2 Safety Regulations

TRANSLATION OF THE ORIGINAL INSTRUCTIONS
Safety regulations
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Dok. Name:Sicherheit_EN_01.2016
Revisionsdatum: 13.01.2016
Safety regulations
OUR ADRESSE:
I BAU HAMBURG
Ingenieurgesellschaft
Industriebau mbH
Rödingsmarkt 35
D-20459 Hamburg
Tel.: +49 (40) 36 13 09 0

Fax: +49 (40) 36 39 83
E-mail: info@ibauhamburg.de
Internet: www.ibauhamburg.de
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TABLE OF CONTENTS
1 Information ................................................................................................................................... 5
1.1 Manufacturer and originator .............................................................................................. 5
1.2 Safety symbols used ......................................................................................................... 6
2 Preliminary remark ...................................................................................................................... 6
3 Product-specific documentation ................................................................................................ 7
4 Generally applicable safety regulations .................................................................................... 7
5 Intended purpose of use ............................................................................................................. 8
6 Unauthorised modifications ....................................................................................................... 8
7 Requirements for the personnel ................................................................................................ 9
8 Warning notices in the product-specific documentation ........................................................ 9
9 Operating conditions ................................................................................................................. 10
10 Safety precautions to be taken before commissioning ......................................................... 11
11 During operation ........................................................................................................................ 11
11.1 General............................................................................................................................ 11
11.2 Protective and safety devices ......................................................................................... 12
11.3 Personal protective equipment and clothes .................................................................... 12
12 Safety instructions for assembly, inspection and maintenance work ................................. 13
12.1 General............................................................................................................................ 13
12.2 Access to the silo interior (material store) ....................................................................... 15
12.2.1 Hazard assessment ........................................................................................................ 15
12.2.2 Protective measures ....................................................................................................... 16
12.2.3 Organisational measures ................................................................................................ 18
12.3 Transport of machines in the plant .................................................................................. 19
12.4 Electrical equipment ........................................................................................................ 20
12.5 Welding and burning work .............................................................................................. 20
12.6 Hydraulic and pneumatic systems .................................................................................. 21
12.7 Lubricants and auxiliary materials (oils, greases and chemical substances) ................. 21
12.8 Lubricant ......................................................................................................................... 21
12.9 Spare parts and accessories .......................................................................................... 22
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13 Emergency shut-down ............................................................................................................... 22

14 Dangers and malfunctions ........................................................................................................ 22
15 Safety information for electrical equipment ............................................................................ 22
16 Loading and unloading .............................................................................................................. 23
17 Storage ........................................................................................................................................ 23
18 Warranty and liability ................................................................................................................. 23
19 Liability disclaimer ..................................................................................................................... 24
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1 Information
1.1 Manufacturer and originator
IBAU HAMBURG
Ingenieurgesellschaft
Industriebau mbH
Rödingsmarkt 35
D-20459 Hamburg
Tel.: +49 (40) 36 13 09 0

Fax: +49 (40) 36 39 83
E-Mail: info@ibauhamburg.de
The copyright to this operating manual is held by IBAU HAMBURG.

This operating manual contains information which may not be duplicated, distributed or
used for purposes of competition without authorisation or passed on to third parties, either
in part or in full.
This also applies analogously to the data processing programs employed and the
associated program descriptions.
In the event of the extension or exchange of existing programs, the purchaser obligates
himself to destroy the preceding versions, any copies thereof and the exchanged
documentation, insofar as no other regulation exists.
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1.2 Safety symbols used

Table 1 Safety symbols used in the operating manual
DANGER
This symbol indicates a direct danger to the life and the health of persons.
Disregarding these instructions leads to serious damage to health, extending as
far as life-threatening injuries.
WARNING
This symbol indicates a possible danger to the life and the health of persons.
Disregarding these instructions can lead to serious damage to health, extending
as far as life-threatening injuries.
CAUTION
This symbol indicates a possibly dangerous situation. Disregarding these
instructions can lead to slight injuries or damage to property.
ATTENTION
This symbol gives important instructions for the proper handling of the machine.
Disregard of these instructions can lead to malfunctions of the machine or
disruptions to its environment.
NOTICE
This symbol refers to explanations of concepts
2 Preliminary remark
These safety instructions are part of the product-related technical operation
documentation. They are intended to protect people and property against injury and
damage that could be caused by inappropriate use, misoperation, inadequate or improper
maintenance or other incorrect handling of IBAU products.
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3 Product-specific documentation
The product-specific documentation, to which these safety regulations belong, contains
important instructions concerning installation, commissioning, maintenance and accident
prevention, which you should be aware of in order to avoid mistakes and omissions that
could have serious consequences.
The trained personnel who are assigned to work on the machine by the operating
company (i.e. all persons who are entrusted with the installation, operation, maintenance
or repair of the IBAU products or the plant in which they are installed) must therefore read
the product-specific documentation in its entirety before starting work and must follow the
instructions that it contains. This must be ensured by the operating company.
The operating company must carry out an effectiveness check.
The product-specific documentation contains the information required for all work on and
with IBAU products that is carried out by specialists (see also section 7: Requirements for
the personnel).
For reasons of clarity, not all detailed information on possible design variants can be
included and not every conceivable case of installation, operation or maintenance can be
taken into account.
ATTENTION
The current product-specific information is to be requested in writing from IBAU
HAMBURG before commencing installation/work.
IBAU HAMBURG accepts no liability for damage caused by disregard of the product-
specific documentation.
The product-specific documentation is to be kept readily to hand at the place of use of the
machine / plant at all times.
4 Generally applicable safety regulations
The product-specific documentation and these safety regulations are not a replacement
for the generally applicable legal and other obligatory regulations for the prevention of
accidents, health and safety at work and environmental protection, nor do they limit such
regulations. Any safety regulations imposed by the operating company for the complete
plant are not invalidated by the IBAU HAMBURG product-specific documentation and
safety regulations, but are considered to be superordinate.
The operating company itself is responsible for ensuring adherence to the obligatory laws,
regulations, ordinances and health and safety at work rules applicable to the respective
place of installation as well as to the existing national regulations for the prevention of
accidents and any internal work, operating and safety regulations imposed by the
operating company.
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5 Intended purpose of use

All IBAU products and all other parts belonging to the IBAU HAMBURG scope of supply
may be used only for the intended purpose. The intended purpose of use is derived from
the product-specific documentation in conjunction with the technical specification, which is
part of the contract. In particular, the technical data and the data concerning permissible
use (installation, connection, environmental and operating conditions), which are
contained in the order documents, the operating manual, the type plate details and the
remaining product documentation, among others, are decisive here.
Any other use or use extending beyond this is deemed to be inappropriate and is
therefore not permitted. The manufacturer is not responsible for any damage resulting
from this. The operating company bears the risk alone.
Use for the intended purpose also includes following the operating manual and adhering
to the inspection and maintenance conditions.
The product-specific documentation can refer only to the intended use of the machine /
plant as based on the order. Particular local conditions or particular cases of use of which
the manufacturer was not aware can give rise to situations which therefore cannot be
accounted for in the operating manual. In this case, the operating company must ensure
safe operation or shut down the machine / plant until measures for the safe operation
have been agreed or carried out in agreement with the manufacturer or another
responsible authority.
NOTICE
Intended purpose of use (EC machinery directive) means the use/operation of
machines and plants as specified by the manufacturer/distributor.
This also includes a description of the use of machines/plants/devices,
protective systems and devices according to the device group and category and
observing all manufacturer’s data necessary for the safe operation of the
devices, protective systems and devices.
6 Unauthorised modifications
IBAU products must not be modified, extended or converted without the manufacturer’s
written permission if such actions would impair their safety or function!
ATTENTION
Unauthorised modification of the machine / plant leads to the invalidity of the EC
declaration of conformity / EC declaration of incorporation.
This also applies to changes to the adjustments of factory-fitted safety devices and to
welding on statically relevant parts.
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7 Requirements for the personnel

Work (e.g. assembly / installation, operation, maintenance and repair) on or with IBAU
HAMBURG machines / plants may be carried out only by trained and qualified personnel
with special knowledge and experience in the respective specialist field who have
received plant-specific training and have been assigned to such work. This applies in
particular to servicing and repair work on the electrical, mechanical, hydraulic and
pneumatic devices on the components and on the plant.
NOTICE
Qualified personnel are persons who, on account of their training, experience
and instruction, as well as their knowledge of relevant standards, regulations,
rules for the prevention of accidents and operation conditions, have been
authorised by the person responsible for the safety of the plant to carry out the
respectively necessary tasks and thereby to recognise and avoid possible
dangers (refer also to DIN VDE 0105 or IEC 364 for definitions of qualified
electricians).
It is the responsibility of the machine / plant operating company to ensure that the
persons assigned to use and maintain the machines / plants are in possession of the
requisite technical competence.
If the personnel do not present the appropriate qualification and are not in possession of
the necessary knowledge, they must be trained and instructed accordingly by the
operating company. The instruction must be documented in writing by the operating
company.
The scope of responsibility, competency and monitoring of the personnel must be
precisely defined and regulated by the operating company so that no unclear
competencies arise.
It must be ensured that only authorised personnel who have been assigned to do so work
on machines / plants. It is the operating company’s responsibility to ensure that no
unauthorised persons work on the machines / plants. The respective legally permissible
minimum age must be observed.
Work on the electrical equipment of the machine / plant may be carried out only by a
skilled electrician in accordance with the respectively applicable electrotechnical rules.
Among other things, knowledge of first-aid measures and the local rescue facilities is
necessary. Unqualified persons are forbidden to work on high voltage systems by, for
example, DIN VDE 0105 or IEC 364.
When working at voltage levels higher than 1 kV, switching operations may be performed
only by persons in charge who, on account of their training, possess a written switching
authorisation for systems at the respective voltage level.
8 Warning notices in the product-specific documentation
In the respective product-specific documentation, all provisions, regulations and notices
that concern safety and whose disregard could pose a hazard to persons and/or the
machine / plant and its function, are marked by headings such as ‘ATTENTION’,
‘CAUTION’, ‘WARNING’ and ‘DANGER’ and are in addition typographically highlighted.
WARNiNG
Notices attached directly to the machine, such as warning notices, direction of
rotation arrows etc., must be obeyed without fail and must be kept in a fully
legible condition by the operating company.
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9 Operating conditions
Dependence on other plants and devices is not predictable by us and must be checked
separately by the operating company.
Furthermore, the following conditions, provided they do not lie within our scope of
responsibility, must be fulfilled for the normal operation of the plant:
• properly completed assembly;
• properly installed and adjusted safety devices;
• a successfully completed test run with all necessary adjustments;
• instruction of the operating personnel on the operation of the plant and the relevant
safety regulations;
• if hot or cold machine parts pose hazards, they must be protected against contact
and marked appropriately;
• hazards due to electrical energy must be prevented (refer e.g. to the VDE, IEC or
public suppliers regulations for details);
• the plant must be easily accessible;
• a sufficient number of persons must be responsible for and trained in the correct
operation of the machines / plants.
All work such as transport, assembly, installation, commissioning, maintenance and repair
is to be carried out by qualified and assigned persons and checked by responsible
technical personnel.
The following must be observed in particular here:
• the technical data and the data concerning permissible use (assembly, connection,
environmental and operating conditions), which are contained in the order
documents, the operating manual, the type plate details and the remaining product
documentation, among others;
• the general safety regulations;
• the local, plant-specific regulations and requirements;
• the proper use of tools, lifting and transport equipment;
• the use of personal protective equipment.
The operating company must carry out an effectiveness check.
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10 Safety precautions to be taken before commissioning

The trouble-free function and safety of the machine is ensured only when it is used for its
intended purpose (see item 5) in accordance with operating manual and the specifications
in the confirmation of order.
The operating staff must ensure each time before starting up
• that no persons or obstacles are in the danger area of the plant or inside the
protective devices;
• that the plant has no obvious security defects;
• that all signal, warning and protective devices as well as indicator lamps are in
working order;
• that the protective devices are properly attached;
• that any existing transport locks have been removed;
• that all protective devices and safety-related devices (e.g. detachable protective
devices, emergency stop devices, sound insulations, extraction devices etc.) are
present and in working order;
• Before switching on the plant and starting up the components, it must be ensured
that nobody can be endangered by the switching on of the plant and the start-up of
the components!
ATTENTION
Test and check lists are to be maintained by the operating company
11 During operation
11.1 General
All components are to be used only if in a technically perfect and operable condition in
accordance with their designated use and only by safety-conscious persons who are
aware of the risks involved.
Refrain from using any mode of operation that could impair the safety of personnel or the
machines / plants.
The machines / plants must not be put into operation by unauthorised persons.
On no account may the inspection covers be opened during operation, as there is a risk
of injury. The inspection covers may be opened only when the machine / plant is switched
off and secured against being switched on again and only after the machine / plant has
come to a complete standstill.
Persons must not be transported by the machine / plant or parts thereof.
During operation, any potential danger area must be secured by the operating company
in such a way that nobody can enter or remain in this area unobserved.
If the machine / plant is in operation, it may only be entered after agreement with the
operator and only after the machine / plant has been brought to a standstill. The operator
must not permit unauthorised persons to enter the machine / plant. This must be ensured
by the operating company.
The operating company must ensure that the plant is not left unsupervised during
operation.
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The operating company must ensure that the operator always remains within reach of the
controls (suspended switch panel, control consoles etc.) when the machine / plant is in
operation.
Protective devices must not be removed during operation.
Motors may be used only in the designated form. Any other use is inadmissible.
Conveying pipes and air lines must not be touched, since the temperatures of their outer
walls can exceed 60 °C. They may not be dismantled before the internal pressure has
been released and conveying pipes have been emptied.
The operator must ensure the cleanliness and tidiness of the workplace on and around
the machines by means of appropriate instructions and checks.
Personnel must be familiarised with the location and operation of fire extinguishers. The
fire alarms and fire fighting possibilities must be observed.
WARNING
Particular caution must be exercised in the case of machines driven by diesel or
petrol engines, since there is a risk of poisoning by exhaust gases. The rooms
must be sufficiently aerated and ventilated.
Attention must be paid to the indicator lamps when switching on and switching off as well
as to the start-up warnings!
Extraction, venting and cooling devices must not be switched off or removed when the
machine / plant is in operation!!
If necessary, the maintenance area must be cordoned off over a wide area by suitable
means.
11.2 Protective and safety devices
The plant may be operated only with all protective and safety devices fitted.
The operating company must ensure that no protective and safety devices are
dismounted, disabled or modified, not even during test runs.
11.3 Personal protective equipment and clothes
The operators must be informed by the operating company about the wearing of personal
protective equipment (PPE), such as safety glasses, protective helmets, ear protectors
and safety footwear.
Personnel may not wear long hair hanging loose, loose clothes or jewellery (including
rings), since there is a risk of injury due to being drawn in or getting caught up!
The operating company must perform effectiveness checks.
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12 Safety instructions for assembly, inspection and maintenance work

12.1 General
Good maintenance increases the safety of the plant and lowers operating costs. The
operational reliability of the components is impaired if these are not maintained in
accordance with the maintenance instructions or, in the worst case, not maintained at all.
It is essential that the instructions in the operating manual be followed when carrying out
maintenance work. In particular, the specified intervals for recurring checks and
inspections / maintenance are to be adhered to.
As a rule, the plant should be inspected daily for noticeable changes, oil leakages and
damage independently of the specified inspection / maintenance intervals.
As a matter of principle, any work (e.g. maintenance or repairs) on the machine / plant is
to be carried out only when it is at a standstill and has been secured against being
restarted inadvertently. The procedure for stopping the machine, which may be described
in the product-specific documentation, must be adhered to.
When working on electrical components, all conducting lines are to be disconnected from
the power supply before starting work and secured against being inadvertently switched
on again.
When carrying out any maintenance, repair or other work on the plant, it must be secured
against inadvertent or unauthorised switching on (again) (lock the main switch or circuit
breaker with a lock and remove the key; attach a warning sign to the main switch or use a
LOTO system).
Explanation of Lockout Tagout (LOTO) systems:
Lockout Tagout system: a tool for companies that have to ensure that their employees are
adequately protected against electrical, mechanical and fluid-related dangers at the place
of work.
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7 steps to reliable protection with Lockout Tagout (LOTO) systems:

1 Preparation
Make all preparations to switch off the energy source. Ascertain which energy source is
involved (e.g. mechanical or electrical) and above all the risks that are associated with it.
Locate and identify the isolating switches and make the necessary preparations for
locking the energy source.
2 Information
Notify all directly affected employees, e.g. operators and managerial staff, that the
machine / plant is to be switched off. Also inform them about the measures that are to be
carried out.
3 Switch off
Switch the machine / plant off.
4 Lock
Lock / close all energy sources using a respectively suitable locking device in order to
isolate the plant or machine from the energy source. Attach locks so that relevant
switches or valves cannot be operated during the maintenance work. You can additionally
warn against inadvertent switching on using lockout tags.
5 Test
Test electrical circuits and machine controls to ensure that the energy supply is
completely switched off.
6 Repair and maintenance
The necessary repair or maintenance work is to be carried out by trained and/or assigned
personnel.
7 Returning to service
After completion of the work, remove all Lockout Tagout systems and make sure that all
tools and mechanical and electrical locking devices have been removed from the
machine. Before restoring the energy supply, you should now inform all affected
employees once again that the energy sources are about to be switched on again.
The operating company must ensure that all safety and protective devices are attached or
put into operation again immediately after completion of the work.
To this end, the operating company must maintain test and check lists!
Before returning to service, the items listed in the ‘Commissioning’ section must be
observed.
Workshop equipment suitable for servicing work is absolutely necessary for the
performance of such work.
The proper execution of assembly, inspection, maintenance and repair work is to be
carried out by expert personnel who have been trained for the work, and must be checked
by a qualified and responsible person.
Screwed joints loosened for maintenance and repair work are to be tightened to the
specified tightening torques again after completion of the work.
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If it should be necessary to dismount safety devices for maintenance and repair work, the
safety devices must be remounted and their function tested after completion of the work.
When carrying out assembly or repair work above the usual working height, climbing aids
or work platforms provided by the operating company for this purpose or other such aids
must be used. Safe accessibility of the plant components must be ensured by gangways
and work platforms.
Machine and plant components must not be used as climbing aids!
The operating company must keep all grips, steps, railings, landings, platforms and
ladders free from dirt, snow and ice.
When working at greater heights, safety gears are to be worn in accordance with the
applicable legal and national regulations to prevent falling.
Suitable ear protectors must be worn when carrying out inspection work on machines /
plants that are in operation, in particular when opening sound-insulating hoods.
Leakages (e.g. from shaft seals) of dangerous materials to be conveyed (e.g. explosive,
toxic or hot) must be drained off in such a way that there is no danger to persons and the
environment. Legal regulations must be adhered to.
During cleaning using cleaning spray or detergents, attention must be paid to the
applicable specifications in the safety data sheets and operating instructions, since there
is a danger of poisoning when inhaling and caustic burns on contact.
The operating company must make the necessary PPE available.
Machines / plants must be cleaned before beginning repair or maintenance work on them.
Do not use aggressive cleaning agents.
12.2 Access to the silo interior (material store)
12.2.1 Hazard assessment
The silo operating company must carry out a hazard assessment before the start of work
inside the silo.
Technical or organisational measures must be taken against the hazards and stresses
determined in the hazard assessment.
The measures defined are to be recorded in a permit note or in the operating instructions.
The hazard assessment attached as a sample can be used; however, plant-specific
hazards are to be accounted for in it (e.g. material-specific).
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12.2.2 Protective measures

Before the interior of the silo is entered via the lateral silo manholes or via the silo
manhole in the cone, the operating company must ensure by means of a visual inspection
of the silo interior, which takes place via the silo manhole(s) installed in the silo roof, that:
• there are no material overhangs in the immediate vicinity of the aforementioned
entrances (lateral or cone) (danger of being buried)
• the residual material level is such that the sinking in of people is securely avoided
(danger of suffocation)
Furthermore the operating company must ensure that:
• the silo is not filled during the inspection (danger of being buried).
• no mechanical or welding work takes place in the vicinity of the silo roof that could
result in objects or welding sputter falling down.
• there is sufficient aeration and ventilation of the silo interior when hot work is
performed (e.g. welding or flame cutting).
• sufficient fire extinguishing agents are available and a fire watch is assigned due to
the flammability of the slide fabric when hot work is carried out in the work area.
• the silo discharge components (e.g. lump crushers, flow-control gates) are switched
off and secured against being switched on again.
When entering the silo interior via the silo manhole(s) on the silo roof, the following points
must be considered:
• Entrance is permitted only using approved and suitable silo entrance equipment. The
country-specific regulations must be observed here.
• The person entering the silo must be secured by suitable PPE against falling.
In all cases, personal protective equipment (PPE) consisting of safety shoes, work
clothes, helmet and safety glasses must be worn when entering the silo.
The wearing of dust masks can be necessary when entering silos that are already filled
with bulk materials.
Further protective measures are to be taken according to the safety data sheet for the
specific bulk material (e.g. caustic lime: causes skin irritation, serious eye damage and
irritation of the respiratory organs).
If the entrance through the silo manhole into the interior of the silo involves a danger of
falling, appropriate personal protective measures must be taken (e.g. full body harness
secured by a rope).
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The covers of the silo manholes are provided in the factory with pictograms as shown in
figure 1. The pictograms must always remain well visible, even after a subsequent coat of
paint!
Silo manhole for installation in Silo manhole for silo roof

the silo cone and sides
Fig. 1: Silo manholes with pictograms
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12.2.3 Organisational measures

a) Work procedure organisation
A factory work procedure organisation must stipulate which person will carry out the
organisational measures and who is assigned as the on-site supervisor or flagman.
b) Instruction of all people involved in the work
Before commencement of the work and on the basis of the hazard assessment, the
operating company must instruct all assigned people about the hazards and the
necessary protective measures according to the permit note or operating instructions.
c) Supervisor
Before commencement of the work in silos, the operating company must appoint a
reliable person to supervise the work. He must be familiar with the work and authorised to
issue directions.
If several companies are involved in the work, there must be general agreement as to
who will act as the general supervisor.
The supervisor can issue the permit note on behalf of the operating company. He must
ensure that the defined protective measures are adhered to.
The supervisor must perform the necessary checks before and during the work at
appropriate intervals. The intervals depend on:
• the hazard potential
• the reliability of the employees
• the nature of the protective measures taken
d) Flagman
The operating company must assign at least one flagman when work is carried out in
silos. He must be in constant contact with the people working inside the silo.
An emergency signal may only be used as a measure of the constant contact; it does not
replace a flagman.
The flagman must be able to summon help at all times. He must be familiar with the
defined emergency and rescue measures.
A flagman is not necessary if it is certain that:
• there are no hazards due to materials or equipment
• the people inside the silo can leave it without outside assistance and summon help at
any time, and that no lack of oxygen can occur.
e) Locking the silo manholes
Following the work, the operating company must ensure that no unauthorised persons
can enter the silo. This includes the proper fitting of the locks supplied by the factory for
the safety-relevant inner access openings and the proper attachment of the outer doors.
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12.3 Transport of machines in the plant

When exchanging machine parts and larger subassemblies with marked and tested
attachment points, they must be carefully fastened to the lifting equipment and secured so
that they cannot pose any hazard. Only suitable lifting equipment in a technically perfect
condition and with an adequate load capacity as well as load handling devices / lifting
gear with an adequate load capacity may be used.
Only trained/qualified persons may be assigned to attach loads and instruct crane
operators. The instructor must maintain visual contact with the operator of the lifting
equipment or be in suitable verbal contact with him.
Lift machines properly using only approved / suitable lifting gear and hoisting equipment
and only in accordance with the specifications in the respectively applicable operating
manual (attachment points for load handling and load handling devices etc.)!
WARNING
Do not step under suspended loads!
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12.4 Electrical equipment

The electrical equipment of the machines / plants must be inspected and checked
regularly (in accordance with the maintenance schedule). Defects such as loose cable
connections and any mechanical or electrical damage to conducting components must be
rectified immediately by a qualified electrician.
All work on conducting components or machines, e.g. assembly, connection or
maintenance, may be carried out only if the plant is electrically isolated (free from
voltage), earthed, secured against being switched on again and all plant parts are at a
standstill. Refer to item 12.1 regarding Lockout Tagout systems (LOTO).
To this end, the isolated parts must first be checked to ensure that they are free from
voltage, after which they must be earthed and short-circuited and adjacent live parts must
be insulated.
Observe the 5 safety rules:
• switch off;
• secure against switching on again;
• check freedom from voltage;
• earth and short circuit (compulsory when working on overhead networks over 1 kV);
• Cover or shield adjacent live parts.
12.5 Welding and burning work
Dust and flammable materials must be removed from the machine / plant and the area
surrounding it before carrying out any welding or burning work. Rubber and plastic parts
must be covered over.
WARNING
There is a danger of fire and poisoning if the instructions for welding and
burning work are disregarded.
Observe the following instructions:

• ensure sufficient ventilation;
• ensure adequate extraction of the welding fumes;
• it is essential to comply with welding regulations when carrying out welding work;
• weld only when the machine is switched off and secured;
• when welding using electrical devices, all electronic components should be
dismounted or at least all electrical connections should be isolated;
• when welding in closed containers, welding current sources with the marking S or, in
the case of older devices, K or 42V are to be used;
• use an insulating intermediate layer when welding in closed containers;
• welding work in closed containers must always be carried out by 2 persons (one
person secures from the outside).
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12.6 Hydraulic and pneumatic systems

Work on pneumatic / hydraulic mechanisms may be carried out only by qualified persons
with special knowledge and experience of pneumatic / hydraulic systems.
All lines, hoses and screwed connections must be checked regularly (in accordance with
the maintenance schedule) for leaks and externally recognisable damage. Damage is to
be rectified immediately by a qualified person. The hose connections must be replaced at
the specified or appropriate intervals (in accordance with the maintenance schedule),
even if there are no externally recognisable safety-relevant defects.
CAUTION
Sections of the system and pressure lines (compressed air) that need to be
opened must be depressurised in accordance with the operating manual before
commencing with repair work. Checking by operating the manual override on
the pilot valve indicates the effectiveness of this measure
The operating company must ensure that no lubricating or governing oil lines that are
under pressure are opened and that no screw connections that are under pressure are
tightened, since there is a danger of injury due to possibly escaping oil.
After the cleaning of air and oil lines, these must be examined to ensure that there are no
leaks, loose connections, chafe marks and damage. The operating company must ensure
that any defects found are rectified immediately.
12.7 Lubricants and auxiliary materials (oils, greases and chemical substances)
The safety regulations applying to the respective product must be observed when
handling oils, greases and other chemical substances.
CAUTION
Exercise caution when handling hot lubricants and auxiliary materials - there is
a danger of scalds and burns!
The operating company must ensure the safe and environmentally-friendly disposal of
lubricants, auxiliary materials and parts that have been replaced.
The respective operating manuals contain special instructions on disposal.
12.8 Lubricant
The choice of lubricants is also important for problem-free operation.
Correctly selected lubricants and lubrication intervals contribute significantly to a
reduction in the frequency of malfunctions and a reasonable service life for the machine.
Only when the above conditions are met can the lubricant fulfil the functions required of it
(a stable lubricating film, wear reduction, protection from corrosion, noise reduction, heat
dissipation, sealing). The lubricants and lubrication intervals specified in the product-
specific documentation must be observed. Oils, greases and other lubricants must not be
mixed!
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Safety regulations
12.9 Spare parts and accessories

When carrying out maintenance work, the operating company must ensure the use of
correct spare parts that meet the technical requirements specified by the manufacturer.
This is ensured with original spare parts. The installation or attachment of parts that are
not original IBAU HAMBURG parts or accessories may affect constructively specified
characteristics of the equipment under certain circumstances. Under no circumstances
can the manufacturer be held responsible for damage caused by the use of non-original
parts and accessories.
13 Emergency shut-down
After an emergency shut-down, the plant may be restarted only if the reason for the
emergency shut-down has been eliminated.
14 Dangers and malfunctions
All IBAU parts are built according to the latest state of the art and the recognised national
safety rules as well as the legal and EU regulations.
In the event of malfunctions of the component or the plant, the plant must be shut down
immediately and secured against restarting. Malfunctions of the part or plant that could
impair safety must be rectified immediately by the responsible qualified person.
Deviations from normal operation, for example higher temperatures, vibrations, noises
and others, suggest that the function is impaired. In this case, in order to avoid
malfunctions that could lead directly or indirectly to injuries to persons or damage to
property, the responsible operator / maintenance personnel must be informed and the
machine / plant must be immediately shutdown by technical personnel in order to find and
eliminate the causes. This must be ensured by the operating company.
The operating company must ensure that everyone who recognises a direct danger to
persons when operating the machine / plant shuts it down immediately, e.g. by actuating
an emergency stop button (if one exists). This also applies to the occurrence of damage
to parts of the plant, which also necessitates an immediate shutdown.
15 Safety information for electrical equipment
Electrical machines or devices are operating equipment for use in industrial plants. During
operation, these items of operating equipment have dangerous, bare live parts and
possibly also moving or rotating parts. Therefore, they can cause serious injuries or
material damages, for example in the case of impermissible removal of the necessary
protective covers, improper use, misoperation or inadequate maintenance. The operating
company must ensure that the points mentioned above are adhered to.
The person responsible for the safety of the plant must therefore ensure that
• only persons who are qualified for such work are assigned to work on the electrical
equipment;
• persons who are not qualified are prohibited from working on or near to electrical
equipment.
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Safety regulations
16 Loading and unloading

During loading, unloading and installation, the rules for the prevention of accidents and
the permissible loads of means of transport and hoisting equipment must be observed.
Damage to components discovered following delivery must be informed to the transport
company and IBAU HAMBURG immediately in writing; the commissioning of the
component affected must be suspended if necessary.
Parts or assemblies that have to be dismounted for transport purposes must be mounted
carefully before recommissioning.
17 Storage
The components must always be stored in a frost-free, dry, roofed-over place until
assembly.
The components must always be protected against external influences such as rain
water, snow, ice, impacts or breakage!
The service life of the lubricants and seals is reduced in the case of a longer period of
storage.
Refer to the information regarding long-term storage in the operating manuals of the
machines / plants.
18 Warranty and liability
IBAU HAMBURG’s warranty obligations arise from the respective delivery contract, which
is neither extended nor limited by these safety instructions or other instructions.
IBAU HAMBURG accepts no liability for:
• unauthorised technical and structural modifications (drive conditions, performance,
speed, software);
• improper installation, commissioning, maintenance and repair;
• inadequate monitoring of machine parts that are subject to wear;
• improperly executed repairs;
• damages resulting from disregard of the operating manual;
• injuries to personnel or material damage to the machine as a consequence of
illegible or missing warning and instruction signs;
• the installation or attachment and use of parts which are not original IBAU
HAMBURG parts or accessories;
• damage caused by foreign bodies in the material to be conveyed;
• disregard of the safety instructions in this printed document releases IBAU
HAMBURG from all warranties and liability for damages.
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Safety regulations
19 Liability disclaimer
We have checked the contents of the product-specific documentation for correlation to the
parts described. We regularly check the details in the product-specific documentation and
make any necessary corrections to the latest versions. Nevertheless, deviations cannot
be excluded; therefore we cannot give any guarantee of complete correlation.
We reserve the right to make technical changes.
NOTICE
Request your up-to-date version of the ‘Safety regulations’ in writing
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Safety regulations
Notes
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Safety regulations
IBAU HAMBURG Ingenieurgesellschaft

Industriebau mbH
Rödingsmarkt 35
D – 20459 Hamburg
Tel.: +49 (40) 36 13 09 0
Fax: +49 (40) 36 39 83
E-Mail: info@ibauhamburg.de
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TRANSLATION OF THE ORIGINAL INSTRUCTIONS

Tel.: +49 (40) 36 13 09 0

13 Emergency shut-down ............................................................................................................... 22

Tel.: +49 (40) 36 13 09 0

The copyright to this operating manual is held by IBAU HAMBURG.

1.2 Safety symbols used

5 Intended purpose of use

7 Requirements for the personnel

The operating company must carry out an effectiveness check.

10 Safety precautions to be taken before commissioning

12 Safety instructions for assembly, inspection and maintenance work

7 steps to reliable protection with Lockout Tagout (LOTO) systems:

12.2.2 Protective measures

Silo manhole for installation in Silo manhole for silo roof

12.2.3 Organisational measures

12.3 Transport of machines in the plant

12.4 Electrical equipment

Observe the following instructions:

12.6 Hydraulic and pneumatic systems

12.9 Spare parts and accessories

16 Loading and unloading

IBAU HAMBURG Ingenieurgesellschaft

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