The Safe Start-Up of Plant, Machinery, and Equipment After a Shut-Down Period

Understanding the Risks of Restarting Equipment

During shut-down periods, machinery and equipment are often left idle, which can result in:

• Deterioration: Components may degrade due to moisture, dust accumulation, or corrosion.
• System Failure: Electrical systems, software, or hydraulic components may fail to restart correctly.
• Operational Hazards: Employees may be unfamiliar with start-up procedures or new risks introduced by maintenance work.

A thorough start-up plan mitigates these risks and ensures compliance with health and safety legislation.

Legal and Regulatory Requirements

The safe operation of machinery and equipment is governed by UK legislation and standards, including:

• Health and Safety at Work etc. Act 1974 (HSWA):

Employers are required to ensure the health, safety, and welfare of their employees and others who may be affected by their operations. This includes implementing safe systems of work for restarting machinery and equipment.

• Provision and Use of Work Equipment Regulations 1998 (PUWER):

PUWER mandates that all equipment provided for use at work is safe, suitable, and properly maintained. Regulation 6 specifically requires that equipment is inspected after assembly, before use in situations where safety depends on installation conditions or where significant changes have been made (i.e. major modifications, refurbishment or repair work).

• Electricity at Work Regulations 1989:

These regulations require electrical systems to be maintained in a safe condition. Restarting electrical equipment after a shut-down necessitates checks to ensure no damage or faults have occurred.

Key Steps for a Safe Start-Up

1. Pre-Start-Up Planning

Effective preparation ensures a smooth and safe restart. Key tasks include:

• Reviewing Maintenance Records: Ensure that all maintenance performed during the shut-down has been completed, documented, and verified.
• Risk Assessment: Conduct a new risk assessment to identify any hazards introduced during the shut-down. Under the Management of Health and Safety at Work Regulations 1999, risk assessments must be reviewed and updated as necessary.
• Communication: Provide employees with a detailed briefing on start-up procedures, including potential hazards and safety measures.

2. Inspecting and Testing Equipment

Prior to restarting machinery, thorough inspections and tests should be carried out:

• Visual Inspections: Check for signs of damage, corrosion, or wear. Look for leaks, misalignments, or any changes in the physical condition of equipment.
• Functional Testing: Test safety systems, such as emergency stops, interlocks, and alarms, to ensure they operate correctly.
• Electrical Testing: Inspect electrical systems for signs of insulation damage, loose connections, or moisture ingress. Portable appliance testing (PAT) may also be required for certain equipment.

3. Ensuring Safe Isolation

Verify that all isolation procedures, such as lock-out/tag-out (LOTO), have been correctly removed. HSE’s HSG253 provides detailed guidance on safe isolation, emphasising the importance of removing all energy sources before reactivating equipment.

4. Sequential Start-Up Procedures

Restart equipment in a controlled sequence:

• Individual Component Testing: Start individual systems or components separately to verify functionality before integrating them into the overall system.
• Gradual Loading: Apply loads gradually to avoid overloading equipment or causing sudden mechanical stress.

5. Verifying Environmental Conditions

Ensure the working environment is safe for start-up:

• Ventilation: Confirm that ventilation systems are operational, especially if the equipment produces fumes or dust.
• Temperature and Humidity: Check environmental conditions to ensure they are within the equipment’s operational parameters.

6. Training and Competence

Employers must ensure that all personnel involved in the start-up are competent and adequately trained. This includes:

• Specific Start-Up Training: Training on the specific machinery being restarted, covering hazards, safety features, and operational controls.
• Emergency Procedures: Familiarise employees with emergency stop procedures, fire safety protocols, and evacuation plans.

Best Practices for Safe Start-Up

1. Develop a Start-Up Checklist

A detailed checklist ensures that no critical steps are overlooked. Items to include:

• Confirmation of maintenance completion.
• Inspection and testing records.
• Verification of safe isolation procedures.
• Environmental condition checks.

2. Communicate Effectively

Clear communication is vital to ensure everyone involved understands their roles and responsibilities. Use daily briefings, signage, and written procedures to keep teams informed.

3. Engage Third-Party Specialists

For complex equipment, consider engaging specialists to assist with inspections and start-up. For example, liaison with a Finch Consulting engineer to ensure compliance with

relevant British Standards requirements and provision of reassurance that the correct controls and mitigation measures are in place.

Post-Start-Up Monitoring

The start-up process does not end once equipment is running. Continuous monitoring is essential to identify any issues that may arise:

• Initial Performance Checks: Monitor equipment closely during initial operation for unusual noises, vibrations, or performance deviations.
• Feedback from Operators: Encourage operators to report any concerns or abnormalities immediately.
• Follow-Up Inspections: Conduct a follow-up inspection after a defined period to verify equipment condition and performance.

In summary

Restarting plant, machinery, and equipment after a shut-down period requires meticulous planning, adherence to legal requirements, and the implementation of best practices. By prioritising inspections, safe isolation, and sequential start-up procedures, organisations can minimise risks and ensure a smooth transition back to operations. Compliance with UK legislation and standards, coupled with a culture of safety, protects employees, equipment, and productivity. Taking a proactive strategy towards start-up, not only ensures the safety of your people, plant and processes, but also minimises downtime, allowing you to meet your production targets for January.