Operate Equipment Safely

Please note that this is NOT a 'first-time' start-up procedure which is likely to be far more comprehensive e.g. after maintenance or commissioning.

This procedure assumes that all of the above requirements have already been completed e.g. assessments, documentation, and training.

• Visually inspect the equipment for damage, leaks, wear, or missing parts etc.
• Make sure no maintenance work is ongoing. It is important to seek advice if repairs were required or completed since the last time the equipment was used.
• Check support systems are available e.g. cooling water, electrical power or air etc.
• Check the fluid level is in the normal start-up range with cylinders in the safe, shut-down condition.
• Check the fluid temperature is within the normal range for start-up. Warm the fluid to the correct working temperature if possible and definitely if the ambient temperature gets too cold.
• Check the handle positions are correct for all line isolating valves. Also check their security locks, if fitted.
• Check the actuators or loads are clear to move.
• Check instrument readings are within the normal start-up ranges, particularly accumulator pre-charge pressures.
• Check all guards are in place and there is no risk to anyone from flying hoses, fittings, or moving parts.
• Press the start button(s) in the prescribed sequence. If there are any unusual noises or movements then press the stop button immediately and seek assistance.
• Check that the gauges and instrumentation move to within the expected ranges.
• Observe the filter clogging indicator movements as these are likely to show higher readings when the fluid is cold.
• Gradually increase any speeds, feeds or pressures until the normal working conditions are met.
• Check instrumentation readings are still within expected ranges.

This list only covers a simple installation and will not include all potential issues. Always check the specific start-up procedure for your equipment.

While the equipment is running:

• Always listen and watch for any noises or movements that may indicate the start of something failing or wearing out. Stop immediately if concerns are raised.
• Constantly monitor the gauges and instrumentation for unusual reading, or readings that drift outside the normal working range.
• Constantly monitor for leaks or fluid smears that may indicate a larger leak is about to start.
• Look out for other personnel and stop them getting too close to working equipment or walk into areas that could be potentially unsafe.
• Keep records of system operation e.g. how long sequences take, maximum and minimum temperatures relative to the ambient conditions, number of cycles, or on-load operating hours etc.

Shut down procedures are not necessarily the reverse of start-up procedures and likely to include:

• Wait for all operating or automated sequences to finish and the equipment to return to standby conditions.
• Gradually low all speeds, feeds or pressures where possible.
• Make sure all loads are returned to a safe where they cannot fall or creep and further.
• Press the stop button(s) in the prescribed sequence.
• Wait for the pressures to decay and the gauges or instrumentation to return to their zero or off conditions.
• Open accumulator safety block drain down valves if pressure venting does not occur naturally.
• Do not close any ball valves or isolators unless the shut-down procedure specifically advises you to.
• Isolate the electrical supply.
• Record all relevant operating details, times or abnormal operation in the relevant documents.
• Leave warnings on the equipment and notify all relevant personnel if any abnormal operation has occurred.

All maintenance procedures and repairs should be recorded and the operator should have access to this information. It is important for the operator to know when work has been carried out on equipment so that they can implement appropriate precautions where required. For anyone operating a machine, it is always good to know that the proper maintenance procedures are in place and that all work has been adequately recorded and reviewed.

As part of the maintenance procedure, it is important the machine operator reports and records all breakdowns, accidents or abnormal performance. This is the only way that support staff can be made aware of potential issues and can therefore carry out the appropriate actions.