Above all, maintenance work in electroplating must be carried out safely. The priority is not to endanger employees. In addition, regular maintenance contributes to the longevity of the systems and protects against production downtime.
In electroplating, as in many trades, regular maintenance measures are an essential component. The main aim here is to ensure the best possible operational safety and minimize health risks for employees. Basically, maintenance also includes the inspection, servicing and repair of systems and components, whereby various hazards for those responsible must be taken into account. Sources of danger such as falls from heights, contact with corrosive chemicals or injuries caused by mechanical system components require comprehensive protective measures. Experts differentiate between technical protective measures, personal protective equipment (PPE) and organizational requirements.
Prevention in practice
Regular inspections and maintenance work on safety-relevant components such as aircraft engines are particularly important (Photo: santima/stock.adobe.com)For all work in this area, the risk assessment forms the basis for all further measures. Before maintenance work is carried out, it is important to ensure that those responsible are aware of all the risks for employees and contractors and minimize them accordingly. Technical safety precautions include, for example, fall protection such as railings, platforms or stable covers for process containers. Pipelines must be completely emptied and depressurized before work begins in order to prevent hazards from chemical residues. Electrical and mechanical systems are protected against unintentional start-up by means of shutdown and repair safety devices. All work in this context is only carried out with prior approval and in compliance with the specified protective measures. In addition to the Ordinance on Industrial Safety and Health and protective measures such as those in the Ordinance on Hazardous Substances (GefStoffV), industry-specific guidelines such as DGUV regulation 113-001 play a key role, as they provide practical advice on occupational safety, particularly when handling electroplating baths, electrolytes and electrical voltages. DIN EN 60079-17, which describes the requirements for the testing and maintenance of systems in potentially explosive atmospheres, is also relevant.
Avoiding accidents, repairing damage
PPE is mandatory for activities in the vicinity of process containers, when transferring chemicals and during maintenance work. The equipment includes chemical-resistant gloves, respirators, safety goggles, safety shoes and protective clothing. Employers determine the type and scope of PPE based on the risk assessment and check its condition regularly. Additional protective measures such as skin protection plans and hygiene guidelines supplement the equipment in some cases. Operating instructions ensure that all work is carried out safely and define specific rules of conduct. They provide information on hazardous substances, the necessary protective measures and what to do in the event of operational disruptions and emergencies. These instructions serve as the basis for regular briefings, which take place at least once a year. This means that those responsible are familiar with the correct handling of electrolytes, for example, and can also recognize material changes to electrodes.
Close safety gaps
Basically, maintenance is always carried out at fixed intervals, whereby all safety-relevant components such as extraction systems, emergency stop devices, temperature probes and other protective devices are checked. According to the German Ordinance on Industrial Safety and Health (BetrSichV), this is always carried out by qualified persons and ends with the documentation of the individual steps and results in a corresponding log. Those who rely on a digital version here can not only make this easily accessible to all important parties, but also set appropriate reminders so that deadlines are not forgotten and all responsible parties are informed accordingly. Shorter inspection intervals may be necessary if the chemical load or other special operating conditions make this particularly necessary, such as in potentially explosive areas where the Hazardous Substances Ordinance applies. Only when inspectors can confirm a safe operating condition is the prerequisite for recommissioning deemed to have been met. Before giving the go-ahead, the respective manager is then responsible for checking whether the responsible persons have completed all work properly, the hazardous area has been cleared and the company can now safely put the system back into operation. This minimizes the risk of accidents at work and promotes sustainable operational management.
Prevention before repair
In addition to these technical measures, an effective maintenance strategy also takes into account organizational requirements, such as clear communication channels, the definition of responsibilities and the provision of sufficient resources for training and maintenance work. Before starting, for example, all systems must be disconnected from the power supply and all galvanic baths must be completely drained. Those who rely on systemic maintenance management and digital support for logging and scheduling can make a decisive contribution to minimizing downtimes and extending the service life of their own systems in the long term. The aim here is always to act preventively rather than reactively. This not only improves safety, but also efficiency and sustainability in the electroplating industry.
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Support from professionals
The author of this article, Carsten Müller, is Managing Director of ESW - ECHT! SMART WORK GmbH. The company sees itself as a service partner for the smart monitoring and documentation of inspection and maintenance work. By providing each object to be inspected with a scannable QR code, tasks can be called up directly via a cell phone or tablet, among other things. In this context, the software allows maintenance appointments to be scheduled, inspection forms to be completed on a mobile device and even direct photo documentation. With a central, online filing system, the software coordinates all individual inspection tasks and thus provides cost-effective and resource-saving logging. Incomplete, incorrect or overlooked inspections are therefore a thing of the past. ESW advises and supports small and medium-sized companies in particular on the successful realization and implementation of all digital maintenance documentation.
Carsten Müller
