations be carried out by the

maintenance comp any?

Yes. However, plant owners must ensure that the competent

person w ho un dertakes a thoroug h exam inat ion has

approp riate practical and theoretical kno w ledge.

Frequen t ly Asked Qu est ion s


45/45

UKC00589C April 2005

Royal & Sun All iance Insurance plc (No.93792). Registered in England and

Wales at St M ark's Court, Chart Way, Horsham , W est Sussex RH12 1XL.

Authorised and regulated by the Financial Services Authority.

Documents

Engineering Inspection Guide from Sun Alliance