UVV inspections for Enerpac products
1. Basics of UVV inspections for Enerpac products
Enerpac products, particularly hydraulic tools and systems, are classified as work equipment under the Operational Safety Ordinance (BetrSichV) and DGUV regulations, requiring regular safety inspections. The legal basis for the inspection obligation is defined in § 14 BetrSichV as well as relevant DGUV regulations, such as DGUV Regulation 3 (electrical equipment) or DGUV Regulation 100-500 (formerly BGR 500, for lifting equipment and other work equipment). The aim is to ensure the safety of employees and prevent accidents due to wear, damage, or improper use.
Hydraulic tools from Enerpac are subject to additional specific regulations depending on the area of application:
- DGUV Regulation 54 (Hydraulic Presses), if it concerns presses.
- DGUV Rule 109-017 (Lifting gear and lifting equipment), if the tools are used in lifting operations.
- DGUV Regulation 68 (Industrial Trucks), if used in combination with forklifts or similar equipment.
2. Are annual UVV inspections necessary for Enerpac products?
The necessity of annual UVV inspections depends on several factors:
- Type of work equipment: Hydraulic tools such as cylinders, pumps, or wrenches are subject to mandatory inspection because they contain safety-relevant components that can become hazardous due to wear or damage.
- Risk assessment: According to § 3 of the BetrSichV, a risk assessment is carried out to determine the type, scope, and intervals of inspections. For many Enerpac products, the risk assessment results in an annual inspection, especially with intensive use or in safety-critical areas such as lifting operations.
- Manufacturer specifications: Enerpac specifies mandatory inspection intervals in the operating and maintenance instructions, which are part of the safe use of the equipment.
- Conditions of use: With intensive use (e.g., in three-shift operation), harsh environments (e.g., construction sites), or after exceptional events (e.g., accidents or repairs), shorter inspection intervals are required.
For most Enerpac products, annual UVV inspections are mandatory, especially for hydraulic tools in safety-critical applications such as lifting or tensioning operations. Deviations from the annual inspection cycle are justified by a documented risk assessment, e.g., in cases of low usage or proven minimal wear.
3. What is checked during a UVV inspection of Enerpac products?
The UVV inspection of Enerpac products includes the following steps to ensure operational safety:
Visual inspection:
- Cylinders, hoses, and pumps are inspected for external damage such as cracks, deformations, or corrosion.
- Connections, seals and valves are checked for leaks.
- Safety devices such as overpressure valves or shut-off valves are checked.
Function test:
- The flawless function is tested under operating conditions, e.g. the pressure buildup and reduction in hydraulic pumps.
- The mobility of pistons or other moving parts is checked.
- Control systems, if present (e.g., for electrically operated pumps), are checked.
Measurements:
- Pressure tests are conducted to ensure that the devices can withstand the specified maximum pressure without leaks or weaknesses.
- For devices with electrical components, electrical measurements are performed according to DGUV Regulation 3, e.g. insulation resistance or protective conductor testing.
Documentation:
- A test report is created containing information on date, inspector, scope, identified defects, and recommendations.
- A test sticker is affixed, indicating the date of the next inspection.
Defect rectification:
- Detected defects (e.g., leaking hoses, worn seals) will be rectified before further use.
- Repairs are only carried out by qualified professionals, ideally in consultation with Enerpac or authorized service partners.
4. Who is allowed to conduct the UVV inspections?
UVV inspections for Enerpac products are carried out by a competent person in accordance with the Technical Rules for Operational Safety (TRBS 1203). A competent person has:
- Relevant vocational training or work experience, e.g. as an industrial mechanic, hydraulic specialist, or electrician.
- Knowledge of specific Enerpac products and their safety requirements.
- Familiarity with the relevant DGUV regulations and standards, e.g. DIN EN ISO 4413 for hydraulic systems.
Possible examiners are:
- Internal employees who are qualified through training (e.g., at the LTS Academy or similar providers).
- External service providers such as TÜV NORD, MPS Elektrotechnik GmbH or specialized testing institutes with experience in hydraulic systems.
- Service technicians from Enerpac or authorized partners who have product-specific expertise. Through our strategic partner WK Hydraulik, an official Enerpac Service Center Partner, we offer these UVV inspections to you. Visit the product detail page of your Enerpac product, click on "Request UVV inspection," and you will receive a quote within 24 hours. Soon, you will also be able to purchase the UVV inspection for your Enerpac product directly in our shop.
5. Special features of Enerpac products
Enerpac products have specific characteristics that must be considered during the UVV inspection:
- High pressures: Hydraulic tools operate at pressures up to 700 bar or more. Hoses, seals, and connections are inspected with particular care to prevent leaks or bursting hazards.
- Electrical components: Some Enerpac pumps or controls are electrically powered and subject to DGUV Regulation 3. Electrical safety tests, e.g. insulation resistance, are carried out.
- Modular systems: Many Enerpac tools are part of modular systems (e.g., combinations of pumps, cylinders, and hoses). The entire system, including the compatibility and secure connection of the components, is tested.
- Lifting and tensioning applications: When used in lifting operations, additional regulations apply, such as DGUV Rule 109-017 for lifting gear or DGUV Principle 308-002 for lifting platforms.
The detailed maintenance and inspection instructions in the Enerpac operating manuals are observed, as they contain specific inspection points or intervals for individual products (e.g., RC series hydraulic cylinders or ZE series pumps).
6. Procedure of a UVV inspection for Enerpac products
A UVV inspection for Enerpac products is carried out as follows:
Preparation:
- All devices to be inspected (e.g., serial numbers, type designations) are recorded.
- The operating manual and maintenance logs are reviewed.
- A risk assessment is conducted to determine the scope of the inspection.
On-site inspection:
- A visual inspection for external damage, wear, or leaks is performed.
- The function is tested under operating conditions, e.g. by a pressure test at 110% of the rated pressure.
- Safety-relevant parameters, e.g. pressure or electrical values, are measured.
Documentation:
- A test report is created containing information on tester, date, results, and defects.
- A test sticker with the date of the next inspection is attached.
Follow-up:
- Detected defects, e.g. due to replacement of hoses or seals, are rectified.
- The test protocol is archived at least until the next inspection.
7. Consequences of non-implementation
Failure to conduct annual UVV inspections for Enerpac products results in the following consequences:
- Fines: Violations of the BetrSichV or DGUV regulations can result in fines of up to 10,000 euros.
- Liability: In the event of damage (e.g., an accident caused by a defective hydraulic tool), the employer is liable, and the employers' liability insurance association may refuse benefits.
- Operational outages: Unverified devices cause failures or damage, leading to production downtime.
- Criminal consequences: In cases of serious violations or accidents, criminal proceedings may be initiated against responsible individuals.
8. Practical tips for businesses
- Hire a professional to conduct a risk assessment to determine inspection intervals and scopes for your Enerpac products.
- Qualify internal employees as competent persons or commission external service providers who are familiar with Enerpac products.
- Integrate UVV inspections into a maintenance schedule to meet deadlines. Digital tools like ToolSense or fleet management software support you in this.
- Contact Enerpac or authorized service partners such as WK Hydraulics, an official Enerpac Service Center & Distributor Partner, for product-specific testing or repairs.
- Keep a logbook for each device documenting all inspections, repairs, and maintenance. This is required during audits by occupational associations or insurers.
9. Costs and service providers
The costs for UVV inspections of Enerpac products vary depending on the provider, device type, and scope of inspection:
- External service providers such as TÜV NORD or MPS Elektrotechnik charge approximately 50–150 euros per inspection.
- Enerpac and authorized partners such as our partner WK Hydraulik offer maintenance and testing services, the costs of which are available upon request.
- Synergy effects reduce costs when multiple devices are tested simultaneously.
Recommended service providers:
- TÜV NORD: Specialized in UVV inspections for industrial work equipment.
- WK Hydraulics: As an Enerpac Repair Center Partner, WK Hydraulik performs product-specific UVV inspections and repairs.
10. Conclusion
Annual UVV inspections are legally required for most Enerpac products, especially hydraulic tools and systems, based on risk assessments and manufacturer specifications. The inspections include visual, functional, and measurement checks and are carried out by qualified personnel. Companies integrate the inspections into a maintenance plan, maintain thorough documentation, and, if necessary, involve Enerpac or specialized service providers like WK Hydraulik, an Enerpac Service Center Partner, to ensure compliance with regulations and guarantee the safety of employees.
