Statutory requirements for the management of pressure
systems,
lifting equipment & power presses.
Forward
Legislation
places a statutory duty upon the University with regard to the management of
pressure systems, lifting equipment and power presses. This document provides guidance on the
University of Nottingham’s requirements for the management and statutory
inspection requirements associated with these assets.
Pressure systems
The Pressure
Safety Systems Regulations 2000 require that all pressure vessels and
associated pipe work must be assessed initially to determine the appropriate
regime of regular inspection and testing, this is called the "written
scheme of examination". Thereafter arrangements must be made for this
inspection and testing to be undertaken at the correct intervals. The
University has engaged Allianz as the competent person to undertake these
activities.
Inspection
frequencies may be variable between different types of pressure system asset
and will be determined by the Allianz inspection engineer.
The details of
all systems, including for example autoclaves and air receivers, must be
notified at the time of installation or purchase to the Responsible Person, who
will arrange for them to be added to the insurer’s database, to be assessed,
insured and regularly inspected. The procedure for this can be found on the
Commercial Services Website (follow the links to Insurance; Engineering and
Statutory Inspections; Standard Inspections for Pressure Vessels and Lifting
Equipment http://www.nottingham.ac.uk/commercial-
services/insurance_files/local/engineering_statutory_inspection.php).
The safe working
limits of the system must be clearly marked on it. As a minimum this should
include the maximum pressure for safe working. Larger, complex systems may also
require marking with temperature, time, volume, flow rate, heat input or
coolant flow limits as appropriate. The operating instructions should contain
all the information needed for safe operation of the system including start-up,
shutdown, standby and emergency situations. The Allianz Engineer will also
label the system with an asset number, test date and next test date.
In addition to
any thorough examinations in accordance with the written scheme, the system
should be subject to routine maintenance and inspection checks. These checks
should include looking for signs of corrosion, leakage and external damage. Particular
attention should be paid to the seals at doors and lids. Systems should be
regularly cleaned out or drained of condensate, to ensure the removal of
corrosive residues.
Lifting equipment
A summary of the
requirements of the Lifting Operations and Lifting Equipment Regulations 1998
is given in University guidance: http://www.nottingham.ac.uk/safety/loler.htm. Equipment such as lifts, cranes,
chairs, ropes and slings must not be loaded beyond the safe working loads
specified for each one. Safe loads must be clearly marked on each piece of
equipment and the appliances should be tested periodically, as advised by the
insurance inspector.
Lift trucks must
be operated by authorised persons only. The standard to which operators should
be trained and authorised as specified in the Approved Code of Practice “Rider
Operated Lift Trucks - Operator Training”, http://www.nottingham.ac.uk/safety/Fork_lift_truck_guidance_July_2011.doc.
Inspection
frequencies for lifting machinery such as overhead cranes, chain blocks, lift
trucks etc. is 12 months unless it is used for ‘man riding’ when the frequency
is 6 months. For lifting tackle such as chains, ‘D’ shackles, slings etc. - 6
monthly inspection intervals.
All new items of
lifting equipment must be notified at the time of installation or purchase to
the responsible person who will arrange for them to be regularly inspected in
line with the Lifting Operations and Lifting Equipment Regulations 1998.
Power presses
The
requirements in part IV of PUWER 98 apply to power presses that are wholly or partly
used to work metal. They do not apply when a press is used to work non-metals,
hot metals or metal powders. For other ‘presses’ that present similar risks
but do not fall within the strict definition of a power press, for example
hydraulic presses, regulation 6 of PUWER may apply where both an initial and
periodic inspection of the machine may be required.
Power
presses, all their guards, the control systems and ancillary equipment (for
example automatic feed systems) must be maintained so that they do not put
people at risk. Maintenance work on power presses must be carried out safely,
i.e. machinery is shut down and isolated, and is done by people who have the
right skills and knowledge. Presses and
their safety devices must be thoroughly examined by a competent person at the
required intervals.
Each
School/Department owning pressure systems must appoint a Responsible Person to
co-ordinate maintenance and examination of such equipment. The competent person
(Allianz Engineer) is someone the employer has selected to carry out the
thorough examination and test of the power press, its guard(s) or protection
device(s). They are usually employed by specialist inspection organisations and
need sufficient practical or theoretical knowledge and experience to detect
defects or weaknesses and decide how far these will affect the safe operation
of the press.
Inspection
frequencies for the examination of a power press, along with their guards and
protection devices, is at least once in every period of six months or, where
the tools are fenced exclusively by means of fixed fencing, every 12 months.
The periodic examination is intended to ensure that safe conditions are
maintained and that any defect or deterioration is remedied in good time. The
competent person can use the information gained during the initial thorough
examination and test to focus on the things that are most likely to cause
problems
Roles and responsibilities of Responsible
Persons within Schools/Departments
(See Appendix
2 for summary of duties)
For the
management of maintenance and inspection of lifting equipment, pressure systems
and power presses, the Head of School/Department must appoint a Responsible
Person (usually the SSO/DSO) for the coordination of this activity. Although
these duties may of course be delegated to a competent nominated person within
the school/department for day to day management, the responsibility to oversee
this activity will remain with the SSO/DSO who will be the primary contact for
their School/Department for University with regard to lifting equipment,
pressure systems and power press communications.
Adding new items and removing old items
of equipment to/from the Allianz Database
To ensure that
the University and its responsible persons are able to monitor lifting,
pressure and power press assets it is vital that they are correctly recorded on
the Allianz database. The School/Departmental Responsible Person must arrange
for new assets to be added and old redundant assets to be removed as required.
This is done at https://www.eservices-allianzengineering.co.uk/eServices/interface/userProfile.asp .
This is the responsibility of the
University, not Allianz. The add/delete buttons within the database will prompt you for information such
as location; plant number; serial number; plant type; next inspection date,
however, it should be noted that these add/delete buttons do not directly
change the database, they initiate an email to the inspecting engineer who will
either delete the asset on receipt of the request or, make arrangements to
attend site to inspect the asset and then make the relevant entry onto the
database.
For new builds
or new project work, the Responsible Persons must establish what new equipment
is to be installed / removed.
It is also the
responsibility of School/Departmental Responsible Persons to ensure that assets
remain within test date by monitoring the inspection dates of these types of
assets and then liaising with the relevant Allianz engineer to coordinate
inspections as required. This should be done before assets go ‘out of test
date’. (See Appendix 1 for current
Allianz engineers contact details)
Asset Marking/Tagging System
A system of
asset marking is used to help with this monitoring.
·
Pressure system and power
presses will be fitted with adhesive labels showing the date of next inspection.
·
Lifting tackle, such as
chains, ‘D’ shackles, slings etc. will be fitted with a colour coded ty-wrap, a
‘current colour’ board will also be provided in the work area.
·
Lifting machinery such as
overhead cranes, chain blocks, lift trucks etc. will be fitted with a PVC disc
showing date of next inspection.
Pressure Systems – Written Schemes of
Examination
To comply with
the Pressure Systems Regulations 2000, a Written Schemes of Examination’ must
be maintained throughout the lifetime of the plant or equipment. The
University’s ‘Written Schemes’ were reviewed in 2010/11 and all are held
electronically on the Allianz database.
For complex
assets and systems, it is the School/Department’s responsibility to provide the
inspection engineer the support of a service engineer to disassemble/reassemble
the system to enable improved access. The latter will normally only be required
for the less frequent, more intrusive thorough examinations. The
School/Department also has responsibility to arrange for ongoing routine
maintenance and repairs or improvements required by the inspecting engineer.
Access to Allianz Database
Responsible
Persons and any other nominated persons will need to have access to the Allianz
database which can be arranged by following the attached link https://www.eservices-allianzengineering.co.uk/eServices/ExternalRegister_1.asp. The University Insurance Officer
will authorise all applications to access the database. Please note that once
access is provided, the system must be accessed regularly otherwise your
password will default following periods of inactivity.
The database has
various levels of access authorisations, minimum levels of which are set by the
University, it
is these levels of authorisation that determine what ‘eNotifications’ are sent
to responsible persons. Please note that
higher levels of access to the database to allow for downloading and reporting
are available upon request.
Email Notifications (eNotifications) following inspections or
attempted inspections
‘Plant not available’ (PNAs)
Allianz
Engineers will notify Responsible Persons where there are items they have not
been able to inspect, either because they cannot be accessed or the equipment
is not ready for inspection. The School/Departmental Responsible person must
coordinate a revisit by the relevant inspector when the equipment is ready and
this must be within the inspection date as far as is practicable.
‘New reports have arrived in InTerFACE’
These
notifications alert responsible persons to relevant database updates which
should be reviewed.
Defect Notifications
‘A’ category defects - (those that pose a serious hazard):
email notification will be sent by the inspecting engineer to the Responsible
Person(s) within 24 hours and will be backed up with a telephone call.
‘B’ category defects - (those defects that require action but
not immediate) will be notified by email within three days to the Responsible
Person.
For all A and B
defects, the Responsible Person should record any remedial action (proposed or
completed) on the Allianz database in the Notes section for the specific item.
In order to
ensure that School/Department receives timely and relevant ‘eNotifications’ and
‘Email notifications’ any changes to who has been designated as the Responsible
Person and local Nominated Persons should be notified by email to the Safety
Office without delay so the Allianz database can
be updated.
Summary
Please note that
the approach described above reflects how the University intends to manage its
lifting equipment, pressure systems and power presses to ensure that these
assets continue to receive the timely inspection and repair required by law.
This approach has been fully agreed with Allianz the University’s inspection
engineers. It
is the responsibility of University Schools and Departments, not Allianz, to
ensure inspections are carried out in line with the written scheme/inspection
frequency.
Appendix 1
Allianz Engineers
details (updated September 2011)
University Park, Medical
School, City Hospital, Kings Meadow
Lifting Equipment
Bob Elkins +44 (0) 115 9294849 / 07870 231303 or by email at robert.elkins@allianz.co.uk
Pressure Systems
Gareth Winter +44 (0) 115 9721019 / 07870 231 701 or
by email at gareth.winter@allianz.co.uk
Power Presses
Andy Harrison +44 (0) 1428 722407 / 07870 231305 or by
email at andy.harrison@allianz.co.uk
Sutton Bonington
Lifting Equipment
Tony Eden +44 (0) 1623 490381 / 07870 231305 or by email at tony.eden@allianz.co.uk
Pressure Systems
Gareth Winter +44 (0) 115 9721019 / 07870 231 701 or
by email at gareth.winter@allianz.co.uk
Power Presses
Andrew Jones +44 (0) 01827250351 / 07870 231 011 or
by email at andrew.jones@allianz.co.uk
Appendix 2
Summary of duties of School/Departmental
Responsible Persons:
·
Each School/Department must
appoint a Responsible Person where there are pressure systems, lifting
equipment and/or power presses that require maintenance and statutory
inspection.
·
To monitor that all relevant
pressure systems, lifting equipment and power presses on their
School/Departmental asset register are entered on the Allianz database.
·
To add / delete new /
redundant items of equipment from Allianz database.
·
To delete any item of
equipment that has been disposed of or has been completely removed from service
(must be isolated from power and not be capable of inadvertent use) from the
Allianz database.
· To monitor and review that all items of equipment
are being inspected in line with the requirements and to identify equipment or
general problems where items are not being inspected within the inspection
dates. Items should not be repeatedly missed without some explanation added to
the notes section for that item.
·
To receive and act upon
email notifications from Allianz , specifically coordinating action for ‘A’ and
‘B’ defects and liaising with Allianz engineer to deal with PNA’s (Plant Not
Available).
·
Arrange for timely preparation
of pressure systems for examinations to take place within the correct period.
·
Arrange the routine
maintenance of pressure systems, lifting equipment and power presses.
If you have any queries regarding the process,
please email bb-safety-office@exmail.nottingham.ac.uk.
Further guidance
on statutory inspection can be found on the Allianz web-site http://www.allianzengineering.co.uk/