SUCCESSFUL MACHINE RELOCATION: NECESSARY LABELING AND DOCUMENTATION

Planning and implementation are of the utmost importance when relocating machines and entire plants. The relocation must be completed within tight deadlines so that ongoing operations are not interrupted for too long. Tight deadlines often also exist within the production facilities from which the machines are to be relocated.

Each machine and each system has its own specifications and requirements for relocation. Accordingly, many details must be taken into account in order to successfully and safely fulfill all the tasks involved. A machine relocation is much more than just transportation.

PHASES AND TASKS IN MACHINE RELOCATION

Before the actual transportation of the machines to be relocated can even begin, various tasks have to be completed. The entire machine relocation process can be divided into different phases, each of which places its own demands on transport companies.

Before transportation

The preparations prior to the relocation of the machines and systems in question are important for various reasons. As part of the survey, all essential information is collected that is relevant for concrete planning, for example for the selection of suitable forklifts, work platforms or cranes.

This also applies to the planning of the work at the new location. The spatial conditions may be different here and therefore require different equipment for moving the machines.

CORRECT MEASUREMENT FOR MACHINE RELOCATION

The measurement includes not only the spatial dimensions of the machines to be relocated, but also their weight. On the one hand, the aim is to find a route through the production halls and across the company premises and to identify and remove possible obstacles at an early stage.

On the other hand, the weight must be taken into account in order to avoid static problems, to find a suitable vehicle for moving the machines and to select a suitable means of transportation. This is also important with regard to the transport route, as heavy-duty transports may not be able to use certain routes.

Apart from that, measuring is a cost factor: the more precise the measurement, the more accurately the machine relocation processes can be planned – and the faster they can be completed. This reduces the periods during which production has to come to a standstill.

Above all, complete surveying and documentation is crucial to answer questions about the infrastructure on site:

• What are the access points to water and electricity at the new location?
• What are the supply and exhaust air characteristics, what about fire protection?
• Are the static conditions at the new location sufficient for the planned machine positioning and for the use of the tools?

The initial condition of the machines is also recorded and documented. Previous damage can thus be identified and recorded, while at the same time ensuring that the machines are not damaged during relocation. This not only has insurance reasons with regard to transportation, but also facilitates acceptance at the new location and helps to check safety aspects before recommissioning.

Data that is essential for the functioning of the machine may still need to be backed up. This includes databases or configurations. This task should always be carried out when relocating machines with electronic components.

Dismantling and transportation

Dismantling often requires the involvement of various specialists in order to dismantle mechanical, electrical, pneumatic and hydraulic components and connections properly. All product documents, drawings and layouts are checked in advance.

Reassembly and recommissioning

At the new location, the procedure is carried out in reverse order, so to speak, but also with the involvement of appropriate specialist personnel. This may also include manufacturer fitters or system operators. This is particularly useful if mechanical components need to be realigned or the electronics need to be fully checked.

It is not uncommon for a relocation of machines to be used to reorganize production. This can mean setting up or retooling machines differently or even reorganizing entire production lines.

A new measurement ensures that all components and the machine as a whole are positioned as intended. An acceptance report confirms that the relocation has been carried out correctly. Certifications or audits may be required for quality assurance. Finally, a functional test is carried out, which is also fully documented. If no defects are found during this check, the relocated machine can be put back into operation.

DOCUMENTATION FOR MACHINE RELOCATION: WHAT DOES IT ALL INVOLVE?

Complete documentation for a machine relocation covers all phases of the move and also includes the necessary labeling.

Documentation for disassembly, transportation and reassembly

Before dismantling, it is important to clarify whether there is already up-to-date machine documentation for the systems in question. This can be used as a basis for documenting the actual condition of the machine. For this purpose, characteristic data is recorded and logged and, if necessary, a machine capability test is carried out.

Loading lists, freight documents and documentation for customs formalities are required for transportation – depending on how far the machine has to be transported for the relocation.

During reassembly, documentation is important insofar as it must be clarified which information is to be used for setting up, marking out the machine axes and leveling the systems. Either the documented actual state at the old location is used for this or the manufacturer’s specifications and available machine layouts are used.

During commissioning, an accident prevention regulation test (UVV) or equipment test in accordance with DGUV regulation 3 may need to be carried out for fixed or mobile equipment. During machine acceptance, it must be clarified whether a standard protocol exists for this or whether other criteria should be applied.

Necessary documentation and markings for machine acceptance

Various documents and markings must be taken into account during machine acceptance, which must be carried out for recommissioning. These include

• Inspection logbook or work equipment, machine or inspection file in which the results of the machine inspection must be documented if the safety of these machines depends on the assembly conditions or if these machines are subject to influences that can lead to damage
• Maintenance schedule with maintenance and replacement intervals
• Maintenance log or maintenance file, in which details of the maintenance and replacement intervals and the persons responsible for maintenance are to be provided
• Manufacturer’s information on the machine so that safety information can be obtained directly from the manufacturer
• GS marking to ensure safety and health when the machine is used as intended
• CE marking on the machine
• Hazard warnings on the machine
• Labeling with technical data (device labeling)
• CE Declaration of Conformity, which specifies the standards and accident prevention regulations that the manufacturer has applied during machine testing
• complete operating instructions containing at least information on the operating conditions, foreseeable malfunctions and experience already gained in operating the machine
• Documented and signed instruction of employees
• Marking of operating areas in the vicinity of the machine where there is a risk to health and safety (i.e. access and stay bans, warning and safety requirements)
• Identification of devices that allow disconnection from each individual energy source
• Inspection sticker

RELEVANT SAFETY CHECKS FOR A MACHINE RELOCATION

In order to ensure safe operation after the machine relocation, the affected machines and systems are subjected to a comprehensive inspection. DGUV Regulation 3 and the Technical Rule for Operational Safety TRBS 1201 are among the relevant regulations.

DGUV Regulation 3: Scope and extent of the inspection

The legal framework for testing electrical devices and systems is provided by the Occupational Health and Safety Act (ArbSchG), the Ordinance on Industrial Safety and Health (BetrSichV) and the Technical Rules for Industrial Safety (TRBS). In addition, the German Social Accident Insurance (DGUV) provides regulations that entrepreneurs can use to check the safety of the machines and systems in use.

DGUV Regulation 3 is relevant in connection with machine relocations and the (re)commissioning of machines. It concerns

• portable electrical equipment,
• stationary electrical equipment,
• stationary and non-stationary electrical systems and
• electrical machines.

According to the regulation, the technical inspection is divided into different sections:

• The preparation (or order check) corresponds to an inventory in which, among other things, previous test logs, circuit diagrams and overview plans and other documentation are checked.
• During the inspection, evidence of previous inspections is checked, as well as other safety aspects such as markings, accessibility, protective measures, system protection and possible negative changes.
• The main purpose of testing is to check the effectiveness of the protective and signaling devices, such as residual current devices.
• The measurements are used to determine whether the necessary protective measures against electric shocks are effective.

RELEVANT STANDARDS FOR DGUV REGULATION 3

Various standards are applied when inspecting machinery in accordance with DGUV Regulation 3. These are as follows.

For stationary equipment and machines are taken into account:

• VDE 0100-600 and/or VDE 0113-1 for tests before initial commissioning
• DIN VDE 0105-100 for periodic inspections

DGUV Regulation 3: Specifications for documentation

The documentation of the machine inspection is required by law and serves as proof of the regular inspection of equipment and systems. Legal requirements also exist with regard to the minimum content requirements and the result of the documentation.

The legal basis for having to document the inspections carried out can be found in the BetrSichV (§§3 and 14), DGUV Regulation 3 and various other standards that are relevant for the inspection in accordance with this regulation.

While there are no binding specifications for the form of the documentation, there are certain minimum requirements for the content. Required information is therefore

• Name and address of the client, contractor and the name of the tester,
• Listing of the individual test protocols for inspection, testing and measurement,
• Description of the scope of the test and details of the system and equipment data,
• Test basis,
• Reason for the examination (first or repeat examination),
• measuring and testing devices used,
• Inspection date, signature of the inspector and the system operator.

The documentation is concluded with the result, i.e. a brief assessment of the condition of the tested machine or system. Possible categories for this are

• Serious defects are safety-relevant defects that must be rectified immediately due to the risk to life, health and property.
• Defects without acute danger must be rectified soon, otherwise they will lead to a hazard.
• Deficiencies that have already been found and rectified in the course of the audit, whereby the list also serves as an indication of possible key deficiencies that should be given particular attention in further audits.
• Recommendations for continued operation and for any necessary retrofitting and/or improvements, as suggested by VDE 0105-100, for example.

The documentation must be retained and the results must be archived at least until the next inspection.

Technical rule for operational safety TRBS 1201

TRBS 1201 specifies the German Ordinance on Industrial Safety and Health with regard to the testing and inspection of work equipment and systems requiring monitoring. Among other things, it specifies the requirements that tests and inspections must fulfill in this context. In addition, TRBS 1201 specifies the type and scope, deadlines and the persons who may carry out the tests.

In order to record the actual condition of a machine or system, the technical rule provides:

• a visual inspection,
• a test of the protective conductor connection,
• a measurement of insulation resistance, protective conductor current, touch current and leakage current,
• testing and checking the protective measures.

The minimum requirements for documentation must also be complied with when testing in accordance with TRBS 1201, therefore information is required on

• the type of audit,
• the scope of testing,
• the result of the audit and
• Name and signature of the verifying person.

The records must be kept at least until the next test is carried out.

 

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