EPCM PROJECT 5067: CONFIDENTIAL TO MARCOBRE S.A.C.

, Mina Justa

SAFETY

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1.1 SAFETY CONSIDERATIONS FOR THE USE OF THIS EQUIPMENT

The following safety guidelines must be read and understood prior to any
operation or performance of maintenance on this system.

SAFETY PROCEDURES DRAWINGS – CATHODE STRIPPING SYSTEM

The following safety drawings are located at the end of this section:

5067-E-00003-001 – Power Distribution Control

5067-E-00002-001 – HP Power Distribution- Robot & VFD’S
5067-E-00002-002 –HP Power Distribution – Safety Switched Small HP Motors
5067-E-00002-004 – 24VDC Distribution - Internal
5067-E-00002-005 – 24 VDC Distribution – Stations and Remote I/O
5067-E-00002-008 – Safety and internal I/O Rock - Arrangement
5067-E-00002-009 – Safety and Internal I/O Rock Communication Module Connection
5067-E-00002-010 –Safety Input Module #1 – Estop and Safely Solenoids
5067-E-00002-011 – Safety Output Module #2 – MCR’s
5067-E-00002-012- Safety Output Module #3 – Safety Solenoids and Contactors
5067-E-00002-013- Input Module #4 –MCR’s and Safety Contactors
5067-E-00002-014 - Input Module #5 – HPU Control and OCC devices
5067-E-50000-002 - Safety and Internal I/O Rock - Arrangement
5067-E-50000-003 - Field Safety and I/O Rock – Communication Module Connection
5067-E-50000-004- Safety Input – Module #1 Safety Circuit
5067-E-50000-005- Safety Input – Module #2 Light Curtains
5067-E-50000-008 – Safety Input – Module #5 Entry Gates
5067-E-50000-009 - Safety Output – Module #6 Entry Gates and Beacon Lights
5067-E-50000-010 – Safety Device Connections – Entry Gates

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MACHINE OPERATION AND MAINTENANCE

 Personnel should not attempt to operate or maintain the Cathode Washing and Stripping System
or its related equipment without proper understanding of this manual, all plant and tankhouse
safety codes and local governmental regulations relating to Occupational Health and Safety.

 Never open or work on any part of the machine without first turning off and locking out power
per the plant procedure.

 Safety fences are installed around the mechanical moving components. Never enter these fenced
areas during normal system production operation.

 Never start any maintenance procedure requiring the use of the maintenance platforms without
ensuring the associated platforms are clear of all obstacles and handrails are secure.

Never attempt to service or inspect these systems unless you are in a secure and safe working
position.

See Electrical Drawings, for electrical safety devices used on this system.

DO NOT SERVICE OR ADJUST ALONE

 Under no circumstances should one person reach into or enter any enclosure area beyond the
machinery casework or any area beyond that of normal operator boundaries for the purpose of
servicing or adjusting the equipment.

Entry into the machine area for servicing must be made in the presence of someone who is also
authorized to do so and capable of rendering first aid.

MACHINE SAFETY PROCEDURES

 The following general safety precautions (items 1.2 through 1.5) are not related to any specific
procedure and therefore do not appear elsewhere in this manual. These are recommended
precautions that personnel must understand and apply during the many phases of operation and
maintenance.

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1.2 MECHANICAL SAFETY

The following safety guidelines must be read and understood prior to any
operation or performance of maintenance on this system.

HEAVY EQUIPMENT FALLING HAZARD

 Ensure that all personnel wear appropriate protective clothing, for example, safety shoes, hard
hats, eye protection, etc.
 Beware of area vehicle traffic and loads on overhead cranes or lifting devices.

Some components of the Cathode Washing and Stripping System may have been designed with
allowance for Lock Pins or Mechanisms. These devices must be designed for blocking moving or
suspended machine components while performing maintenance or adjustments. Such pins or
mechanisms are no substitute for proper lock out procedures. They must be designed only to prevent
component movement after hydraulic, pneumatic or electric energy sources have been removed by
proper lock out procedure. Appropriate redundant controls/measures must be in place to ensure the
locking devices are removed prior to starting the machine. In general, all equipment should be
independently secured to support the load when Operational or Maintenance personnel are working
in the vicinity.

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ROTATING AND MOVING EQUIPMENT

 Exercise extreme caution in the area of this equipment while it is in operation. Never step into
the area of operation of any of the robots during operation. Death or severe injury may result if
personnel fail to observe safety precautions.

 Ensure a minimum level lockout procedure is followed prior to entering the robot area. Ensure that
the proper lockout procedure is followed before starting any inspection and/or service.

Refer to the Field Lock-Out Procedures in Section 1.5.

Lock out power before removing any equipment cover guards, access
doors or covers. Failure to follow these instructions
may result in personal injury or property damage.

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1.3 ELECTRICAL SAFETY

The following safety guidelines must be read and understood prior to any
operation or performance of maintenance on this system.

V LETHAL VOLTAGE

Lethal Voltage is used in the operation of this equipment. Death or severe injury may result if
personnel fail to observe safety precautions.

Ensure that the lockout procedure is followed before starting inspection

and/or service on electrical components, cabinets and junction boxes.
This includes signal voltages and control circuits as well as power
distribution.

KEEP AWAY FROM LIVE CIRCUITS

 Operating and maintenance personnel must always observe all electrical safety regulations. Do
not replace components or make adjustments inside the equipment with high voltage supply
turned on. To avoid casualties always remove power and discharge the circuit to ground before
touching it.

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L ATTENTION

To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before
performing any work on any variable frequency drive. Measure the DC voltage on the +DC bus
terminal at the power terminal block and the –DC test point. The voltage must be zero. Refer to the
variable frequency drive user manual for test point locations.

RESUSCITATION

 Personnel working with or near high voltages should be familiar with modern methods of
resuscitation. Such information may be obtained from the Plant Safety Officer or the local
Occupational Health and Safety Agency.

COMMUNICATIONS EQUIPMENT

 Portable communication devices such as hand-held two-way radios emit RF signals. The strength
of this signal may be enough to trigger proximity devices and cause unpredictable operation of
logical devices such as computers, PLC equipment, including remote racks, etc. The likelihood of
this occurring is proportional to the strength of the transmitter and the distance to the device

As a general rule, these devices should never be ‘keyed’ near to

such equipment, especially during operation

 Further information and operational guidelines may be obtained from the Plant safety Officer.

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L ATTENTION – LASER RADIATION

There are optoelectronic devices used in this system that are sources of IEC class 1 and 2 laser
radiation. The sensors are marked with the following labels:

Class 1: No Risk to Eyes or Skin 1

These laser products pose no risk to eyes or skin under normal operations and conditions, including
instances when users view the beam directly with optics that could concentrate the output into the
eye.

Class 2: Low Risk to Eyes, No Risk to Skin2

These products emit light that poses very little risk to the human eye, even when viewing the beam
directly with optics that could concentrate the output into the eye. The eye’s natural aversion
response to bright light prevents injury to the eye. However, these lasers do pose a dazzle hazard.

Details about the devices that emit laser radiation can be found in section 3-Installation, Setup and
Adjustment.

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1.4 HYDRAULIC SAFETY

The following safety guidelines must be read and understood

prior to any operation or performance of maintenance on this
system.

HYDRAULIC FLUID UNDER PRESSURE

 Death or severe injury may result from personnel failing to observe safety precautions. Never
check for leaks by running hand over hose or hydraulic connections. A pinhole leak can be almost
invisible and can pierce the skin into the body. Even if no pain is felt, a serious emergency exists.
Obtain medical assistance immediately to prevent loss of limb.
 Perform proper lockout procedures before servicing or adjusting. Refer to Section 1.5.
 Always relieve residual pressure on hydraulic cylinders, lines and other devices before performing
maintenance or before trying to clear a jam.
 Be careful to relieve residual pressure in a controlled manner on any hydraulic cylinders, actuators
and other devices supporting overhead loads.

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 Hydraulic pressure test points are sealed with a protective screw thread cap. To prevent possible
contamination to hydraulic fluid, clean the area surrounding the test point before removing cap
and ensure the cap is screwed back into place after use.

It is hazardous to ship or relocate the HPU without first removing the tank
oil and properly discharging any accumulator pressure, if applicable.

PNEUMATIC SAFETY

The following safety guidelines must be read and understood

prior to any operation or performance of maintenance on this
system.

AIR UNDER PRESSURE

 Death or severe injury may result from personnel failing to observe safety precautions in high-
pressure systems. Never place an exposed hand or any other part of the body to air under
pressure.

 Always bleed the air pressure on pneumatic cylinders before performing maintenance or trying
to clear an abnormal condition. Ensure system air pressure is relieved in a controlled manner.

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1.5 LOCK-OUT PROCEDURES

The safety precautions outlined in the following drawing (located at the end of this section) must be
adhered to when clearing, adjusting, or maintaining any of this equipment :

50000-000/001 Cathode Stripping System - Safety Concept Drawing

A minimum level lockout procedure must be performed to allow

safe access to the machinery for service purposes. Check with
the Plant Safety Officer for the specific procedures required at
this plant.

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