Annex 2 - Check lists
Extraction system | Yes | No | |||||
---|---|---|---|---|---|---|---|
Extraction system suitable for neat oil machining? (Instructions for use/technical documentation) e. g.: | |_| | |_| | |||||
- | Design free of ignition sources | |_| | |_| | ||||
- | Arc-free fan drive on the intake side | |_| | |_| | ||||
- | System and ducting earthed | |_| | |_| | ||||
Air flow monitored (pressure, flow controls)? | |_| | |_| | |||||
- | Extraction starts when machine starts | |_| | |_| | ||||
- | Flow too low: signal indication, machine tool failure indication | |_| | |_| | ||||
Extraction capacity adjusted via throttle valve/speed control | |_| | |_| | |||||
Extraction system integrated into extinguishing concept: | |||||||
- | Provide sufficient quantity of extinguishing agent in extraction system and separator | |_| | |_| | ||||
- | If applicable, extinguishing nozzle and fire detection in separator | |_| | |_| | ||||
- | Consider fan overrun | |_| | |_| | ||||
Ducting: | |||||||
- | Slightly inclined without depressions (if applicable, provide MWF drain) | |_| | |_| | ||||
- | Provide inspection holes/control openings | |_| | |_| | ||||
- | Regular inspection for deposits, if necessary, cleaning? | |_| | |_| | ||||
For ducting system: Prevention of fire propagation, e. g. by means of | |||||||
- | Flame arresters (in pipes and in the machining area) | |_| | |_| | ||||
- | Shut-off valves (at the machine tool) | |_| | |_| | ||||
Effective pre-separation at the machine outlet, e. g. by means of baffle plates, pre-separators | |_| | |_| | |||||
Regular maintenance of system and ducting: Maintenance schedule (Instruction handbook) | |_| | |_| | |||||
In case of fire: Interruption/extraction by means of | |||||||
- | Fan motor-brake (reduction of overrun) | |_| | |_| | ||||
- | Automatic shut-off valve | |_| | |_| | ||||
Pressure relief device | Yes | No | |||||
Route flames and hot gases into safe areas | |_| | |_| | |||||
Installation in the cover areas | |_| | |_| | |||||
Provide pressure relief area: ~ 0.1 m2/m3 work room (see VDW 3002) | |_| | |_| | |||||
Reliable opening at minimal excess pressure (« 5 mbar) | |_| | |_| | |||||
Reliable closing subsequent to pressure relief | |_| | |_| | |||||
Suitability as protective device verified by the manufacturer (e. g. test) | |_| | |_| | |||||
No flammable materials (wooden crates, insulation materials) in the danger zone around the pressure relief device | |_| | |_| | |||||
Danger zone warning signs around the pressure relief device | |_| | |_| | |||||
Metalworking fluids | Yes | No | |||||
Low-emission metalworking fluid used? | |_| | |_| | |||||
1: | Observe characteristics, e. g. in the safety data sheet, product information | |_| | |_| | ||||
Example: For MWF with a viscosity of 4.1 [mm/min at 40°C] | |||||||
- | Flash point | > 120°C (see Table 1) | |_| | |_| | |||
- | Noack evaporation losses [250°C] | < 85 % (see Table 1) | |_| | |_| | |||
2: | MWF with anti-mist additives (consider filterability) | |_| | |_| | ||||
MWF compatible with hydraulic oils, slideway oils (multi-functional oil)? | |_| | |_| | |||||
Sufficient quantity of MWF (MWF circuit, storage tank) during machining (see VDI 3035)? | |_| | |_| | |||||
No drag-in of large quantities of: | |||||||
- | Cleaning agents and solvents (on workpiece/part) into the MWF circuit | |_| | |_| | ||||
- | Hydraulic oil into the MWF circuit | |_| | |_| | ||||
MWF supply: | |||||||
- | Monitored? (pressure or flow controls) | |_| | |_| | ||||
- | Sufficient cooling quantity, MWF nozzles? | |_| | |_| | ||||
- | MWF nozzles arranged in the best possible way? | |_| | |_| | ||||
Avoid considerable temperature increase of the MWF | |||||||
- | Increase of MWF temperature by 10°C = doubling of misting | |_| | |_| | ||||
- | MWF temperature monitored? | |_| | |_| | ||||
- | Possibility of cooling: e. g. baffle plates, MWF container used sufficiently large? | |_| | |_| | ||||
Extinguishing system | Yes | No | |||||
Use suitable extinguishing agent (consider fire class) | |_| | |_| | |||||
Attention: | |||||||
- | For extinguishing gases, e. g. carbon dioxide (CO2) consider danger to personnel (see BGR 134, BGI 888) | |_| | |_| | ||||
- | For metal fires (magnesium, aluminium, titanium): only use suitable extinguishing agents, e. g. fire class D! | |_| | |_| | ||||
- | For powder extinguishers: considerable material damage in the interior of the machine tool possible | |_| | |_| | ||||
Provide a sufficient quantity of extinguishing agent: | |||||||
- | Also consider extraction system, chip conveyer, holes .... | |_| | |_| | ||||
- | Consider flow-off losses (e. g. overrun, extraction ...) | |_| | |_| | ||||
Extinguishing system: | |||||||
- | Planning and installation: By a specialist company, possibly in agreement with the manufacturerrsteller | |_| | |_| | ||||
- | Components, planning and installation: consider the state-of-the-art (e. g. VdS Directives..) | |_| | |_| | ||||
- | Planning and installation: Demand approval test and approval protocol | |_| | |_| | ||||
- | Positioning: No adverse effects by pressure or flame propagation | |_| | |_| | ||||
- | Electrical supply and control system independent of machine tool | |_| | |_| | ||||
- | Interlocking of the extinguishing gas supply during setting and maintenance work (non-electrical or electrical shut-off devices, see BGR 134, BGI 888) | |_| | |_| | ||||
- | Regular checking of extinguishing agent tanks fill-levels: e. g. pressure controls, weighing devices | |_| | |_| | ||||
- | Gas extinguishing system: Provide sufficient pressure relief options | |_| | |_| | ||||
- | Considerable material and environmental damage, personnel injuries: Automatic extinguishing systems! | |_| | |_| | ||||
Fire detection and extinguishing: | |||||||
- | Use optical and/or thermal fire detection elements | |_| | |_| | ||||
- | Fire detection elements: Consider the state-of-the-art (e. g. VdS Directives) | |_| | |_| | ||||
- | Optical sensors: | - | consider suitability (e. g. MWF mist) | |_| | |_| | ||
- | keep clean (e. g. by air purging) | |_| | |_| | ||||
- | Thermal sensors: | - | fire detection slower than with optical sensors | |_| | |_| | ||
- | Extinguishing nozzles: | - | suitable for the relevant extinguishing agent | |_| | |_| | ||
- | consider arrangement: if possible, do not direct towards door labyrinths | |_| | |_| | ||||
Extinguishing hole and machining area door in case of fire: | |||||||
- | Only to be opened by fire service and specially instructed persons | |_| | |_| | ||||
Regular testing of the extinguishing system (see BGR 134) | |_| | |_| | |||||
Instruction | Yes | No | |||||
Function and handling of the machine tool and the extinguishing system in case of fire | |_| | |_| | |||||
Optical sensors: Avoid light flashes (lighters, welding) | |_| | |_| | |||||
Special hazards (NEVER!): | |||||||
- | Opening of the machine door in the event of a fire in the interior: Hazard of backfire | |_| | |_| | ||||
- | Wearing oil soaked clothing: Fire hazard (wicking) in case of backfire | |_| | |_| | ||||
In the case of fires or explosions (BGI/GUV-I 560): | |||||||
- | When the alarm activates: Leave the danger zone immediately | |_| | |_| | ||||
- | Use escape and rescue routes | |_| | |_| | ||||
- | Search for help: Fire service, emergency telephone numbers | |_| | |_| | ||||
Hazards during ignition of the MWF mixture: | |||||||
- | Violent flame ejections at pressure relief devices/subsequent fires possible | |_| | |_| | ||||
- | Flame ejection at machine tool door gaps and openings | |_| | |_| | ||||
- | Extinguishing agent CO2: Hazard of suffocation (above 5 % CO2 volume in air) | |_| | |_| | ||||
- | During extinguishing process: Ejection of flames in the door area | |_| | |_| | ||||
- | Hazard of suffocation in confined spaces due to fire smoke and fumes | |_| | |_| | ||||
- | Do not touch machine components subsequent to fire: Possibly live (electric shock) and hot (burns) | |_| | |_| | ||||
Reduce fire hazard - Preventive measures: | |||||||
- | Regular emptying of chip container to avoid self-ignition | |_| | |_| | ||||
- | Regular emptying of machine tool oil pans (extract oil) | |_| | |_| | ||||
- | No combustible materials (cardboard/carton/oil-soaked rags) in the vicinity of the machine tool | |_| | |_| | ||||
- | General smoking prohibition: No cigarette ends in chip containers/oil pans | |_| | |_| | ||||
Machine tool | Yes | No | |||||
Machine tool suitable for neat oil machining (non water-miscible MWF)? | |_| | |_| | |||||
Oil machining dealt with in the "Technical documentation"? | |_| | |_| | |||||
Extinguishingsystem present? | |_| | |_| | |||||
Extraction system present? | |_| | |_| | |||||
Extinguishing system deactivated when machining room door open? | |_| | |_| | |||||
Machining room door stays interlocked during machining and emergency stop? | |_| | |_| | |||||
Machining room door non-interlockable when the machine is open and switched-off? | |_| | |_| | |||||
No oil pool formation in the machining area, drive room or handling area? | |_| | |_| | |||||
No oil pool formation in the area outside the machine (oil pan regularly emptied)? | |_| | |_| | |||||
Sufficient pressure resistance of guarding? | |_| | |_| | |||||
Pressure relief device present? | |_| | |_| | |||||
Door labyrinths resistant to outbreak of flames? | |_| | |_| | |||||
Other openings (e. g. loading and unloading openings, gaps) in the operating area covered? | |_| | |_| | |||||
If applicable, extinguishing hole present? | |_| | |_| | |||||
Transparent screens made of polycarbonate undamaged (see DIN EN ISO 23 125, VDW 0209)? | |_| | |_| | |||||
Transparent screens positively fitted (not with rubber edging)? | |_| | |_| | |||||
Alarm device present? | Optical | |_| | |_| | ||||
Acoustic | |_| | |_| | |||||
Marking: Information signs, CO2 hazard warnings, extinguishing system? | |_| | |_| | |||||
Machine tool: Control system (example) | Yes | No | |||||
Start of machine: | |||||||
- | Extraction system on/chip removal on | |_| | |_| | ||||
- | Door interlocked (with guard locking) | |_| | |_| | ||||
- | Extinguishing system ready to operate (optical and thermal sensors, activation) | |_| | |_| | ||||
- | MWF supply monitored | |_| | |_| | ||||
Extinguishing process: | |||||||
- | For CO2: If applicable, activation delay set (BGR 134) | |_| | |_| | ||||
- | Extraction system off | |_| | |_| | ||||
- | MWF supply off | |_| | |_| | ||||
- | Extinguishing system ready to operate | |_| | |_| | ||||
- | Doors interlocked (with guard locking) | |_| | |_| | ||||
- | Alarm device (optical/acoustic) active | |_| | |_| | ||||
- | Machine drive off | |_| | |_| | ||||
Opening of the door: | |||||||
- | Extinguishing system inactive | |_| | |_| | ||||
- | MWF supply off | |_| | |_| | ||||
- | Machining process safely stopped | |_| | |_| | ||||
- | Extraction system: If applicable, keep in mind short overrun! | |_| | |_| |