WILMS GMBH

Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Safety guidelines

2.1 Explanatory notes on Hazard notes 2

2.2 Preliminary comments concerning safety guidelines.............................................4

2.3 Safety instructions for certain phases of operation................................................5
2.3.1 General................................................................................................................. 5
2.3.2 Commissioning.....................................................................................................5
2.3.3 Special work in the scope of using the system and repair activities as well as
troubleshooting in the sequence of work; disposal................................................6
2.4 Organisational measures......................................................................................8
2.4.1 Safety instructions.................................................................................................8
2.4.2 Personal protection...............................................................................................8
2.5 Informal safety measures......................................................................................9
2.6 Notice of special types of risks............................................................................10
2.6.1 Moving the system..............................................................................................10
2.6.2 Electrical energy / equipment..............................................................................10
2.6.3 Dust, steam, smoke............................................................................................11
2.6.4 Hydraulics, pneumatics.......................................................................................11
2.6.5 Noise................................................................................................................... 12
2.6.6 Oils, greases and other chemical substances.....................................................12
2.7 Safety guidelines.................................................................................................13
2.7.1 Guidelines, standards, directives........................................................................13
2.7.2 Hazardous substances in the waste water processing system............................13
2.7.3 Hazardous substances with regard to the Ordinance on Hazardous Substances14
2.7.4 Substances hazardous to water..........................................................................15
2.8 Safety guidelines when working on pipelines......................................................17
2.9 Accident prevention when working on electric systems.......................................18
2.9.1 Notes on applicable guidelines, standards and regulations.................................18
2.9.2 Fundamentals for working on electric systems according to BGV A 2.................18
2.9.3 Inspection and Maintenance...............................................................................19
2.9.4 First Aid in Electrical Accidents...........................................................................21
2.9.4 Fire Protection....................................................................................................22
2.9.5 Fires and Explosions...........................................................................................22
2.9.6 Inspection and Maintenance..............................................................................22
2.9.7 Instructions on Residual Risks............................................................................23
2.10 Safety Directives for Waste Disposal..................................................................24
2.10.1 Prevention of Waste............................................................................................24
2.10.2 Obligation of Identification...................................................................................24
2.10.3 Obligation for Caution and Supervision...............................................................24
2.10.4 Transport approval for waste...............................................................................24
2.10.5 Transport guidelines............................................................................................25
2.10.6 Further summaries and enhanced safety instructions for the operator.................25
Affix: Brief information for work and hazardous substances..............................................26

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.1 Explanatory notes on Hazard notes

The hazard notes used in the operating instructions serve to signalise possible risk
sources on the system immediately.
The following symbols and signal words listed are included in this documentation:

Danger !
designates an immediate imminent danger.
Death or severe injuries will result if ...

Warning !
designates a possible imminent danger.
Death or severe injuries may result if ...

Attention !
designates a possible dangerous situation.
Minor injuries and / or property damage may result, ...
designates a point or a situation that must be observed to be able to guarantee
Notice !
the trouble-free operation of the system.

Warning against corrosive substances

Warning !
Behaviour:
Working with corrosive substances should only be carried out when wearing
corrosive proof protective clothing and corrosive proof tools or containers (e.g.
bottles, tanks). Unauthorised personnel and people not wearing corrosion proof
protective clothing should not access the place of work.
There is not only a risk of destroying your clothing, but also chemical burns to
your eyes and skin (in fewer cases, also to the mucous membrane).
Chemical burns to eyes may lead to an irreparable damage to your vision.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Warning against poisonous substances

Warning !
Behaviour:
Poisonous hazardous substances should only be handled by such people that
have been assigned for this purpose by the contractor. If the operating
instructions are not observed, this may lead to severe injuries to health or even
to death of the person operating.
Hazardous substances that have poisonous or very poisonous features must
always be stored in closed rooms or cabinets that cannot be accessed by
unauthorised personnel. The requirements and the handling of poisonous
hazardous substances must be limited to daily consumption quantities for one
shift (max. 8 hours).
Store separate to foodstuffs. Observe hygienic measures. Avoid skin contact.
Always consult a doctor with accidents or indisposition.
Warning against dangerous working voltage
Warning !
Behaviour:
In the work rooms marked as so, only those persons are allowed to perform their
work that have the necessary technical expertise (e.g. professional electrician or
those that have been trained in electric engineering) and are in possession of the
necessary assignment from the contractor.
Unauthorised persons are not permitted to access the marked work places or
open the marked cabinets.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.2 Preliminary comments concerning safety guidelines

Your system is a high quality technical product that fulfils your requirements on
safety and reliability even more when you follow and apply our advice for working
safety, operation, care and maintenance work.
The system is fitted with a large number of safety installations, however, injuries to
people and damage to property cannot be exempted that results from improper use
and maintenance.
Always observe the respective safety guidelines, even before beginning with the
commissioning or before starting with maintenance or repair work.
This chapter should also provide you with an overview of the safety guidelines and
recommendations that you require where a brief summary of their contents with
regard to the operation and maintaining of the system.
The guidelines and engineering rules quoted here will be changed or enhanced in
Notice !
respective periods. Such revisions must be observed by the operator themselves.
We do not provide a revision service here.
As long as such changes do not affect the fundamental safety guideline issues, the
respective commercial regulatory authority or testing authority responsible for you
inform you of such changes and if necessary, apply respective requirements.
In case the system should be operated in a country where the guidelines and
standards mentioned above are not valid, the operator is obliged to acquire these
and to enable the operating and maintenance personnel to access them. We then
recommend that these are inserted within this category in the operating
instructions.
Furthermore, the operator is obliged to inform the operating personnel of the
accident prevention guidelines, the proper use of the system, the operating
instructions, about any health risks, behaviour when there is a risk of fire and the
use of fire extinguishing equipment when being hired and at least once a year.
Valid accident prevention guidelines must be observed for all maintenance work.
These are the guidelines of the BGV (Trade Association Ordinance) in Germany.
Access to emergency switches as well as escape routes must be kept clear. All
access doors at the place of installation of the system must be perceived as
escape doors and should not be blocked by devices, containers or other objects.
Special hazard points must be clearly marked using signs. Electric work as well as
weld work should only be carried out by trained professionals.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.3 Safety instructions for certain phases of operation

2.3.1 General
Refrain from all methods of working that contravene to safety regulations!
Meet measures so that the system is only operated in a safe and functional
condition! Only operate the system when all protective equipment and safety
related equipment, such as removable protective installations, Emergency OFF
installations, workroom boundaries, noise insulation equipment, extraction units are
at hand and are functional!
Check the system for external visual damage and defects at least once every shift!
Changes that may have occurred (including the operating conditions) should be
reported to the responsible department / person immediately! If necessary stop and
secure the system immediately!
With malfunctions, stop and secure the system immediately!
Remedy malfunctions immediately.
Do not turn off or remove extraction and ventilation systems when the system is
running!

2.3.2 Commissioning
Observe the starting up and shutting down procedures, running up of the system
and control displays according to the operating instructions!
Before starting up / initiating the system, make sure that nobody can be harmed by
the system starting up.
All staff must be informed about the upcoming movement of the system.
Before the system can be commissioned, all protective installations, limit switches
and other protective measures must be checked for their function and
completeness. A check must be made for possible foreign objects on all parts of
the system
During the commissioning, no person or object is allowed to stay in the vicinity of
the hazard area.
During the initial commissioning, special attention must be made that the correct
system data is entered.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.3.3 Special work in the scope of using the system and repair activities as well as
troubleshooting in the sequence of work; disposal
The setting, maintenance and inspection activities and schedules, including details
for replacing parts / partial equipping specified in the operation instructions must be
observed! These activities should only be carried out by profession members of
staff.
Inform the operating personnel about special and repair work before their
implementation! Specify a supervisor!
With all types of work that effect the operation, the production adaptation, the
refitting or the setting up of the system and its safety related installations as well as
inspections, maintenance and repairs, observe the starting up and shutting down
procedures according to the operating instructions and the instructions for repair
work!
Cordon off the repair area adequately when required!
If the hazard area of the system has to be entered for the purpose of maintenance
and repair work, the safety measures must be equipped (e.g. acknowledgement
switch) so that if an unwanted situation should arise, the system can be shut down.
If the system has to be shut down completely for maintenance and repair work, it
must be secured against accidental reactivation:
Secure the main switch with a padlock
Put a warning sign on the main switch
Motors and certain parts of the system can reach operating temperatures that can
lead to burns. Work carried out on these parts should only be carried out when they
have cooled to an adequate temperature.
Individual parts and large assembly groups must be carefully fixed and secured to
lifting gear when replacing so that no risks can be caused by this. Only use suitable
and technically sound lifting gear as well as load carrying equipment with adequate
carrying capacity! Do not stand underneath or work under suspended loads!
Only experienced personnel should be assigned with slinging loads and instructing
crane drivers! The instructor must be positioned in the field of vision of the operator
or have an intercom.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

With assembly work above head height, always use safety relevant climbing aids
and work platforms intended for this purpose. Never use the parts of the system as
a climbing aid! Wear fall protection equipment when performing maintenance work
at greater heights!
Keep all handles, steps, railings, landings, platforms and ladders free of dirt!
Clean the system and, in particular here, all connections and screw connections
from oil or cleaning agent at the beginning of the maintenance / repairs! Do not use
aggressive cleaning agents! Use fibre free cleaning cloths!
Respective protective clothing must be worn when using operational safety
hazardous substances that have been approved by the department.
Before cleaning the system with water or steam vapour (high pressure cleaner) or
any other cleaning agents, all openings and parts should be covered or sealed
where water, steam or cleaning agents are not allowed to enter because of safety
and / or functional reasons. This especially applies to electric motors and switching
cabinets.
After cleaning, all parts covered / sealed must be completely removed!
After cleaning, inspect all hydraulic oil lines for leaks, loose connections, wear
locations and for damage!
Eliminate faults detected immediately!
With maintenance and repair work, always tighten loosened screw connections.
If safety installations have to be dismantled for setting up, maintenance work or for
repair work, the safety installations must be checked immediately after completing
the maintenance and repair work and the refitting of the safety installations.
Ensure that the operating and auxiliary materials as well as replacement parts are
disposed of environmentally friendly!

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.4 Organisational measures

2.4.1 Safety instructions
Personnel that have been assigned with carrying out the maintenance and repair
work must be vocally instructed about the observance of safety guidelines and
instructions half-yearly and in a written form every two years. This instruction will
be carried out by the operator. Furthermore, instructions should be carried out after
special events or technical modifications.
The personnel should not have their hair open and long, wear baggy cloths or
loose jewellery which includes rings. There is a risk of injuries, e.g. by catching.
Use personal protective clothing when necessary or as required by law!

2.4.2 Personal protection

All people working in hazardous areas of the system marked by safety and hazard
instructions must wear the corresponding protective clothing.
This especially applies to hard hats, goggles, gloves, safety shoes and tight
clothing. The guidelines of the employers liability insurance association should be
additionally observed.
Observe all safety and hazard instructions on the system!
Keep all safety and hazard instructions on the system in a complete and readable
condition!
The colour markings of the hazard areas on the floor as well as those of the signs
must differ considerably from other colour markings within the system in their
shape, colour and implementation.
With safety relevant changes to the system or their operating condition, stop the
system immediately and report the malfunction to the responsible department /
person!
No modifications, attachments or modifications are allowed to be made to the
system without the approval of the manufacturer as these may influence the safety!
This also applies for the installation and setting of safety equipment as well as for
welding work carried out on bearing parts. There is a risk for life and limb, such as
crushing, eye injuries, broken bones as well as severe internal and external
injuries, etc.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Spare parts must conform with the technical requirements specified by the
manufacturer. This is always guaranteed when fitting original spare parts.
Never carry out programme changes (software) to the programmable system
controller!
Replace the hydraulic hose lines within the stated or in adequate periods, even
when no safety relevant defects can be recognised!
Observe the mandatory or specified terms for recurring checks / inspections
specified in the operating instructions!
Familiarise yourselves with locations and use of fire extinguishers!
Observe the possibilities for reporting a fire and for fire fighting!

2.5 Informal safety measures

A copy of the operating instructions should always be stored on the system -
supervisors office.
As an enhancement to the operating instruction, the generally accepted, legally
and other binding regulations for accident prevention and environmental protection
must be observed and instructed!
Such responsibilities can also be related to, e.g. the handling of hazardous
substances or the provision of / wearing of personal protective equipment.
Enhance the operating instructions to include instructions such as the duty of
supervision and obligation to report for considering special operational features
with regard to operational organisation, work sequences and personal applied.
Through respective instructions and checks, the user plant has to guarantee the
cleanliness and the clear arrangement of the work place and the scope of the
system.
The personnel assigned with activities on the system must have read the operating
instructions before starting work - this especially applies to the chapter "Safety". It
is too late after you have started. This especially applies to those personnel that
are occasionally active on the system when, e.g. setting up or maintaining.
Occasionally check the safety and danger awareness of the operating personnel by
observing the operating instructions!

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.6 Notice of special types of risks

2.6.1 Moving the system
All staff must be informed about the upcoming movement of the system.
When possible, only one person should be in the vicinity of the hazard area of the
system and a second person with visual contact outside the hazard area next to an
Emergency Off button.
If several employees are active in the hazard area, they must all have visual
contact with each other.
Components, tools and other objects should not be clamped or lead to short
circuits or fall down resulting from the movement of the system.
Movements that lead to an immediate risk for people or property damage must be
avoided.

2.6.2 Electrical energy / equipment

The system should only be equipped and operated with products where their use
has been approved by the manufacturer.
Only use original fuses with prescribed intensity of current! Immediately switch the
system off at the main switch when disturbances occur with the electrical energy
supply!
Observe all safety and hazard instructions on the electrical equipment!
Electric control rooms must always be kept locked.
All work on the electrical equipment or operating resources should only be carried
out by a certified electrician or by trained personnel under supervision and
monitoring of a certified electrician using the electro-technical regulations.
The penetration of dirt and moisture into electric control rooms (e.g. swarf, water,
dust) must be prevented in all cases. In special cases, the cabinet and the system
must be covered and before being commissioned again, checked according to the
valid VDE- guidelines.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.6.3 Dust, steam, smoke

Welding, burning and grinding work on the system should only be carried out when
this has been expressly approved, e.g. risk of fire!
Before carrying out welding, burning and grinding work, clean the area around the
system from dust and combustible substances and ensure for adequate ventilation
during the work!
When working in enclosed rooms, when necessary, observe the national
guidelines!
When working where dust may develop, care should be taken that the switching
cabinet remains closed.

2.6.4 Hydraulics, pneumatics

Work performed on the hydraulic equipment should only be carried out by
personnel that have special knowledge and experience of hydraulics.
After switching off, the energy still stored must be considered. Before repairing,
bleed the line! If necessary, remove the potential energy - UW 10 17.
Check all lines, hoses and screw connections for leaks and externally visible
damage on a regular basis! Repair damage immediately! Oil spraying out may lead
to injuries and burns.
Depressurise the system sections and pressure lines (hydraulic, compressed air) to
be opened before beginning with the repair work according to the assembly group
description!
The hydraulic and compressed air lines must be routed professionally and should
be protected against damage! Do not mistake the connections! Fittings, length and
quality of the hose lines must correspond with the requirements and be approved
by the manufacturer.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.6.5 Noise
Existing sound insulation installations must be positioned in their protective position
on the system during operation.

Personal ear protection should be worn where prescribed!

When working on system parts (e.g. ventilators and pumps) where their operating
noise has a noise level > 75 dB , ear protection must be worn.

2.6.6 Oils, greases and other chemical substances

When dealing with oils, greases and other chemical substances, the applicable
safety guidelines and work safety that apply for the product and the measures
specified by the operational safety must be observed!
Take care when dealing with hot operating and auxiliary substances (risk of burning
or scalding)!

When disposing of the substances listed, the Water Resources Act for liquids
endangering a body of water must be observed.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.7 Safety guidelines

2.7.1 Guidelines, standards, directives
EC Machine Directive 89/392/EC and its revisions 91/ 368/EC und 93/44/EEC;
DIN EN 292-1 and 292-2 Machine Safety;
Low Voltage Directive 73/23/EEC;
DIN EN 60204-1 : 1997-12 Electrical equipment of machines;
DIN EN 23746 Acoustics - Determination of sound power levels of noise sources;
DIN EN 31202 Acoustics - Noise emitted by machinery;
Water Resources Act; Ordinance on Hazardous Substances;
Ordinance for workplaces; Workplace guidelines;
Data sheet "Guidelines for the operating and behaviour for storing substances
hazardous to water"
"Rules for the use of protective clothing" ZH 1/700 and the following.

2.7.2 Hazardous substances in the waste water processing system

General Information
Most operating materials processed in waste water processing systems are
harmful to humans and the environment.
The system operator is responsible for informing themselves about the risks
resulting from operating materials used and the respective valid accident protection
guidelines and safety regulations and for their adherence.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.7.3 Hazardous substances with regard to the Ordinance on Hazardous Substances

If hazardous substances are used in the system with regard to the Ordinance on
Hazardous Substances (German - GefStoffV) / Working Material Regulation
(ArbStoffV), these relevant guidelines of this directive must be observed.
This especially applies to:
1. Obligation to label the containers, tanks and lines (this also applies to containers
that are used in-house),
2. Observation of risk instructions (R-Phrases) and safety guidelines (S-Phrases),
3. Generation and design of operating instructions in a way and language that can
e understood by the employees. This means that the instructions must be
translated into the country language when applying foreign employees.

The Ordinance on Hazardous Substances (Working Material Regulation) does not

include all hazardous substances. There may also be a risk to health resulting from
substances where there is no obligation to label according to this ordinance. For this
purpose, it is necessary to check all working materials used for possible hazardous or
for features posing a risk to health before they are used and, if necessary, also apply
the guidelines of the Ordinance on Hazardous Substances for these substances as
well.

See also safety data sheets of the chemical producers / suppliers.

The operating instructions for the waste water processing systems must be
observed with great care!
When safety and / or protective equipment is removed or not used, risks may occur
from or to the waste water processing system.
Misuse of the waste water processing system is forbidden.

Measures should be met so that the potential of energy (liquids and or compressed
air and / or electric energy) are not at hand on the units during service interruptions
and / or downtimes of the waste water processing system.

Due to these risks that may result when contact with / or by breathing in of
substances, gases and vapours that are a risk to health, it is necessary to wear
personnel protective equipment.

The recommendations of the manufacturer must be observed!

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.7.4 Substances hazardous to water

A large proportion of the substances used in the waste water processing system
are substances hazardous to water with regard to the Water Resources Act.
The operator of systems where liquid substances that are hazardous to water are
stored must place the data sheet "Guidelines for the operating and behaviour for
storing substances hazardous to water" at a permanent location near to the system
where it can be clearly seen and instruct the operating personnel of its contents.
Systems where substances that are hazardous to water are stored or processed
must be maintained or operated so that the contamination of surface water and
ground water is not possible.

Containers with liquid substances hazardous to water must be provided with a

labelling that can be clearly read and designates which material is stored in or can
be filled into the container.

Before filling a container with a liquid substance that is hazardous to water, a check
should be made as to how much liquid the container can store and is all safety
installations are at hand, are functional and have been correctly set.
When filling and emptying the containers for liquid substance that are hazardous to
water, the pipes and hoses used must be connected with each other sealed tight
and leak-free. Movable lines must be able to be viewed across their entire length
and should be illuminated under dark conditions.

Safety equipment, such as the overfilling of the containers must be continuously

effective.

Maintenance work, cleaning and repairs to the system where substances that are
hazardous to water are processed or stored should only be performed by specialist
businesses that fulfil the guidelines determined in 19 EEC.

The cleaning of remaining residues and waste mixed with storage liquids must be
collected and disposed of so that the bodies of water are not subsequently
negatively modified in their physical or biological features.

With systems that are subject to mandatory testing for storing liquids hazardous to
water, the operator is responsible for the due implementation of the statutory
inspections by a technical expert.

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Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

If there is a risk that water could be endangered or contaminated in the event of

damage or resulting from operational malfunction, the system must be
decommissioned and emptied immediately.

A risk to waterbodies applies when a significant quantity of a liquid substances

hazardous to water escapes to a surface waterbody and enters a waste water
processing system (drainage system, sewage plants) contrary to normal conditions
or has leaked into the ground or when the system is suspected to have a leak.

In such cases, the respective responsible authorities or the next police

station must be notified by telephone immediately.

The system operator is responsible for the notification as well as all of those
persons assigned with filling, emptying, repairing, cleaning, monitoring and
checking the system as well as those that are responsible for the substances
hazardous to water escaping from the system

The Ordinance on Hazardous Substances commits the owner to create

operating instructions where the handling of risks resulting from hazardous
substances that are a risk for humans and the environment as well as the
respective protective measures and rules are determined. When the
documents provided by the the manufacturer / supplier are incomplete,
depending on the requirements, these must be enhanced by the operation
related enhancements and processed in a way and language that can be
understood by the employees. This may mean that it has to be translated
into a foreign language.

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.8 Safety guidelines when working on pipelines

Work carried out on pipelines, fittings and units that transport or contain hot liquids
or steam should only be performed when the heating system has been switched off
and the lines or the unit have cooled down completely and are depressurised.
The shut-off valve in front of and behind the line part or unit affected must be
closed and adequately secured against unauthorised or accidental opening during
the period where the work is being performed. When possible, the contents of the
lines or units must be drained.

The Pressure Vessels Regulation DK 621.642-986 must be observed.

Notice ! A control valve is not a shut-off device!

It is not sufficient that the control valve fitted in the hot water or steam line is closed
for shutting down the heating system. The main hand shut-off valve must be closed
in this line.
The same applies to work carried out on pipelines, fittings and units that supply
aggressive substances such as acids or leach. Before commencing work on these
pipelines and units here, they must be emptied in a suitable manner. When doing
so, protective clothing must be worn and the respective guidelines concerning the
handling of acids and leach must be observed. Residues of acids or leach must be
removed by rinsing thoroughly with water. Special regulations that exist for certain
units or systems must be observed.

High temperatures should not be applied to plastic lines and other parts made of
plastic.
The permissible highest temperature must be observed for the respective material.

P LAS T I C P R O C E S S I N G
With repair and maintenance work
Connecting PVC hard with PVC soft is not permitted.
(Example: Soft PVC flat seals between hard PVC flanges)
Plasticiser diffuse into PVC hard and embrittle the material.
Result: Stress cracking
Observe the DIN and manufacturer guidelines

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Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.9 Accident prevention when working on electric systems

2.9.1 Notes on applicable guidelines, standards and regulations
The accident prevention guidelines (German BGV A 2), the VDE guideline VDE
0100 as well as the regulations of the responsible authorities must be observed
when carrying out operating and maintenance work to electric systems.

2.9.2 Fundamentals for working on electric systems according to BGV A 2

"The operator must ensure that the electric system and operating equipment are
only set up, modified and repaired by a certified electrician or by trained personnel
under supervision and monitoring of a certified electrician using the electro-
technical regulations. Furthermore, the operator must ensure that the electric
system and operating equipment are operated according to the electro-technical
regulations."
"If a fault has been detected on an electric system or electric operating equipment,
therefore, does not or no longer corresponds with the electro-technical regulations,
the operator has to ensure that the fault is eliminated immediately. In case an
immediate risk arises, make sure that the defective electric system or the electric
operating equipment is no longer used."
"Electric systems and operating equipment must have a safe condition and must
be kept in this safe condition."
"Electric systems and operating equipment should only be used when they comply
with the operational and local safety requirements with regard to the operating
mode and environmental influences."
"The active parts of the electric system and operating equipment must correspond
with their voltage, frequency, usage category and their operating location be
protected against direct contact using insulation, position, arrangement or fixed
installed equipment."
"Electric systems and operating equipment must be constructed so that during
working and handling activities, where, due to imperative reasons, the protection
against direct contact according to paragraph 4 must be cancelled or made invalid,
- the voltage-free condition of the active parts can be established and secured or
- the active parts can be protected against direct contact through additional
measures when considering the voltage, frequency, category of usage and the
operating location."

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Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.9.3 Inspection and Maintenance

Electrical systems and fixed electrical production equipment must be inspected for
its correct function before the initial commissioning and after each modification and
maintenance, however at least every 4 years by a professional electrician.
Malfunctions must be eliminated immediately.
All parts of the machines and system where inspection, maintenance work or
Warning !
repair work should be carried out must be switched voltage free. First the parts
switched voltage free should be tested, then ground and short-circuit as well as
isolate the adjacent parts with the voltage turned on.
Working at electrical systems under voltage is not allowed. The UVV 7.0 8
Warning !
regulates special cases if the voltage-free condition cannot be produced due to
exigent grounds. Thus, personal protective equipment and insulating tools as
well as insulating parts covered must be used. Do not work alone!

The electrical equipment of a system is to be inspected / checked regularly.

Defects, such as loose connections, worn insulation or heat-damaged cabling,
must be removed immediately.
When working on high-voltage construction groups, after releasing the voltage,
connect the supply cable to the earth and the components, e.g. condensers, short-
circuit with an earthing rod. Follow the instructions of the equipment manufacturer.
During the installation of the unit control, it may not be welded in the immediate
vicinity of the open switching cabinet (open EPROMs) since the contents of the
EPROMs are destroyed by UV irradiation.
The power should always be switched off during the modifications and repairs to
Warning !
electrical systems. Furthermore, arrangements must be made that unauthorised
persons cannot switch on the power back on again. This is particularly important
if the repair location and the main switch or the fuse are spatially separated from
one another. This is particularly applicable when connecting the solenoid valve
or for the rear connections of the measuring tools if a switching cabinet is open.
Warning ! Work on electrical systems with the voltage turned on is not allowed. The system
must be switched to voltage free and secured against being switched back on
before carrying out the maintenance and repairs work.

The voltage-free condition of an electrical system is achieved by the following

safety measures:
- Releasing
- Securing against reactivation
- Establishing the voltage free condition
- Earthing and short-circuiting
- Covering or cordoning off adjacent parts with the voltage turned on.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Despite of all precautions, if an accident should occur, observe

the following steps:

1.) The electric circuit is to be interrupted by switching off, pulling the plug and
socket or device or removing the fuses. If the current cannot be interrupted
immediately, the person affected should be separated from the parts with the
voltage turned on by means of a non-conducting object or removed by using his
/ her clothes.
The assistant may never resort to electrically conducting objects.
2.) Do not touch the person affected and metal parts or conducting floor (stone
floor) at the same time. (Use the insulating mat)
3.) When there is respiratory arrest, immediately carry out resuscitation at the site
and location (do not remove clothing). Due to the large breathing need, do not
wait for the ventilators, but rather start immediately with the respiration. The first
few minutes are especially important.
4.) The most minor accident caused by electrical current must also be taken
seriously. If after a short time, the injured person also often apparently recovers,
he must nevertheless undergo medical treatment. Toxic substances, which are
likely to lead to severe liver damage, are formed by burned body cells.
Therefore, drink as much water or milk as possible.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.9.4 First Aid in Electrical Accidents

Finding a person

Observing and registering the With power failures

situation Measures for Turn off low voltage
guaranteeing personal safety Remove plug
High voltage: Maintain distance,
Inform professionals to
Turn off
Determining the state of awareness
(loud) response / touch

Not responsive
Responsive Emergency Call for help
Shake on the shoulder

Assistance when
necessary (e.g. Check for breathing, if necessary
Shock containment) free the respiratory path

Breat at hand No breath

Check pulse (on the neck)

Stable recovery position
(continually check for
consciousness, breathing
and circulation)

Pulse at hand Pulse not at hand

mouth to mouth resuscitation heart-lung

resuscitation

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.9.4 Fire Protection

In the installation room of the plant, supply sufficient numbers of visibly and
officially approved suitable hand-held fire extinguishers at readily accessible sites
with less hazards.
In addition, accessories for the extinguishing of fires on clothing of persons, e.g.
extinguishing blankets, are provided at suitable locations. The extinguishing
blankets are protected from contamination of any kind.
All access doors at the place of installation of the plant or plant doors are perceived
as escape doors and should not be blocked by devices, containers or other
objects.

2.9.5 Fires and Explosions

The company must register any fire and any explosion at the system to the
professional association and competent trade control office, even if no personnel
injury occurred.

2.9.6 Inspection and Maintenance

The efficiency of the safety, measurement and control devices is inspected at least
annually. Malfunctions must be eliminated immediately.
Written proof of inspections and maintenances must be conducted.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.9.7 Instructions on Residual Risks

When working with chemicals, the instructions of the manufacturer must be followed. The
manufacturer is responsible to apply corresponding warning and processing instructions for
good visibility and legibility in the language of the country, in which the product is used to, to the
package or container. If protective clothing should be necessary, these must be provided by the
operator and worn. The operator is obliged to observe that the statutory safety and protective
measures are observed.

In inappropriate operations, maintenance or repairs of the system, injuries to

Attention ! personnel and damage to property cannot be excluded.
Therefore, the system operator is obliged to inform the operating personnel of the
accident prevention guidelines, the proper use of the system, the operating
instructions, about any health risks, behaviour in extraordinary incidents, e.g. in
the case of of fire at least once a year before and after the hiring.
Persons under 18 may not operate the system.

The personnel must continue at a safety-conscious work.

As there is a particularly high risk of severe accidents when the work on electrical systems and
production materials, work of any kind at electrical installations may only be conducted by
electricians or under the supervision of an electrical technician.
Before beginning work on electrical installations or within the vicinity of electrical installations,
which are insecure against any contact, the respective installation is to be switched voltagefree.
In addition, it is to be ascertained that the voltage cannot be switched back on by third parties
during the duration of the work.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.10 Safety Directives for Waste Disposal

Chemicals that can be applied are no longer part of waste. Their disposal is, therefore, not
suited in accordance with the chemical legislation, but rather according to the respective
disposal directives of the waste legislation and the supplementary legal ordinances.
The waste legislation differentiates between waste water and waste ( 1 paragraph 3 No. 5):
"If substances are introduced into a body of water or waste water processing system, the waste
legislation does not apply, but rather the water law. A specification concerning this can be
obtained in the Technical Details-Waste, Appendix C, Section I: "Substances, which are
predominantly aqueous, for example: rinsing and processed water".
According to the Waste Legislation ( 1 Paragraph 1) wastes are mobile objects,
which the owner wishes to dispose of: subjective waste concepts or
their organised disposal for the welfare of the community, in particular environmental protection,
which is offered : objective waste concepts (also called forced waste).

2.10.1 Prevention of Waste

The utmost goal of the Waste Legislation is measures for the prevention and utilisation of waste.
In addition, the Waste Legislation also intervenes in the operation of a production process, in
which the Federal Immission Control Act is referred to. This mentions a three-fold graduated
responsibility hierarchy.
In this, the uppermost duty of the operators of plants requiring approval is
prevention,
use of preventable residues and
disposal without affecting the welfare of the community.

2.10.2 Obligation of Identification

The following duties and prohibitions are individually formulated:
Obligation of identification
Obligation for separate disposal (commixture prohibition),
Reduction and pledge duty,
Production and application restrictions for certain products.
For example, the obligation of identification is specified by the following ordinances:
Ordinance concerning the disposal of consumed halogenated solvents (HKWAbV),
Ordinance on Hazardous Substances;
CFC halon ban regulation,
Technical regulations for hazardous substances (TRGS 201).

2.10.3 Obligation for Caution and Supervision

The owner or producer of waste rejects is fundamentally responsible for the waste until the
waste was definitively and environmentally compatible evaluated and / or removed. He must
enquire assiduously whether the company considered is actually able of the waste disposal
offered.

2.10.4 Transport approval for waste

A transport approval must be provided for the transportation of waste refuse
(12 Section 1 AbfG).
If the owner transports the waste by themselves, they require an official transport approval or an
exemption provided by the responsible authorities.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

2.10.5 Transport guidelines

After the assembly of the system and its auxiliary devices, normally no more system parts need
to be transported. This is why the required assembly / disassembly instructions for such
complete systems are not included in this operating instruction.

If it should be necessary to relocate a part of the system or an auxiliary device for whichever
reason, contact should be established with the manufacturer.

We recommend that the customer services of the manufacturer is assigned with such work.

2.10.6 Further summaries and enhanced safety instructions for the operator
Legislations, guidelines and regulations for the accident prevention together with the operation
of the system must be observed.

They are not included in the scope of the existing operating instructions.

General Information:
Access to emergency switches as well as escape routes must be kept clear at all times.
Special hazard areas must be marked using respective warning signs.
Safety equipment and electric safety locking mechanisms should not be modified or
deactivated. Their trouble-free function must be checked on a regular basis.
The system is not allowed to be operated If defects are detected on the safety equipment, until
these have been eliminated.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Affix: Brief information for work and hazardous substances

Highly flammable liquid substances (solvents, thinner) general
Possible container
markings

Guidelines for Only use explosion protected devices.

behaviour when Make sure the room has adequate ventilation.
handling the Earth when filling the container.
substances
Keep the container sealed tight.
Do not breath in vapours.
Do not eat or drink in work or storage rooms.
Avoid contact with skin, eyes or clothing.
Clean your skin only with specified materials.
Use skin protection substances.
Leaking liquids should not run into the drainage system!
Personal Safety shoe with antistatic sole.
protective Work clothing made of chemical resistant material.
equipment Leakproof protective goggles and suitable protective gloves.
Respirator mask with suitable filter.
Workplace
markings

First Aid After contact to skin Rinse with plenty of water. If necessary, apply a
loose bandage
After eyecontact Rinse for several minutes with your eye opened
wide.
Visit an eye specialist
After swallowing Drink a lot (no milk, no alcohol). Avoid vomiting!
After breathing in Ensure the provision of fresh air.

Further information should be obtained from the safety data sheets of the chemical
manufacturer or chemical supplier. The details in the safety data sheets have priority compared
to the existing brief information.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Substances that are harmful to health and are poisonous (solid state) general

Possible container
markings

Guidelines for Keep workplace clean.

behaviour when Use skin protection substances.
handling the Observe special measures for cancer causing substances.
substances
Do not eat or drink in work or storage rooms.
Keep the container sealed tight.
Avoid spilling and collecting dust when filling or refilling.
When mixing substances, follow the specified sequence and dosing.
Dispose of spilled and remaining substances according to the
regulations.
Avoid contact with skin, eyes or clothing.
Observe the R & S Phrases.
Personal Safety shoe with antistatic sole.
protective Work clothing made of chemical resistant material.
equipment Leakproof full protective goggles and suitable protective gloves.
Respirator mask with suitable dust or combination filter.
Workplace
markings

First Aid After contact to skin Immediately wash dust away with lots of
water.
After eyecontact Rinse for several minutes with your eye
opened wide.
Visit an eye specialist
After swallowing Drink a lot (no milk, no alcohol). Cause
vomiting!
After breathing in Fresh air supply. Visit a doctor.

Further information should be obtained from the safety data sheets of the chemical
manufacturer or chemical supplier. The details in the safety data sheets have priority compared
to the existing brief information.

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 WILMS GMBH
Abwasseranlagen und
Wilms GmbH Otto-Hahn-Str.26 D-59423 Unna Oberflchentechnik

Corrosive substances (acids, leach) general

Possible container
markings

Guidelines for Keep workplace clean.

behaviour when Do not breath in vapours.
handling the Keep the container closed.
substances
Use a balloon tipper, pump or lifter for emptying or refilling. Never
suck-on using your mouth!
Do not eat or drink in work or storage rooms.
Use skin protection substances.
Only use intended acid or leach-proof containers..
Avoid spilling and unnecessary evaporating when filling or refilling.
Wash moistened clothing immediately.
Personal Protective boots (do not wear leather shoes!)
protective
Work clothing made of chemical resistant material.
equipment
Leakproof full protective goggles or face protection mask,
Suitable protective gloves, respirator mask with suitable filter.
Workplace
markings

First Aid After contact to skin Rinse with plenty of water. If necessary, apply a
loose bandage
After eyecontact Rinse for several minutes with your eye opened
wide.
Visit an eye specialist
After swallowing Drink a lot (no milk, no alcohol). Avoid vomiting!
Visit a doctor.
After breathing in Fresh air supply. Visit a doctor.

Further information should be obtained from the safety data sheets of the chemical
manufacturer or chemical supplier. The details in the safety data sheets have
priority compared to the existing brief information.

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