Environment, Health and Safety
General Safety Standard For Industrial Equipment
Rev 1.0 4.14.2015
General Safety Standard for Industrial Equipment Environment, Health and Safety
PREFACE
Chrysler has always put employee safety first over all other needs. Over the last thirty years manufacturing has seen an increasing use of robots, and automation with a corresponding increase in the use of safeguarding requirements. To ensure employee safety, each manufacturing group developed their own safeguarding requirements to meet manufacturing’s changing environment.
The goal of the committee was to reduce or eliminate redundant, outdated, incorrect, and confusing statements and documents while ensuring compliance with government regulations applicable industry consensus standards and FCA-NAFTA standards. This applies to new purchases as well as existing equipment.
The first step in this process was to gather and review the most commonly referenced FCA- NAFTA standards, those being Chrysler Manufacturing Engineering Do’s & Don’ts, Powertrain Safety Standards, SMI-109 Safeguard of Robots and Robot Systems, SMI-145 Automation Safeguarding Requirements, and SMI 162 Control Reliability of Machinery and Equipment. The next step was to identify any statements that can be considered applicable to all equipment and suppliers regardless of the equipment type, who specified it, or where it operates. Where relevant industry consensus documents were published, they were compared for proper inclusion and recorded. The statements not included were returned to the proper FCA – NAFTA group for their disposition.
In parallel with this effort, a review of OSHA regulatory requirements relevant to employee workplaces was documented. This step allowed the committee to align the existing Chrysler safety standards with respective OSHA requirements and identify any unclear or outdated requirements. As each new statement was confirmed, its source was recorded to ensure an understanding of the statement’s origins and provide direction for more information.
Finally, this process was reviewed to understand discrete requirements within NAFTA (Canada, Mexico, and the U.S.) that have unique regulations. Those differences are identified.
The result is a new FCA – NAFTA General Safety Standard for Industrial Equipment that provides clear direction for all suppliers and personnel as well as requirements for equipment from acquisition and operation through disposal using FCA – NAFTA methods that follow established industry and regulatory requirements.
This standard has the full approval of the FCA – NAFTA Corporate Environment, Health, and & Safety organization. It complies with and supports FCA - NAFTA Corporate Process Guideline ADM 059 Federal and State OSHA Administration.
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The following personnel have directly or indirectly contributed to the development of this new standard.
Frank Bargerhuff Manufacturing Engineering Jim Brown Manufacturing Engineering – Powertrain Angela Cook Warren Stamping Plant Environment, Health & Safety Francesco Demelis Manufacturing Engineering Lisa Gunn Corporate Health & Safety Christian Heider Manufacturing Engineering – Powertrain Greg Irwin Manufacturing Engineering Jessica Jannaman Corporate Health & Safety Al Johnston Corporate Environmental Keith Jones Corporate Environmental Kyle Jones Corporate Environmental Counsel Wendy Kue Corporate Health & Safety Mark Medici Advance Stamping Manufacturing Engineering John Mequio Corporate Health & Safety Joseph Mitory Advance Stamping Manufacturing Engineering Steve Perrott Corporate Health & Safety Steve Romund Manufacturing Engineering Greg Rose Corporate Environment, Health & Safety Kim Rouleau Advance Stamping Manufacturing Engineering Mark Sementilli Windsor Assembly Plant Mark Smith Manufacturing Engineering – Powertrain Gary Stanczuk Corporate Environmental
The following non-FCA personnel have provided technical support for this new standard.
Jamie Hansen Unifor (National Union of Canada) George Schuster Rockwell Automation Corey Jasper Schneider Electric
FCA Environment, Health, and Safety would like to thank everyone for their contributions on this standard.
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General Safety Standard Revision Summary
It is the user’s responsibility to ensure the appropriate version of this standard is used for a specific project. Any questions regarding version applicability to a specific project should be directed to the assigned FCA – NAFTA project engineer or Specifying Authority for disposition.
Any questions or comments with respect to this standard should be directed to FCA – NAFTA Environment, Health and Safety for disposition.
The following revision(s) to this standard have been approved by FCA-NAFTA Environment, Health and Safety.
Rev Date Clause Description Released By April14,2015 All Release Greg Rose
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Contents PREFACE ...... III
1.0 GENERAL...... 1
1.1 PURPOSE...... 1 1.2 SCOPE...... 1 1.3 DEFINITIONS ...... 1 1.4 COPYRIGHT...... 1 1.5 DEVIATIONS, REVISIONS, SUPPLEMENTS, AND INTERPRETATIONS ...... 1 1.6 STANDARD CONVENTIONS...... 2 1.7 FCA RESPONSIBILITIES...... 2 1.8 SUPPLIER RESPONSIBILITIES...... 2 2.0 DESIGN FOR SAFETY...... 3
2.1 GENERAL...... 3 2.2 HAZARD MITIGATION ...... 3 2.3 SAFETY DESIGN REVIEW ...... 4 2.4 PROJECT MANAGEMENT - PLANNING:...... 4 2.5 PROJECT MANAGEMENT - PROCESS...... 5 2.6 PROJECT MANAGEMENT – DESIGN ...... 5 2.7 PROJECT MANAGEMENT - CONSTRUCTION ...... 5 2.8 PROJECT MANAGEMENT – INSTALLATION ...... 5 2.11 DISPOSAL...... 6 2.12 COMPONENT APPROVAL...... 6 3.0 EQUIPMENT HAZARDS ...... 8
3.1 GENERAL HAZARDS...... 8 3.2 CONSTRUCTION/DEMOLITION HAZARDS...... 8 3.3 WALKING AND WORKING SURFACES ...... 8 3.4 FACILITY HAZARDS/EGRESS ...... 9 3.5 AIR QUALITY AND VENTILATION ...... 9 3.6 OCCUPATIONAL NOISE HAZARDS ...... 10 3.7 NON-IONIZING RADIATION (ELECTROMAGNETIC-EMR/EMF) HAZARDS ...... 10 3.8 LASERS...... 11 3.9 ERGONOMIC HAZARDS ...... 12 3.10 HAZARDOUS MATERIALS...... 12 3.11 COMPRESSED GASES ...... 12 3.12 SPRAY FINISHING USING FLAMMABLE AND COMBUSTIBLE MATERIALS ...... 13 3.13 DIPPING, COATING, AND SPRAYING ...... 13 3.14 CONFINED SPACE HAZARDS ...... 13 3.15 HAZARDOUS ENERGY ...... 13 3.16 ELECTRICAL HAZARDS ...... 14 3.17 FIRE SAFETY HAZARDS ...... 14 3.18 THERMAL SURFACES (BURNS) ...... 14 3.19 OVERHEAD HAZARDS...... 15 3.20 MOVING HAZARDS ...... 15 3.21 POINT OF OPERATION HAZARDS ...... 16 3.22 UNINTENDED MOTION ...... 16 4.0 SAFEGUARDING...... 17
4.1 GENERAL...... 17 4.2 GENERAL SAFEGUARDING REQUIREMENTS ...... 17
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4.3 FIXED GUARDS ...... 18 4.4 BARRIERS AND FENCING...... 18 4.5 ADJUSTABLE BARRIER...... 19 4.6 MOVABLE BARRIERS AND GATES ...... 19 4.7 BLOCKING...... 20 4.8 MECHANICAL STOPS...... 21 4.9 BRAKES ...... 21 4.10 PRESENCE SENSING ...... 21 4.11 AWARENESS BARRIER/SIGNALS...... 21 4.12 UNAUTHORIZED ACCESS ...... 21 4.13 LOAD/UNLOAD WORKSTATIONS...... 22 5.0 ELECTRICAL SAFEGUARDS ...... 23
5.1 GENERAL...... 23 5.2 SUPPLY ...... 23 5.3 SHOCK ...... 23 5.4 ARC FLASH ...... 24 5.5 GROUNDING...... 24 5.6 CONTROL CIRCUITS ...... 24 5.7 STOP CONTROL CIRCUITS ...... 25 5.8 START CONTROL CIRCUITS ...... 26 5.9 PRESENCE SENSING DEVICE INITIATION CONTROL CIRCUITS (PSDI)...... 26 5.10 CONTROL DEVICES ...... 26 5.11 LOCATION AND MOUNTING...... 28 5.12 CONDUCTORS, CONNECTORS, AND WIRING METHODS ...... 28 5.13 MUTING ...... 28 5.14 ALTERNATIVE SAFEGUARDING ...... 29 6.0 MARKING AND SAFETY IDENTIFICATION ...... 30
6.1 GENERAL...... 30 6.2 COLORS ...... 30 6.3 WARNING LABELS ...... 31 6.4 SIGNAGE ...... 31 6.5 VISUAL DISPLAYS ...... 31 6.6 ROTATING BEACONS ...... 31 6.7 HORNS...... 31 6.8 DOCUMENTATION ...... 32 6.9 SIGNAL WORDS ...... 32 6.10 SAFETY SYMBOLS...... 32 7.0 OTHER SYSTEMS ...... 33
7.1 GENERAL...... 33 7.2 HYDRAULIC SAFEGUARDS ...... 33 7.3 PNEUMATIC SAFEGUARDS...... 33 8.0 SPECIFIC EQUIPMENT SYSTEM SAFEGUARDS ...... 35
8.1 GENERAL...... 35 8.2 ASSEMBLY SYSTEMS ...... 35 8.3 CONVEYOR SAFEGUARDS ...... 35 8.4 CRANE SAFEGUARDS ...... 35 8.5 METAL CUTTING EQUIPMENT SAFEGUARDS ...... 35 8.6 PRESS EQUIPMENT SAFEGUARDS ...... 36 8.7 ROBOT AND ROBOT SYSTEM SAFEGUARDS...... 36 8.8 FACILITY MECHANICAL SAFEGUARDS ...... 37
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8.9 INDUSTRIAL TRUCKS AND MOVING PLATFORMS ...... 37 9.0 REFERENCES...... 38
9.1 ANSI PUBLICATIONS - AMERICAN NATIONAL STANDARDS INSTITUTE, WASHINGTON, DC...... 38 9.2 ASTM PUBLICATIONS - AMERICAN SOCIETY OF TESTING MATERIALS, WEST CONSHOHOCKEN, PA ...... 39 9.3 CANADIAN STANDARDS ASSOCIATION, TORONTO, ON, CANADA...... 39 9.4 FCA NAFTA, CORPORATE AUDIT, AUBURN HILLS, MI...... 39 9.5 FCA NAFTA, ENVIRONMENT, HEALTH, & SAFETY, AUBURN HILLS, MI...... 39 9.6 INTERNATIONAL ELECTROTECHNICAL COMMITTEE, GENEVA, SWITZERLAND ...... 40 9.7 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION, GENEVA, SWITZERLAND ...... 40 9.8 NFPA PUBLICATIONS – NATIONAL FIRE PROTECTION ASSOCIATION, QUINCY, MA...... 40 9.9 ONTARIO MINISTRY OF LABOR ...... 40 9.10 OSHA PUBLICATIONS - OCCUPATIONAL HEALTH AND SAFETY ADMINISTRATION, U.S. DEPT. OF LABOR...... 40 9.11 UNDERWRITERS LABORATORIES, NORTHBROOK, ILLINOIS ...... 41 9.12 U.S. FDA CENTER FOR DEVICES AND RADIOLOGICAL HEALTH (CDRH) ...... 41 10.0 GLOSSARY OF TERMS...... 42
APPENDIX A FCA - NAFTA FACILITIES...... 47
APPENDIX B FCA - NAFTA ENGINEERING ORGANIZATIONS ...... 48
APPENDIX C REGIONAL REQUIREMENTS...... 49
APPENDIX D BALCONIES, PLATFORMS, LADDERS AND STAIRWAYS ...... 51
APPENDIX E SAFETY DISTANCE...... 55
APPENDIX F PRELIMINARY HAZARD LIST ...... 60
APPENDIX G PRELIINARY HAZARD ANALYSIS ...... 62
APPENDIX H PRE-START HEALTH AND SAFETY REVIEW CHECKLIST ...... 63
APPENDIX J RISK ASSESSMENT EXAMPLE...... 64
APPENDIX K SAFETY COLOR IDENTIFICATION...... 65
APPENDIX L SAFETY LABELS...... 66
APPENDIX M EQUIPMENT DESIGN LAYOUT EXAMPLE...... 68
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1.0 GENERAL 1.1 PURPOSE The purpose of this standard is to provide minimum safety requirements for the design, construction, utilization and disposal of tools, dies, machinery, assembly, other equipment not individually specified herein, and facilities at FCA – NAFTA (FCA) to provide a safe work environment for employees. See Appendix A FCA-NAFTA Facilities for a list of included locations. 1.2 SCOPE 1.2.1 These requirements apply to all tools, dies, machinery, assembly, and other equipment not individually specified herein [hereafter referred to as “equipment”]. 1.2.2 Elements outlined herein are based on industry consensus standards and Federal, State or Provincial regulations and are not intended to replace them. 1.2.3 This standard is intended to meet the requirements of FCA Corporate Process Guideline ADM 059 Federal and State OSHA. 1.2.4 Excerpt text and references from other industry standards and regulations stated herein are provided for clarity but does not limit the use of the referenced documents to only those stated portions. 1.2.5 It is outside the scope of this standard to define or restrict requirements for financial, delivery timing, supplier or component selection unless it can be shown to negatively affect safety to personnel. 1.3 DEFINITIONS Applicable: Relevant or suitable for the problem. Applicable does not imply optional. Approved: Material that meets specified criteria, process, design, method, etc... EHS: FCA Corporate Environment, Health, & Safety. Equipment: unless preceded by a descriptor refers to all of the industrial equipment types (tools, dies, fixtures, machinery, assembly and other equipment not individually specified herein). FCA - NAFTA: The NAFTA region of Fiat Chrysler Automobiles (FCA) May – defines a requirement that is condition dependent. NAFTA: North American Free Trade Agreement region. Plant EHS: FCA local plant Environment, Health, & Safety Shall - defines a requirement. Should - defines a recommendation or preference. Specifying Authority – The FCA organization with the responsibility and authority to define requirements and qualify the equipment being purchased. System: unless preceded by a descriptor refers to a series of individual pieces of equipment connected to perform a related function. Validation: Confirmation that equipment meets the operational requirements. Verification: Determination that materials and processes meet design criteria. Additional definitions are located in clause 10.0 Glossary. 1.4 COPYRIGHT All information contained within this document is copyrighted. It may be reproduced freely if done so in its entirety without alteration and includes this FCA copyright statement.
1.5 DEVIATIONS, REVISIONS, SUPPLEMENTS, AND INTERPRETATIONS 1.5.1 The requirements of this standard are considered mandatory for all equipment. Unless otherwise stated, deviations from the requirements of this standard shall require approval by FCA Environment, Health, & Safety (EHS).
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1.5.2 Revisions to the requirements to this standard shall be referred to FCA EHS for consideration. Engineering group supplemental requirements shall be reviewed and approved by EHS prior to implementation. See Appendix B FCA-NAFTA Engineering Organizations for a list of FCA organizations with supplemental requirements. 1.5.3 Interpretation of referenced standards to a specific application is at the discretion of FCA EHS. 1.5.4 Where conflicts arise between the applicable governmental, industry consensus and this standard, the most stringent requirement shall apply. 1.6 STANDARD CONVENTIONS 1.6.1 Referenced standards and regulations that are not part of a statement are enclosed in [ brackets ] and intended to identify the source of the requirement if more information is needed. 1.6.2 Measurement units are stated as shown in the referenced document to prevent rounding errors. 1.7 FCA RESPONSIBILITIES 1.7.1 It is not the intent of this standard to identify the scope of work for a specific purchase. The FCA Specifying Authority shall identify the supplier scope of work. 1.7.2 Unless otherwise specified, FCA shall supply all personal protective equipment (PPE) for FCA employees. 1.7.3 FCA EHS shall ensure Safety Manufacturing Technical Instructions (SMIs) are available for required in plant operations. 1.8 SUPPLIER RESPONSIBILITIES 1.8.1 Unless otherwise excluded by the equipment scope of work, the supplier shall meet all the applicable requirements of this standard. 1.8.2 Unless otherwise specified, the supplier shall supply all personal protective equipment (PPE) for their employees. 1.8.3 The supplier(s) shall follow the prescribed local plant safety practices when on FCA property.
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2.0 DESIGN FOR SAFETY 2.1 GENERAL 2.1.1 All systems and equipment, methods and controls shall have safe operation engineered into them. The safety of personnel associated with the operation is of prime importance. Informational Note: The term equipment is defined as any apparatus that has one or more of the potential hazards listed in clause 3.0 Hazards, and includes special tools, gages, material handling or other required support equipment. 2.1.2 All equipment and facilities shall meet the applicable requirements of this standard and the: U.S. Department of Labor, or Canadian Ministry of Labor, or Mexico Secretaría del Trabajo y Previsión Social, any local governing requirements. Exceptions: a. Equipment installed prior to August 2007 may be exempt from some of the U.S. Department of Labor requirements as listed in CFR 29 1910.302(b)4. b. Equipment installed prior to April 1981 may be exempt from some of the U.S. Department of Labor requirements as listed in CFR 29 1910.302(b)3. Informational Note: The exceptions apply to electrical portions of the equipment. 2.1.3 Additional plant and/or other FCA equipment specific standards may also be applicable. See Appendix B FCA-NAFTA Engineering Organizations for a list of FCA organizations with supplemental requirements. 2.1.4 Alternative regional equipment specific standards may also be applicable. Regional requirements are stated where known but does limit their use to only those cited. (See Appendix C Regional Standards and Regulations for alternative regional standards.) 2.1.5 Required regional regulations will supersede the referenced U.S. Department of Labor regulations. See Appendix C Regional Standards and Regulations for alternative regional regulations. 2.2 HAZARD MITIGATION 2.2.1 Selection of one or more of the methods in the hierarchy of safeguarding listed in prioritized order below provides the safest and most cost effective solution to hazard control. (1) Eliminate the hazard (2) Substitution (3) Provide engineered controls to mitigate the hazard (4) Provide administrative controls to educate employees and identify hazards (5) Provide employees with personal protective equipment (PPE) to safely work with the hazard. Informational Note: Hierarchy of safety control methods is based on NIOSH, CDC, OHSA, and general industry consensus. 2.2.2 Hazard identification methods may include any or all of the following: Risk assessment(s) when required; Process Concept Review; Job Safety and Risk Assessments (JSRA); Ergonomic assessment; 2.2.3 Analysis of duplicate equipment may not be required if an existing risk assessment for the same piece of equipment manufactured by the same equipment supplier is available. 2.2.4 Preliminary Hazard List (PHL) is an engineering tool to identify hazards. See Appendix F Preliminary Hazard List for an example PHL.
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2.2.5 Preliminary Hazard Analysis (PHA) form is an engineering tool to mitigate identified hazards. See Appendix G Preliminary Hazard Analysis for an example PHA. 2.2.6 When a risk assessment of equipment is required under this standard, it shall follow the requirements of ANSI B11.0 Safety of Machinery; General Requirements and Risk Assessment and approved by EHS prior to implementation. See Appendix J Risk Assessment for an example. 2.2.7 Regional regulations in the province of Ontario Canada may require a Pre-Start Health and Safety Review. [O. Reg. 851, s. 7] See Appendix H Pre-Start Health and Safety Review Checklist for more information. 2.3 SAFETY DESIGN REVIEW 2.3.1 New, remanufactured, or refurbished equipment shall be reviewed for the hazards listed in this standard and identified hazards shall have a safeguarding method provided. Informational Note: ANSI/ASSE Z590.3 Prevention through Design Guidelines for Addressing Occupational Hazards and Risks in Design and Redesign Processes may be used as a reference. 2.3.2 New, remanufactured, or refurbished equipment shall require EHS review and approval when any of the following items are part of the planned installation, operation, maintenance, repair or disposal of the equipment: a. Environmental permits, b. Facility modification, c. Overhead material handling, d. Limited egress or ventilated areas such as a basement, pit, or full body enclosure, e. Class 2 laser or above, f. Operator load or unload stations, g. Handling any chemical listed on FCA ETI 102 Instructions for the Application & Requesting of Non-Production Hazardous and Potentially Hazardous Material. h. Open flame or heating energy source, i. Combustible material, j. Compressed flammable gas, k. Moving hazards. 2.3.3 Upgrading or replacement safeguard(s) on existing equipment shall require EHS review and approval when any of the following are used: New (unapproved) safeguard supplier or Unapproved safeguard product from an approved supplier or New (unapproved) safeguard technology 2.3.4 Integration of equipment into an existing system shall ensure the existing safeguard(s) maintain the existing level of protection. 2.3.5 The personnel involved in the design for safety are the Specifying Authority, Corporate and plant EHS, supplier(s), engineering, maintenance, and operator personnel as needed. 2.3.6 Where no specific personnel or organization is identified in the steps below, the actions are executed with the appropriate personnel as needed. 2.4 PROJECT MANAGEMENT - PLANNING: 2.4.1 The Specifying Authority shall notify EHS of new equipment or alteration purchase through the appropriate project notification system. Informational Note: Current EHS notifications are made using either the Environmental Permit Application Tracking System (EPATS), or the Appropriation Request Report System (ARRS).
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2.4.2 The Specifying Authority shall prepare an Environmental Significant Aspect and Impact list for the equipment. 2.4.3 Review safety best practices of existing equipment. Informational Note: Maintenance Prevention Information (MPI), Problems Found Journals, and Checklist Questions are current tools for identifying best practices and used in the design phase. 2.4.4 Appropriate funding for the planned environmental, health and safety requirements shall be allocated. 2.5 PROJECT MANAGEMENT - PROCESS 2.5.1 Review equipment correlation with the facility (e.g., aisle clearance, utilities, operator locations, material handling, ventilation) 2.5.2 Prepare a PHL for the equipment using the hazard identification methods above. Informational Note: Preparation of equipment PHL is a joint development and analysis process with both the supplier and Specifying Authority involvement. 2.5.3 Document the safety design requirements to the hazards identified in the PHL. 2.5.4 Identify the equipment safeguards to meet the safety design requirements (e.g., barriers, gate access, presence sensing, assist devices, operator controls, PPE, and safety procedures). 2.5.5 A PHA shall be prepared that includes the required equipment safeguards. 2.6 PROJECT MANAGEMENT – DESIGN 2.6.1 Review the safety standards including this standard and any supplemental/alternative requirements with the supplier. 2.6.2 Implement the safety design requirements and equipment safeguards identified in the Project Management Process phase into the design. 2.6.3 Review and approve the final equipment design layout including facility correlation, safeguards and working clearances by corporate or plant EHS prior to construction. See Appendix M for an equipment design layout example. 2.6.4 The PHA is reviewed, issues identified, and resolved. 2.7 PROJECT MANAGEMENT - CONSTRUCTION 2.7.1 Review construction standards with supplier for regulatory code compliance. 2.7.2 All required safeguards shall be installed and operating prior to the build verification. 2.7.3 Verify equipment safety function(s) for proper operation. Exceptions shall be documented. 2.7.4 The PHA is reviewed, issues identified, and a risk assessment prepared. 2.8 PROJECT MANAGEMENT – INSTALLATION 2.8.1 All required safeguards shall be installed and operating prior to equipment validation in the receiving facility. 2.8.2 Validate equipment safety function(s) for proper operation. Exceptions shall be documented. 2.8.3 The risk assessment is updated with unforeseen hazards at the equipment site. 2.9 Equipment installation approval shall require completion of FCA SMI-105 Safety Inspection and Approval of Machinery & Equipment prior to production operation.
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2.10 OPERATION, MAINTENANCE, AND REPAIR 2.10.1 Local plant operations shall ensure that: a. Equipment is properly operated and maintained as designed. b. Safeguard(s) are kept in good working order. c. Lockout (control of hazardous energy) requirements and other alternative methods are posted on equipment. d. Employees are trained in the proper procedures for their job function including safety placards. e. Employees are trained on the proper use of required PPE for their job function. 2.10.2 Continuing operational plant requirements and guidance for personnel shall be maintained and available from plant EHS to ensure safety in the workplace. 2.11 DISPOSAL 2.11.1 The disposal of equipment from FCA facilities shall complete the requirements of FCA SEB 707 Asset Removal and Shipment Procedures to ensure all of the following provisions are met: a. All tanks, sumps, and reservoirs are drained of fluids and waste and properly disposed of. b. Refrigerant(s) are properly evacuated and disposed in accordance with FCA Stationary and Environmental Bulletin (SEB) 410 Refrigeration and Air Conditioning Equipment Regulations. c. CFC contaminated fluids are not mixed with other fluids. Contaminated fluids shall be disposed of as required FCA SEB 410. d. All slugs, scrap, lubricants and fluids are removed and properly disposed of. e. Batteries are removed and packaged according to FCA SEB 802 Non Bulk Battery Shipping Procedures (non-lithium). f. Items containing mercury are properly contained for disposal. g. Electronic waste including instruments, computers, monitors, motor drives, displays, equipment controllers, input/output devices, etc., are recycled through local approved collection programs. h. The reclaimed equipment site is restored to the applicable requirements of this standard to ensure a safe working environment. 2.11.2 Construction safety requirements shall be enforced during removal of equipment from FCA facilities. 2.11.3 Disposal of equipment from non FCA facilities shall follow the applicable requirements of the United States Environmental Protection Agency (EPA), Canadian Environmental Protection Act (CEPA), or Mexican environmental laws as applicable. 2.12 COMPONENT APPROVAL 2.12.1 Components, materials, or devices that pose a shock or fire threat shall be listed, labeled, or identified by a qualified testing laboratory that performs product evaluations and maintains periodic inspection of production of the identified equipment or materials and by whose identification the manufacturer indicates compliance with appropriate standards or tested and found suitable for a specified use. [NFPA 70]
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2.12.2 Components, materials, or devices that OSHA has designated as ‘requiring NRTL approval’ shall be tested and approved by a Nationally Recognized Testing Laboratory (NRTL) [29 CFR 1910.7]. Note that regional regulations in Canada require testing laboratories to be accredited by the Standards Council of Canada. [O. Reg. 438/07] Informational Note: NFPA 70 requires a testing laboratory to be qualified, while OSHA requires a testing laboratory to be nationally recognized by them. Canadian Standards Association (CSA), Factory Mutual Approvals (FM), Intertek Testing Services NA (ETL), TUV, and Underwriters Laboratories (UL) are all acceptable NRTLs. Informational Note: The Standards Council of Canada qualifies national inspection bodies for use in Canada. Canadian Standards Association (CSA), Intertek Testing Services NA (ETL), TUV, and Underwriters Laboratories of Canada (ULC) are all accredited inspection bodies. 2.12.3 Safety rated control devices shall have a safety related parts of a control system (SRP/CS) rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design. Additional information can be found in clause 5.0 Electrical Safeguarding. 2.12.4 Any safe guarding device used for personnel protection shall be approved by EHS. Approval shall be by one of the following: (1) listed on an approved list of materials, or (2) have a written deviation approved by EHS. 2.12.5 Pressure vessels shall conform to the latest ASME Boiler and Pressure Vessel Code - Section VIII and have a National Board Tag. 2.12.6 All other pressurized devices and components shall be pressure tested and rated by the original component manufacturer at four times their published rating unless otherwise specified. 2.12.7 Compressed air piping above ¾” nominal pipe size operated in Canada shall meet the Ontario. Reg. 220/01, s. 5, Technical Standards and Safety Authority (TSSA) requirements. Note: This regulation does not apply to piping that contains liquids not more hazardous than water and that operate at a temperature of 150 degrees F or less and at a maximum allowable working pressure of 250 psi or less.
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3.0 EQUIPMENT HAZARDS 3.1 GENERAL HAZARDS 3.1.1 All equipment shall : be free of sharp edges or burrs, and projections and not create additional hazards. 3.2 CONSTRUCTION/DEMOLITION HAZARDS 3.2.1 Facility spaces or equipment under construction, repair, or demolition shall restrict access to only required personnel. 3.2.2 Personnel working in construction spaces or equipment shall be provided with appropriate personal protective equipment (PPE). 3.3 WALKING AND WORKING SURFACES 3.3.1 Walking and working surfaces shall be designed, constructed, and maintained to provide adequate space around equipment that is clean and dry. Proper drainage and equipment location shall be integrated and maintained. (29 CFR 1910.22) Where wet processes are used, slip resistant walking surfaces shall be provided. 3.3.2 Equipment platforms, balconies, ladders, stairways and walkways shall meet the requirements of 29 CFR 1910 Subpart D. Additional information may be found in Appendix D Balconies, Platforms, Ladders, and Stairways. 3.3.3 Guarding for floor and wall openings large enough for persons to walk into shall be guarded by standard 42 inch (1.1 m) high railing and midrail. [29 CFR 1910.23] Note that regional regulations in the province of Ontario Canada require railings to be a minimum of 36 inch (910 mm) to 42 inch (1070 mm). [O. Reg. 851, s. 11] 3.3.4 Working surfaces 4 feet (1.22 m) higher than the surrounding surface shall be guarded by a standard railing and 4 inch (100 mm) high toe board. [29 CFR 1910.23] Note that regional regulations in the province of Ontario Canada require railings and 5 inch (125 mm) high toe board. [O. Reg. 851, s. 14] 3.3.5 Where railings are not feasible, equipment shall meet the requirements of ANSI/ASSE Z359.1: Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components, and 29 CFR 1910.66. 3.3.6 The use of fall arrest systems shall follow FCA SMI-157 Safety Fall Hazard Control Requirements. 3.3.7 A stairway shall be provided for any equipment elevations requiring routine (daily) inspection, adjustment, or maintenance tasks. [29 CFR 1910.24] Note that regional regulations in the province of Ontario Canada allow fixed ladders or stairs. [O. Reg. 851, s. 19] 3.3.8 Permanent walkways and aisle ways shall be adequately marked to identify their location. 3.3.9 Dimensions for plant vehicle traffic and pedestrian aisles shall follow FCA SMI-161 Safety Guidelines for Pedestrian Safety – Aisle, Dock, and Storage Area Identification. FCA MHEP- 205 Internal Plant Traffic Aisles should be used to determine the minimum aisle widths for the safe operation of powered industrial vehicles and pedestrian traffic. 3.3.10 There shall be no surface tray, cable, conduit, or device located within operator walkways or within 28 inches (711mm) of gate access openings. 3.3.11 Floor mounted tray, mechanical protection or containment system(s) (tray) shall be no less than 8 inches (200 mm) wide, have slip resistant covers that support the expected loads without permanent deformation or damage to the enclosed contents or tray and be of contrasting color to adjacent floor. [29 CFR 1910.24]
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3.3.12 Floor mounted tray shall not be higher than 9.5 inch (241 mm) above the adjacent floor surface. [29 CFR 1910.24] Informational Note: The dimensions on the use of floor mounted tray or containment systems are based on OSHA stair step dimensions to prevent trip hazards. 3.3.13 Gaps between adjacent floor trays shall be less than 1 inch (25 mm) or greater than 18 inch (457 mm). 3.3.14 Step edges, transitions, and trip hazards shall be evaluated and eliminated where possible. Adequate marking and warning labels shall be used where elimination is not feasible. See clause 6.0 Marking and Safety Identification for label requirements. 3.3.15 Bolts and fasteners on working or walking surfaces shall have heads counter sunk or otherwise designed to prevent trip hazards. 3.3.16 Equipment requiring planned or unplanned equipment maintenance and adjustment shall be readily accessible. (See Glossary for definition of readily accessible.) Adequate access shall be determined during design reviews. 3.3.17 Required workspace clearance from electrical equipment and enclosures is specified in clause 5.0 Electrical Safeguarding. 3.3.18 Powered dock boards shall be strong enough to carry the load imposed on them and shall meet the requirements outlined in 29 CFR 1910.30. 3.4 FACILITY HAZARDS/EGRESS 3.4.1 Exits shall be unrestricted and clear of debris and barriers that prevent their use at all times. 3.4.2 Exit doors shall be able to open from the inside without keys, tool, or special knowledge. [29 CFR 1910.36] 3.4.3 The number of building exits shall meet federal, state/provincial, and local building codes. 3.4.4 Where a risk assessment indicates employees may be exposed to hazardous conditions that prevent required access to the exit, an alternate access point with required accessibility shall be provided. 3.4.5 The ceiling of an exit route shall be at least seven feet six inch (2.3 m) high. Any projection from the ceiling must not reach a point less than six feet eight inch (2.0 m). [29 CFR 1910.36] 3.4.6 Access doors and exit routes shall be designed to provide a minimum of 28 inch (711mm) egress clearance. [29 CFR 1910.36] Note that regional regulations in the province of Ontario Canada require a minimum of 36 inch (900mm) access. [Ontario Building Code] 3.4.7 The width of an exit route must be sufficient to accommodate the maximum permitted occupant load of each floor served by the exit route. [29 CFR 1910.36] 3.4.8 Objects or equipment that project into the exit route must not reduce the width of the exit route to less than the minimum width requirements for exit routes. [29 CFR 1910.36] 3.5 AIR QUALITY AND VENTILATION 3.5.1 Employees shall not be exposed to air quality contamination that exceeds the permissible exposure limits outlined in FCA IH-21 Publication of Final Rule for OSHA's PEL Project. 3.5.2 Air quality within manufacturing locations shall comply with FCA IH-25 Chemical Exposure Assessment, and the OSHA chemical specific standards if applicable. [29 CFR 1910.94] Note that regional regulations in the province of Ontario Canada govern access to confined space. [O. Reg. 851, s. 138], and air quality [O. Reg. 851, s. 128]. 3.5.3 Equipment or processes that degrade air quality beyond the required limits shall be: enclosed to control contamination from escaping, and equipped with an air ventilation systems meeting the requirements of FCA IH-12 Basic Design & Operation of Ventilation Systems to remove or prevent contamination of the workplace. Examples include: welding, grinding, machining, spraying, dipping or coating, etc.
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3.5.4 Process enclosures shall control the escape of mist, dust, or liquid into the atmosphere or onto the floor (i.e., design dry floor enclosures with appropriate splash guarding). 3.5.5 Where ventilation exhausts air within the facility (re-circulated air) it shall meet the following requirements: a. HEPA filtration is required for re-circulation of process air. b. Exhaust shall be directed away from work areas to allow proper mixing. c. Recirculated air shall not exceed 10% of the applicable permissible exposure limit. d. Ventilation system shall meet with all applicable local, state, or federal regulations for re- circulating air within the plant. e. Exhaust shall meet the applicable exposure limits as outlined in FCA IH-21 and have the potential effect(s) evaluated by FCA Industrial Hygiene. 3.5.6 Process enclosures, ventilation systems, equipment and materials shall be selected, designed and constructed to prevent the collection or absorption of liquids or the contaminant. Exception: Filter media 3.5.7 Industrial machinery enclosures shall not be designed to be air tight such that mist capture is inhibited. Provisions for air inlets may be required. The location and size of air inlets shall be coordinated during the design stage with the appropriate FCA and supplier personnel. 3.5.8 Exhaust duct connections shall be located on enclosures, above the cutting or splash zones, and designed and located to avoid removing large chips and liquid. 3.5.9 The FCA air contamination limit for dust, that is not otherwise classified, is 10 mg/m3 (e.g. cast iron dust). Where an enclosure is not sufficient to control dust, a dust collection system shall be furnished. 3.5.10 The FCA air contamination limit for oil mist, that is not otherwise classified, is 0.5 mg/m3. Where an enclosure is not sufficient to control oil mist, a mist collection system meeting the requirements of FCA ME-PT Machinery Equipment Specification Section 15889 Oil Mist/Dust Collection Systems shall be provided. 3.6 OCCUPATIONAL NOISE HAZARDS 3.6.1 Equipment shall be designed and constructed to limit sound levels in excess of 77 dBA as measured by FCA IH-06 Hearing Conservation, and associated attachments (Sound Level Standard for Industrial Machinery and Equipment). 3.6.2 Employees shall not be exposed to sound levels in excess of 85 dBA as measured by FCA IH-06 Hearing Conservation, and associated attachments (Sound Level Standard for Industrial Machinery and Equipment). Informational Note: FCA IH-06 Hearing Conservation is more restrictive than Federal requirements. 3.6.3 The supplier shall submit certified sound data form as specified in the FCA IH-06 attachment prior to shipment of all new, refurbished and remanufactured equipment. 3.6.4 Sound attenuating materials capable of absorbing coolant or fluids shall not be used inside enclosures. 3.6.5 Warning signs shall be placed in clear view identifying working areas where sound levels may exceed maximum sound levels. 3.6.6 The use of audible alarms shall meet the requirements of clause 6.0 Marking and Safety Identification. 3.7 NON-IONIZING RADIATION (ELECTROMAGNETIC-EMR/EMF) HAZARDS 3.7.1 All new and refurbished industrial machinery shall conform to the specified electromagnetic field maximum tolerance level of 1000 milligauss at 60 Hz of power measured 39 inches (1 m) from the EMF source as outlined in the June 2002 EMF Questions and Answers prepared by the National Institute of Environmental Health Sciences and National Institutes of Health. 3.7.2 Employees shall not be exposed to electric fields greater than 1 kV/m at 60 Hz.
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3.7.3 Electromagnetic shielding, barriers, fencing, perimeter guarding or location may be used to meet this requirement. 3.7.4 Warning signs shall be placed in clear view identifying high frequency hazards. See clause 6 Marking and Safety Identification. 3.8 LASERS 3.8.1 Lasers and laser systems that exceed the exposure of a Class 1 laser device as outlined 21 CFR Chapter I, Subchapter J, Part 1040.10 Performance Standards for Laser Products, shall be designed, constructed, installed, and operated to the requirements of FCA IH-26 Safety and Health Considerations for Laser Systems and the following requirements. Exception: Lasers that are classified and do not exceed the exposure levels of a Class 1 laser device may be used without additional requirements. 3.8.2 Center for Devices and Radiological Health (CDRH) documentation shall be submitted to Corporate EHS prior to commissioning a new laser system or plant EHS when modifying an existing laser system. CDRH regulations can be found in 21 CFR, Section I, subchapter J, Parts 1002 to 1040.11. 3.8.3 Laser system shall have a low power mode, visible Class 1or Class 2 laser or other approved method for setup and alignment that limits personnel to Class 2 limits and collateral radiation. 3.8.4 Laser system shall incorporate a method to monitor delivered laser energy and provide programmable alarms to indicate a warning and fault levels. 3.8.5 Laser equipment shall incorporate an emission indicator(s). 3.8.6 Laser systems used in welding, part marking or cutting operations shall meet the air quality requirements of this standard. 3.8.7 Laser protective barriers shall meet the requirements outlined in ANSI Z136.1- 2007 Safe Use of Lasers. 3.8.8 Non walk-in enclosures are preferred. Where walk-in enclosures are required, they shall meet one of the following: U.S. FDA Center for Devices and Radiological Health (CDRH) Policy Notice #37 (1985), IEC[EN] 60825-1 clause 4.12 on Walk-in Workcells, ANSI Z136.1 Safe Use of Lasers 3.8.9 A minimum of one observation window shall be provided to allow a clear view of the process. Additional windows may be required based on process requirements. Remote mounted cameras and safe viewing screens are an acceptable alternative to windows. 3.8.10 Where observation windows are used, they shall be equipped with a replaceable optical filter that: reduces transmission of the beam to acceptable levels below the maximum permissible exposure (MPE) for laser wavelengths that can penetrate glass, and requires a tool to remove, and is properly labeled with its ocular density (OD). 3.8.11 Unless otherwise specified, provisions for fire suppression piping access and fastening shall be provided on a wall and or ceiling that meet local and state fire code. 3.8.12 Any access opening that may permit human access to collateral or laser radiation in excess of limits specified herein shall incorporate an approved safety rated interlock. Refer to clause 4.0 Safeguards and 5.0 Electrical Safeguards for more information. 3.8.13 The laser supplier shall offer laser specific training as outlined in of FCA IH-26 Safety and Health Considerations for Laser Systems, Appendix A. 3.8.14 The receiving plant Laser Safety Officer shall review and approve the laser and protective barrier system prior to operation.
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3.9 ERGONOMIC HAZARDS 3.9.1 Equipment shall be designed and constructed to eliminate cumulative trauma disorders to employees resulting from repetitive motion. 3.9.2 New and altered equipment shall be reviewed and approved to the requirements specified in FCA General Ergonomic Requirements for Industrial Equipment prior to release for operation. 3.10 HAZARDOUS MATERIALS 3.10.1 Equipment, components, material, or devices covered under this standard shall not incorporate or require prohibited chemicals listed in FCA ETI-102 Instructions for the Application & Requesting of Non-Production Hazardous and Potentially Hazardous Material, Appendix A Prohibited Chemicals in their installation, operation, maintenance, repair, or disposal. The manufacturer shall be prepared to provide Full Disclosure with Phenyl, PCB’s and Chrome+6 test results for any deliverable in question to the FCA Specifying Authority to be forwarded to the FCA EHS for review. No proprietary protection agreement shall be allowed, to meet this requirement. 3.10.2 All equipment utilizing hazardous, restricted, or regulated materials not limited to greases, lubrication oils, paint, and coolants shall be designed to operate with corporate approved materials in accordance with FCA ETI-102 Appendix B Regulated Chemicals and ETI-102 Appendix C Restricted Chemicals. 3.10.3 Any material delivered to an FCA facility considered a chemical including paint shall require an FCA ETI-103 Regulated Substance Certification Report, prior to delivery. 3.10.4 Surfaces whose repair or maintenance requires machining, grinding, welding or blasting where the material may become airborne or loose including coatings or paint , shall not use or require any potentially hazardous material listed in FCA ETI 102 Appendix A, B, or C, in its repair, maintenance, use, or disposal. 3.10.5 Hard chrome shall not be used except as listed below: Corrosion protection Improved wear resistance when other methods do not perform. 3.10.6 Deviations shall require approval from FCA EHS. 3.10.7 Hazardous materials contained in piping shall be identified following the methods described in ANSI/ASME A13.1 Standard for the Identification of Pipes. [29 CFR 1910.144] SMI 111 Instructions for the Identification of Facility Piping Systems provides additional information if needed. 3.11 COMPRESSED GASES 3.11.1 Facilities and equipment requiring the use of compressed flammable or non-flammable gases such as oxygen, acetylene, nitrogen, or carbon dioxide shall be designed, constructed, and maintained to meet the requirements of 29 CFR 1910.101 Compressed Gases. Note that regional regulations in the province of Ontario Canada govern compressed gases. [O. Reg. 851, s. 49], 3.11.2 The safe handling and storage of compressed gas containers shall be in accordance with the requirements of 29 CFR 1910.101 Compressed Gases and FCA SMI-115, Handling and Storage of Compressed Gas and Fuel Gas Cylinders. 3.11.3 The safe handling, storage, and use of chemical specific compressed gases shall be in accordance 29 CFR 1910.102-105 (acetylene, hydrogen, and oxygen). 3.11.4 Each gas container shall be equipped with a safety relief device as required by 29 CFR 1910.101 Compressed Gases. 3.11.5 Piping, valves, and fittings used to deliver flammable liquids shall meet the requirements of 29 CFR 1910.106 Flammable Liquids. 3.11.6 The safe handling, storage, and use of liquefied petroleum gas shall be in accordance 29 CFR 1910.110 Storage and Handling of Liquefied Petroleum Gases and FCA SMI-131 Liquefied Petroleum Gas – Safe Unloading and Handling of Bulk Quantities.
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3.11.7 Compressed gas piping shall be identified following the methods described in ANSI/ASME A13.1 Standard for the Identification of Pipes. [29 CFR 1910.144] FCA SMI 111 Instructions for the Identification of Facility Piping Systems provides additional information if needed. 3.12 SPRAY FINISHING USING FLAMMABLE AND COMBUSTIBLE MATERIALS 3.12.1 General FCA design guidelines for ventilation systems are contained in FCA IH-12, Basic Design and Operation Principles of Ventilation Systems. 3.12.2 Any spray finishing including manual, automatic, booth and hand held guns using flammable and combustible materials shall adhere to the requirements of 29 CFR 1910.107. Note that regional regulations in the province of Ontario Canada govern explosive and combustible materials. [O. Reg. 851, s. 63] 3.12.3 All spraying areas shall be provided with mechanical ventilation adequate to remove flammable vapors, mists, or powders to a safe location and to confine and control combustible to provide a safe work environment. Mechanical ventilation shall be kept in operation at all times while spraying operations are being conducted and for a sufficient time thereafter to allow vapors from drying coated articles and drying finishing material residue to be exhausted. [29 CFR 1910.107] 3.12.4 Space within the spray booth on the downstream and upstream sides of filters shall be protected with approved fire suppression. [29 CFR 1910.107] 3.12.5 Filters or filter rolls shall not be used when applying a spray material known to be highly susceptible to spontaneous heating and ignition. [29 CFR 1910.107] 3.12.6 Each spray booth having a frontal area larger than 9 square feet shall have a metal deflector or curtain not less than 2 1/2 inches deep installed at the upper outer edge of the booth over the opening. [29 CFR 1910.107] 3.12.7 Each spray booth shall have an independent exhaust duct system discharging to the exterior of the building. [29 CFR 1910.107] Exception: Multiple cabinet spray booths where identical spray finishing material is used with a combined frontal area of not more than 18 square feet may have a common exhaust. 3.12.8 All fans within a single booth shall be so interconnected that one fan cannot operate without all fans being operated. [29 CFR 1910.107] 3.13 DIPPING, COATING, AND SPRAYING 3.13.1 All processes that include a tank containing a liquid other than water, and/or the draining or drying of an object that has been dipped or coated shall adhere to the requirements of 29 CFR 1910.124 & 1910.125 and FCA SEB 705 Secondary Containment Design and Use. These processes include paint dipping, electroplating, pickling, quenching, degreasing, stripping, cleaning, roll coating, flow coating and curtain coating. 3.13.2 Coolant, washer, coating and other flooded or spray systems shall be contained to prevent environmental and housekeeping hazards (dry floor guarding). 3.14 CONFINED SPACE HAZARDS 3.14.1 Equipment and spaces should be designed to avoid employee exposure to confined spaces as described in 29 CFR 1910.146. Note that regional regulations in the province of Ontario Canada govern access to confined space. [O. Reg. 632/05] 3.14.2 Stairways, ventilation, and lighting may be required to reduce or eliminate employee exposure to confined spaces(s). 3.14.3 Spaces meeting the definition of a confined space (29 CFR 1910.146), shall be identified with warning markings and signs. See clause 6.0 Marking and Safety Identification for label warnings. 3.14.4 Access to confined space access shall require approval by the local safety department and follow the prescribed requirements of FCA IH-28 Safety and Health Requirements for Work in Confined Spaces. 3.15 HAZARDOUS ENERGY 3.15.1 Equipment shall be designed to meet the requirements of 29 CFR 1910.147 Control of hazardous energy (lockout) and FCA SMI-107 Control of Hazardous Energy.
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3.15.2 All sources of power shall be provided with a means for disconnecting and locking out. When the source of power is shut off at this disconnecting device, the stored energies (e.g. mechanical, hydraulic, pneumatic, and electric, etc.) in all functions of the machine shall be neutralized. This neutralization shall include both incoming and stored energies. [ANSI Z244.1] 3.15.3 Where access to the equipment may be necessary without lockout/tagout in place, the equipment shall be designed and constructed to enable alternative safeguarding methods as described sub clause 5.14 Alternative Methods. 3.15.4 All equipment with multiple energy sources shall be equipped with FCA approved lockout graphic(s) prior to equipment operation as specified in FCA SMI-105 Safety Inspection and Approval of Machinery and Equipment and SMI-107 Control of Hazardous Energy. See 6.0 Marking for lockout graphic requirements. 3.16 ELECTRICAL HAZARDS 3.16.1 Electrical equipment shall be designed and constructed to meet the requirements of 29 CFR 1910 Subpart S Electrical, and clause 5.0 Electrical Safeguards of this standard. 3.16.2 Equipment, processes, and production and non-production materials shall be selected and installed to prevent employee exposure to arc flash hazards. 3.16.3 Batteries, battery rooms, and handling methods shall meet the requirements of NFPA 70E Standard for Electrical Safety for Employee Workplaces Article 320 Safety Requirements Related to Batteries and Battery Rooms. 3.17 FIRE SAFETY HAZARDS 3.17.1 Fire extinguishers shall be installed and maintained as required by NFPA 10 Standard for Portable Fire Extinguishers and 29 CFR 1910.157. 3.17.2 Facilities and equipment shall be protected from fire hazards as required by NFPA 13 Standard for the Installation of Sprinkler Systems. 3.17.3 Facilities and equipment shall meet the requirements of NFPA 72 National Fire Alarm and Signaling Code. 3.17.4 The safe handling, storage, and use of flammable and combustible liquids shall be in accordance, with NFPA 30 Flammable and Combustible Liquids Code and FCA SMI-112 Handling of Flammable, Combustible, and Toxic Liquids. [29 CFR 1910.106 Flammable Liquids] Note that regional regulations in the province of Ontario Canada require ventilation where flammable liquids are dispensed. [O. Reg. 851.s. 138] 3.17.5 Flammable and combustible liquid(s) shall be limited to 227 L (60 gal) within a single container or cabinet and be properly stored and labeled as flammable or combustible material. [29 CFR 1910.106] See clause 6.0 Marking and Safety Identification for labeling requirements. 3.17.6 Ignition sources shall not be exposed where flammable materials may be present. Where ignition sources are required, the requirements of FCA SMI-117 Hot Work Permits shall be followed. 3.17.7 Materials used shall not produce a flame spread of more than 25 nor a smoke spread of more than 100 when tested in accordance with the following ASTM Test Methods: E1321-13 Standard Test Method for Determining Material Ignition and Flame Spread Properties. E1623-00 Standard Test Method for Determination of Fire and Thermal Parameters of Materials, Products, and Systems Using an Intermediate Scale Calorimeter (ICAL). E162-13 Standard Test Method for Surface Flammability of Materials Using a Radiant Heat Energy Source. 3.18 THERMAL SURFACES (BURNS) 3.18.1 Devices that raise their surface temperature to over 45° C (113° F) shall require a warning label. [ASTM C-1055] See Appendix A.1for label requirements. 3.18.2 Devices that operate or raise their surface temperature above 54° C (130° F) shall require a warning label and be protected from inadvertent contact by location or guarding that does not negatively affect its operation. See Appendix L for label requirements.
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3.18.3 All exposed pipes carrying steam or other material at a temperature above 54° C (130° F) within seven feet (2.1 m) of the floor or working platform or within 15 inches (380 mm) measured horizontally from stairways, ramps, or fixed ladders shall be covered with an insulating material, or guarded to prevent contact and be identified with a warning label. [29 CFR 1910.261] 3.18.4 Hazardous thermal energy, shall be included in the lockout requirements outlined herein including the servicing and maintenance of equipment. Thermal energy shall be dissipated or controlled (as the result of mechanical work, radiation, chemical or electrical resistance). [29 CFR 1910.147] 3.19 OVERHEAD HAZARDS 3.19.1 Work areas in and around the equipment where an employee has access shall be at least 7 ft. 6 in. (2.3 m) high. Any projection from the ceiling must not reach a point less than 6 ft. 8 in (2.0 m) from the floor or working surface. 3.19.2 Fasteners on overhead equipment subjected to vibration, high inertia loads or that create a hazard in an operator area shall incorporate positive fastener retention with indication. 3.19.3 Overhanging loads more than three feet from the floor that will cause a hazard if accidentally dislodged and fall shall be securely attached to equipment with a restraining safety cable that will not permit dislocation of more than 150 mm (6 inches). The cable shall be sized at four times the load restrained and not be fastened to a bolted machine member. 3.19.4 Overhead conveyors and all moving parts passing over walkways, aisles, or workspaces shall be at least 8ft (2.44m) above the walking surface or otherwise guarded from inadvertent contact. [ANSI/ASME B20.1] Exception: Where guarding is impracticable, awareness barriers and markings shall be used to alert personnel. A risk assessment is required. 3.19.5 Overhead conveyors carrying material over walkways, aisles, or workspaces shall have protection from material falling or dripping on the walking surface The lowest point of any protection or guard shall be at least 6ft 8in (2.0m) above the work surface. [ANSI/ASME B20.1] Exception: Where the 6ft 8in minimum height is impracticable, awareness barriers and markings shall be used to alert personnel. A risk assessment is required. Exception: Where the 6ft 8in minimum height is impracticable and the overhead conveyor is in or passes through an egress route, an alternate egress shall be provided. A risk assessment is required. Informational Note: An additional 20 in (507mm) is required between the lowest point of the carried material and the protective guard as required by 3.20.6. 3.20 MOVING HAZARDS 3.20.1 Access to equipment with residual hazard(s) shall be prevented until the hazard(s) have been removed. 3.20.2 Openings in guards and barriers shall prevent contact with the hazardous motion of the equipment by opening size or placement of guard. 3.20.3 Hazards caused by rotating shafts, v-belts, pulleys, chains, sprockets, and all driving means such as splines, gears, and other nip points, etc., shall have guards that enclose the hazard on all sides. 3.20.4 The clearance between all moving equipment and fixed or other moving equipment shall be no less than 1 inch (25mm) for finger clearance. Exception: Shall require a risk analysis 3.20.5 The clearance between accessible (without guarding) moving equipment and fixed or other moving equipment shall be no less than 4 inches (100 mm) for hand clearance. Exception: Shall require a risk analysis 3.20.6 Where the workspace is restricted to qualified personnel, the working clearance between moving equipment and fixed or other moving equipment shall be no less than 20 inches (508mm). [ISO 13854] Exception: See sub clause 8.7 Robots and Robot Systems for limited exceptions.
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3.20.7 Where personnel may be exposed to pinch or crush hazards from slow moving equipment, the equipment shall incorporate an awareness barrier to alert personnel of the potential hazard and perform a safety rated stop prior to entering the hazard as determined by risk assessment. 3.20.8 Accessible openings measuring less than 0.91 meter (36 inches) by 0.91 meter (36 inches) and within 0.91m (36in) of a potential hazard, shall include a fixed doghouse or tunnel style guard, interlocked movable barrier, safety rated presence sensing device or other effective means to maintain a 0.91m (36 in) reach. Exception: Shall require a risk assessment. 3.20.9 Accessible openings measuring 36 inches (0.91 m) by 36 inches (0.91 m) or more and within 0.91m (36in) of a potential hazard shall require an interlocked movable barrier, or safety rated presence sensing device to prevent access to hazardous motion. Exception: Shall require a risk assessment. 3.21 POINT OF OPERATION HAZARDS 3.21.1 Where improper part loading may create a hazard, part monitoring shall be used to insure the part is properly secured before the cycle can start. 3.21.2 Equipment and processes shall be designed, constructed and maintained to allow loading and unloading outside the point of operation to eliminate the hazard whenever possible. 3.22 UNINTENDED MOTION 3.22.1 Equipment shall be designed to prevent any unintended or hazardous motion in the event of a loss or application of any energy source supplied to the equipment. [NFPA79] 3.22.2 Motions shall incorporate brakes or other restraining devices to prevent hazards due to drifting from equipment wear or air leakage. 3.22.3 Clamping or vacuum cup force against the force of gravity shall incorporate mechanical redundancy or other means to prevent a hazard in the event of a loss of power. 3.22.4 Pneumatic assist mechanisms shall incorporate a fixed orifice or pilot operated check valve to prevent free fall speed from exceeding design speed in the event of a loss or application of electric or pneumatic power. 3.22.5 Wire rope assist devices with travels greater than 12 in (300mm) and loads of 20 lbs. (89N) or greater shall incorporate a drop stop and require a risk analysis.
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4.0 SAFEGUARDING 4.1 GENERAL Informational Note: Safeguarding includes hard guards, presence sensing devices, awareness barriers, and administrative measures. 4.1.1 Automatic operations shall be provided with guarding when motion would cause injury. 4.1.2 Equipment and systems shall meet the requirements of ANSI B11.19 Performance Requirements for Safeguarding and 29 CFR 1910.212. 4.1.3 Safeguarding devices shall be secure, tamper resistant, durable and not defeatable. 4.1.4 Safeguarding equipment and devices shall be installed in accordance with manufacturer’s instructions. 4.1.5 The location of equipment or components requiring daily access for operation, inspection or maintenance should be safely accessible during normal equipment operation to reduce employee exposure to hazards. [ANSI Z244.1] 4.1.6 Safeguarding requirements described in this section are based on physical hazards. The principles should be applied to safeguarding chemical, thermal, EMI/EMR and other hazards. 4.2 GENERAL SAFEGUARDING REQUIREMENTS 4.2.1 All guarding shall be designed to completely enclose machinery/equipment so that a person cannot reach around, under, over, or through and come in contact with a hazardous area. The dimensions listed in Table 4.1 Safe Distance shall be used to meet these requirements.
Table 4.1 Safe Distance Distance from Opening to Hazard Maximum Opening <13mm (0.5in) N.A. 13mm – 63mm (0.5 in-2.5 in) 6mm (0.25in) 64mm – 89mm (2.5 in-3.5 in) 11mm (0.38in) 89mm – 165mm (3.5 in-6.5 in) 16mm (0.64in) 165mm – 445mm (6.5 in-17.5 in) 32mm (1.25in) 445mm – 914mm (17.5 in-36 in) 49mm (1.90in) >914mm (36in) 127mm (5.0in)
Informational Note: Table 4.1 Safe Distance is based on ANSI B11.19 and is more restrictive than the requirements of OSHA 1910.217. 4.2.2 Safety distance calculations are listed in Appendix E Safety Distance. [ANSI B11.19] 4.2.3 Barriers and guards shall be made from a material (type and size) of sufficient strength to retain the expected loads from the application. 4.2.4 Barriers and guards shall be free of sharp edges and projections and not create additional hazards. [ANSI B11.19] 4.2.5 Equipment and devices behind guarding that requires frequent visual inspection for improved maintainability should have visual inspection points designed into the guarding to reduce exposure to potentially hazardous conditions. [ANSI B11.19] 4.2.6 Where inspection windows are used, they shall not reduce the effectiveness of the guard to perform its intended function. 4.2.7 Fixed barriers and guards shall require the use of a common hand tool and unfastening of all associated fasteners for barrier or guard removal.
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4.2.8 Lift off type guarding utilizing keyhole slots, removable pins, quick-release attachments or similar means shall not be used. 4.3 FIXED GUARDS Informational Note: Fixed guards are typically small and fully protect belts, chains, pulleys and other rotating shafts or nip points, and require the use of a tool to remove. 4.3.1 Fixed guards shall be constructed with a minimum metal thickness of 16 gauge (0.0598in, 1.52mm). 4.3.2 Fixed guards shall not utilize horizontal hinges for access. 4.3.3 Guards shall be identified on the external surface by the use of a yellow color conforming to SAFETY YELLOW described in clause 6.0 Marking and Safety Identification. Exception: Alternate color(s) may be used if the hazard/guard is otherwise identified as required by OSHA 29 CFR 1910.144. 4.3.4 Hazards and/or hazardous space shall be identified on the guard interior by the use an orange color conforming to SAFETY ORANGE described in clause 6.0 Marking and Safety Identification. Note: MACHINE WHITE may be used on the guard interior for improved visibility when inspection windows are used. 4.4 BARRIERS AND FENCING Informational Note: Barriers are typically larger than a guard and protect an area of equipment or multiple hazards. They may be equipment or floor mounted. 4.4.1 Barriers and fencing shall be designed, constructed and installed from materials that: provide a clear view of the equipment contained, and provide a minimum of 91kg (200 lbs.) of protection in any direction, and are securely fastened in place and removable for equipment service and repair, using common hand tools, and meet the requirements of ANSI B11.19. Note that regional standards in Canada may govern barriers for machinery [CSA Z432-04] or robots and robot systems [CSA Z434- 03]. 4.4.2 Unless otherwise allowed by this standard, barrier height from the working surface shall be no less than that shown in Table 4.2 Barrier Height, when a minimum of 900mm (36 in) of safety distance to the hazard is maintained.
Table 4.2 Barrier Height Region US / Mexico Canada Height 1600mm (63in) 1800mm (71in) [CSA Z432-04] Standard [ANSI B11.19] [CSA Z434-03]
Exception: Shall require a risk assessment. Exception: Robots and robot systems have alternate requirements. See sub clause 8.7. 4.4.3 Additional (strength, height, or width) guarding shall be required when either: the potential of a falling or flying hazard exist, or a pinch point is within 0.91m (36 in.) of the top of the guarding (reach over condition), or additional equipment or devices are attached to and supported by the barrier. 4.4.4 See Appendix E Safety Distance for additional barrier information.
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4.4.5 Gaps or openings between the barrier and the adjacent walking surface shall be no greater than 180mm (7 in). 4.4.6 Minimum opening size in mesh and wire fencing shall meet the requirements of Table 4.1 Safe Distance for their applications. 4.4.7 Perimeter guarding materials may be made of steel or aluminum framing with round wire (woven) panel, clear polycarbonate (Lexan) panel construction, or horizontal oriented expanded flattened metal where visibility is required. Exception: Solid (reduced visibility) panels may be used where sound, light or physical hazards or nuisance dust and dirt may not be contained by mesh. 4.4.8 Unless otherwise specified in this standard, the inside and outside of barrier frame and supporting structure shall be identified by the use of a yellow color conforming to SAFETY YELLOW described in Section 6.0 Marking and Safety Identification. 4.4.9 Mesh and wire type barrier panels should be identified by one of the following methods: Yellow color conforming to SAFETY YELLOW described in Section 6.0 Marking and Safety Identification, or Flat black with an optional yellow awareness mark in the center conforming to FLAT BLACK and SAFETY YELLOW respectively. Exception: Requires EHS approval. Exception: Mesh and wire type panels used on movable barrier gates. See 4.6.11. Informational Note: While other non-safety colors may be used as an alternate, the proper identification of hazards is a requirement. 4.4.10 An enclosure may be arranged to form a barrier if it: meets the general safeguarding requirements and requirements of the barrier for the application (fixed or movable, hazard protection, and visibility of the controlled equipment), and does not compromise the control enclosure or its contents, and does not create a hazard (fire, electric clearance restrictions, etc…) 4.5 ADJUSTABLE BARRIER Informational Note: Adjustable barriers are typically small, machine or tool mounted and provide protection from a single or point of operation hazard(s). 4.5.1 General safeguard construction requirements apply to all adjustable barriers. 4.5.2 Manually adjustable barriers shall incorporate captive fasteners. 4.5.3 Manually adjustable barriers may incorporate quick release fasteners or clamps for adjustment if the adjustable barrier requires opening an interlocked barrier to gain access. 4.5.4 Adjustable barrier position should be integrated into the adjustment of the hazard whenever possible. 4.5.5 Where material or tooling size or shape varies during equipment operation, self-adjusting barriers may be used (e.g., table saw, or in feeds with self-adjusting in-feed guarding) 4.6 MOVABLE BARRIERS AND GATES Informational Note: Movable barrier can be opened without tools and may enclose only a hazard or allow full body entry. 4.6.1 Moveable barriers or fencing with horizontal hinges shall not be allowed.
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4.6.2 A movable barrier shall incorporate a safety rated interlock as described in clause 5.0 Electrical Safety, to prevent access to hazardous motion using one of the following methods: Immediately remove power to the hazard when the movable barrier is opened to expose the hazard. (NFPA79 Category 0 stop) or Prevent the opening of the movable barrier until the hazard, including residual energy, has been removed or disabled (delayed entry). (NFPA79 Category 1 or Category 2 stop) 4.6.3 A moveable barrier protecting a hazard opening larger than 300mm (12in) shall allow the use of a safety lock or hasp with the barrier open position to prevent closure of the movable barrier and activation of the interlock device. 4.6.4 A movable barrier used as a full body gate access point shall: open out and away from the potential hazard be capable of opening from the inside at all times without keys, tools, or special knowledge. be a minimum of 711mm (28in) wide override any delayed entry safeguarding when opened from inside the hazard area. Exceptions: Shall require a risk assessment. 4.6.5 Movable barrier interlock device shall be located to prevent interlock device activation: from within the hazard area with moveable barrier in the open or closed position, and while the moveable barrier is in the open position and the hazard exposed. 4.6.6 Resuming equipment operation after closing the movable barrier shall require a separate action to restart. [ANSI B11.19] 4.6.7 Movable barrier operation may be powered or manually operated. 4.6.8 Powered barriers shall provide protection against body pinch point hazards caused by the barrier. 4.6.9 Vertical moving barriers shall be counterbalanced, counterweighted, or otherwise protected against free fall. 4.6.10 Movable barrier and guide mechanism hazards shall be guarded against nip points. 4.6.11 Where egress from within a fenced or otherwise bounded area may not be readily apparent, the perimeter frame of a movable barrier gate may be identified as a safe exit with SAFETY GREEN as an alternate to SAFETY YELLOW on the hazard side of the gate only. 4.7 BLOCKING 4.7.1 Hazardous motion for the purpose of blocking describes any motion travel of 6 in (150mm) or greater where the effect of gravity on a 10 degree incline or more or a driving force creates a hazard. 4.7.2 Any hazardous motion caused by the release of stored, residual or re-accumulation of energy (mechanical, electrical, pressure, gravity, etc.) shall have a means provided to block the release of that energy or prevent the resultant hazardous motion. [29 CFR 1910.147] 4.7.3 Manually inserted blocking devices shall incorporate a locking means suitable for lock out/tag out. 4.7.4 Access and operation of a blocking device shall not expose personnel to other hazards. 4.7.5 Where loads may vary due to tool changes, the blocking device shall be clearly marked with its load rating. 4.7.6 Where blocked loads may vary due to tool changes, the tooling shall be clearly marked with its weight. 4.7.7 Integral blocking is an acceptable means of blocking.
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4.7.8 All blocking devices shall incorporate a safety rated interlock that disables the driving force and prevents its operation prior to blocking, and displays status to personnel for proper operation. See clause 5.0 Electrical Safety for safety rated interlock requirements. Exception: Where the blocking device can withstand the driving force without hazard, it may be used without a safety rated interlock to the driving force before blocking. 4.7.9 Safety pin location(s) shall be identified using tiger stripe marking at the insertion point. 4.7.10 Remote operated blocking devices shall be monitored for proper operation in both positions and provide a visual means of proper operation. 4.7.11 Safety blocking devices shall use a minimum safety factor of 4 where the supported load is cyclic or without interlock to the driving force. [ANSI B30.26] 4.7.12 Safety blocking devices may use a minimum safety factor of 2 where the supported load is not cyclic and not under power. [ANSI B11.1] 4.7.13 Blocking from multiple locations for a single load, shall require a risk assessment. 4.8 MECHANICAL STOPS 4.8.1 Mechanical stops shall be provided on equipment that has a range of motion greater than its environment or utilization to prevent crush hazards. Exception: Safety Rated Soft Axis and Space Limiting systems may be used with a risk assessment. [RIA 15.06] 4.8.2 The mechanical stops shall be rated at the equipment’s full speed and load capability with a minimum safety factor of 2. 4.9 BRAKES 4.9.1 Friction brakes, when used shall be capable of stopping and/or holding motion at any point in its travel. 4.9.2 Unless otherwise creating additional hazards, motion brakes shall be spring set and require power (electric or mechanical) to release. 4.10 PRESENCE SENSING 4.10.1 Where a presence sensing device and control circuit is used as part of a safeguard, it shall meet the requirements of this sub clause. 4.10.2 Presence sensing and mat safety devices and their control circuits shall be selected and installed meeting the requirements of clause 5.0 Electrical Safety. 4.10.3 Presence sensing and mat safety devices shall be permanently installed at the required safety distance determined by calculations listed in Appendix E Safety Distance. [ANSI B11.19] 4.10.4 The location and mounting of presence sensing and mat safety devices in operator load stations shall prevent unmonitored areas between the sensing area and hazard. 4.10.5 Safety mats shall be permanently installed on a flat surface and prevent trip hazards for proper operation. 4.11 AWARENESS BARRIER/SIGNALS 4.11.1 An awareness barrier or signal, when used, shall be designed, constructed, and installed to prevent the approach to a hazard or restricted area without a conscious effort and/or contact with the barrier. 4.11.2 The awareness barrier shall not create a hazard in and of itself. 4.11.3 Awareness barriers and safety signs shall be used to clearly identify where adjoining work zones intersect without physical barriers. 4.11.4 Awareness barriers shall require additional safeguards as determined with risk analysis. 4.12 UNAUTHORIZED ACCESS Unauthorized access to protected equipment modes and programmable safety devices that may affect equipment safeguards shall be prevented. [ANSI B11.19]
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4.13 LOAD/UNLOAD WORKSTATIONS 4.13.1 Operator manual load stations shall prevent operators from being exposed to hazardous motion by loading outside the hazard area when possible. See 2.2.1 Hierarchy of safeguarding. Exception: Where loading outside the hazard is not feasible, the following shall apply: The operator shall have exclusive control of each equipment cycle, and The station shall be protected by appropriate guarding selected to prevent access to any exposed hazard as determined by a risk assessment. 4.13.2 Where automatic loading or unloading equipment and devices are used, appropriate guarding shall be selected to prevent access to any exposed hazard as determined by risk assessment. 4.13.3 Where manual backup of an automated process is planned into the equipment or system, the following apply. The operator shall have exclusive control of each equipment cycle. The station shall be protected by appropriate guarding selected to prevent access to any exposed hazard as determined by risk assessment. Automated equipment shall be moved to a position that does not interfere with the manual backup operation. Automated equipment in the workstation shall be shut off and locked out.
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5.0 ELECTRICAL SAFEGUARDS 5.1 GENERAL 5.1.1 The statements within this clause are intended to prevent hazards and injury to personnel from electrical shock, burns, fire and unintended motion. 5.1.2 The statements included in this clause represent minimum requirements of basic concepts and discussion points. The statements are not intended to be comprehensive. 5.1.3 Any situation or point not described in this clause relies on the following standards as they apply: NFPA 70 National Electrical Code NFPA 70E Standard for Electrical Safety Requirements for Employee Workplaces NFPA 79 Electrical Standard for Industrial Machinery ANSI B11.19 Performance Criteria for Safeguarding 5.1.4 Industrial control panels shall meet the requirements of UL 508A. 5.1.5 Additional or alternative requirements may be enforced as stated in clause 2 Design for Safety, of this standard. 5.2 SUPPLY 5.2.1 Electrical power supplied shall meet equipment requirements. 5.2.2 A disconnecting means that meets the Type and Requirements of NFPA 79 shall be provided for each incoming electrical supply to equipment. [NFPA 79] 5.2.3 Each incoming electrical supply disconnecting device shall be labeled to indicate the equipment it disconnects and the locations of all related supply disconnecting devices. [NFPA 79] 5.2.4 Where the disconnecting means does not de-energize all live parts, a permanent warning label shall be visible adjacent to the disconnect device and the live circuits. [NFPA 79] 5.2.5 Where additional disconnect devices are used for local and separate electrical isolation, they shall be readily accessible, within sight of the disconnected equipment, and lockable in the open position only. [NFPA 79] Exception: The use of an attachment plug and receptacle as a disconnecting device allowed by NFPA 79 shall require a risk assessment. 5.2.6 Equipment with multiple disconnect device(s) shall not create a hazard if one or more is left in the (open) off position during equipment operation or cause unintended motion when placed in the closed (on) position. 5.3 SHOCK 5.3.1 Electrical equipment operating at 50 volts or more shall be guarded against accidental contact. [NFPA 79] [NFPA 79E] [29 CFR OSHA 1910.303] 5.3.2 Electrical enclosures with live components that may require examination, adjustment, or service while energized shall maintain the clearance shown in Table 5.1 Electrical Clearance measured from live parts if exposed or enclosure front if enclosed. [NFPA 70]
Table 5.1 Electrical Clearance Nominal Voltage Condition A Condition B Condition C to Ground 0-150 0.9 m (36 in) 0.9 m (36 in) 0.9 m (36 in) 151-600 1.0 m (42 in) 1.0 m (42 in) 1.2M (48 in)
Condition A: Exposed live parts on one side and no live or grounded parts on the other side of the working space, or effectively guarded by insulating material. Condition B: Exposed live parts on one side and grounded parts on the other side. Condition C: Exposed live parts on both sides of the work space.
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5.3.3 Each disconnecting means within or adjacent to enclosures housing electrical equipment operating at 50 volts or more shall be interlocked to prevent opening the enclosure unless power is disconnected. [NFPA 79] Exception 1: Where the use of a key or tool is required to limit access to qualified personnel. Exception 2: Where all live parts are protected from direct contact. 5.4 ARC FLASH 5.4.1 Unless otherwise specified, available bolted fault current supplied by the facility bus to the equipment shall be considered 65kA and protected by Class J current limiting fuses. 5.4.2 The equipment supplier shall perform a flash hazard analysis following the requirements of NFPA 70E Standard for Electrical Safety in the Workplace. The analysis shall be provided as part of the electrical design. 5.4.3 The flash hazard analysis required by paragraph 5.4.2 shall include a one line power diagram that identifies the following devices and their characteristics. Disconnect Switch Voltage, current and IAC rating Fuse. Voltage, current and IAC rating Circuit Breaker Voltage, current and IAC rating Motor HP, RPM, FLA Transformer Voltages, KVA Lighting Disconnect Voltages, KVA, IAC Ground connection Flash Protection Boundary and PPE Enclosure Labeling Conductors Lengths Applied voltage, anticipated fault currents (bolted and incident), 5.4.4 New or revised one line diagrams for any equipment shall be provided to the facility for update to the Site Arc Flash program. 5.4.5 To reduce employee exposure to potential arc flash hazards, electrical devices operating at different voltages should be segregated. 5.4.6 The width of the working space in front of the enclosure housing the electrical disconnect should include an additional 18 inches (450 mm) of horizontal space to one side for safe disconnect operation. 5.5 GROUNDING 5.5.1 Equipment and exposed non-current carrying conductive parts that are likely to become energized shall be effectively grounded to a single equipment grounding (protective) location with the incoming supply. [NFPA 79] 5.5.2 All electronic devices and equipment shall be grounded as recommended by the device or equipment manufacturer. 5.5.3 Accessory receptacles and equipment lighting shall be grounded with a separate grounding conductor to the source of supply or transformer secondary grounding terminal. [NFPA 79] 5.6 CONTROL CIRCUITS 5.6.1 Equipment restart after any stop or loss of power shall require removal of the stop condition and operator reset or initiate command. [NFPA 79] 5.6.2 Push buttons or other control devices used on pendants and their circuits that cause motion shall use Hold to Operate controls. [NFPA 79] 5.6.3 Safety rated devices and their respective control circuits shall have an SRP/CS rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design.
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5.6.4 Equipment operation shall require all interlocked safeguards to be installed. [NFPA 79] Exception: Where temporary operation may be required the Alternative Safeguarding Methods in this clause shall be employed. 5.6.5 It shall not be possible to enable an automatic mode or initiate a sequence from an enabling or pendant device, when used as part of an alternative safeguarding method. 5.6.6 It shall not be possible to enter an adjoining workspace without an enabling or pendant device for that adjoining workspace. 5.6.7 The selection of an enabling device shall have supervisory control to prevent: [ANSI B11.19] unauthorized selection and de-selection of an enabling device(s) while it is in use 5.6.8 All selected enabling devices shall require concurrent operation to activate the equipment enabling circuit. [ANSI B11.19] 5.6.9 A Category 0 stop shall be initiated if any selected enabling device(s) is deactivated. [ANSI B11.19] 5.7 STOP CONTROL CIRCUITS 5.7.1 Electrical stop categories are defined by NFPA 79 Electrical Standard for Industrial Machinery and included in the glossary. Unless otherwise stated, references to stop categories in this standard also apply to equipment motion. 5.7.2 Equipment shall have at least one Category 0 stop (immediate). [NFPA 79] 5.7.3 Category 0 stops shall override all other stops. [NFPA 79] 5.7.4 Category 0 and Category 1 (drives off) stops shall be operational in all equipment modes, disable the relevant circuit and override their related start functions. [NFPA 79] 5.7.5 Category 1 stops shall be allowed only in the following applications: Where personnel are not exposed to the hazard caused by delays in stopping. 5.7.6 Category 2 (drives on) stops shall be allowed only in the following applications: Where personnel are not exposed to the hazard, or Where power removal may cause a hazard without additional safeguards in place. A risk analysis shall be required. 5.7.7 The emergency stop function shall perform a Category 0 stop. [NFPA 79] Exception: Category 1 stop (drives off) may be permitted by an emergency stop with a risk assessment of potential hazards. [NFPA 79] 5.7.8 Combining emergency stop and safeguarding circuits shall not reduce the performance of the safeguarding function. (ANSI B11.19] 5.7.9 Reset of an emergency stop device or circuit shall not initiate a restart. [NFPA 79] 5.7.10 Barrier safety rated interlocks shall perform a Category 0 stop when deactivated. Exception: A Category 1 (drives off) or Category 2 (drives on) may be allowed as determined by a risk analysis. 5.7.11 Interlocks that perform a Category 2 stop shall require an additional safeguarding device. Informational Note: An enabling device is an example of an additional safeguarding device.
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5.8 START CONTROL CIRCUITS 5.8.1 Equipment initiation where pinch, shear or other hazards exist shall be protected by one of the following operator controlled methods when their respective requirements are met: Hold to operate control requiring continuous actuation of the control device during the hazardous portion of the equipment cycle. [NFPA 79] Two hand controls requiring concurrent release and continuous actuation of the control devices using both hands until the hazard is no longer present. Additional requirements for two hand control are identified in NFPA 79. Single control permanently located at the proper safety distance as determined from Appendix E Safety Distance. [ANSI B11.19] Single control with presence sensing located at the proper safety distance as determined from Appendix E Safety Distance. 5.8.2 Where more than one operator control station is required to initiate a start, all start control devices shall be operated concurrently. [NFPA 79] 5.9 PRESENCE SENSING DEVICE INITIATION CONTROL CIRCUITS (PSDI) 5.9.1 The use of PSDI as an operator control method shall be determined by risk assessment. 5.9.2 PSDI control circuits and devices shall meet the requirements of ANSI B11.19. 5.9.3 PSDI control functions shall be used only on machines which can be stopped anywhere in their cycle. [ANSI B11.19] 5.9.4 PSDI shall only initiate a single machine cycle for normal production operation. [ANSI B11.19] 5.10 CONTROL DEVICES 5.10.1 The devices identified in this sub-clause shall meet the approval criteria identified in sub-clause 2.12 Component Approval. 5.10.2 The selection of control devices in this sub clause shall be based on the hierarchy of safety in clause 2.2.1 Hazard Mitigation. 5.10.3 A control device that performs a Category 2 stop (drives on) shall not be lockable. 5.10.4 Push buttons that perform an emergency stop shall also: [NFPA 79] [RIA 15.06] a. be RED in color. b. be mushroom or palm operated. c. be unguarded and unobstructed. d. be self latching w/manual reset. e. have positive opening contacts or have a minimum SRP/CS Cat 3 rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design. f. include a yellow background immediately around the push button Note: The red/yellow combination is reserved for emergency stop functions only. 5.10.5 Cable and rope operated devices used for emergency stop shall detect both a broken or pulled cord. [ANSI B11.19] [NFPA 79] 5.10.6 Foot pedal control devices shall not be used for Emergency Stop. 5.10.7 Operator controls for cycle stop or position stop should be yellow in color and may perform a controlled stop for their respective equipment. 5.10.8 Unless otherwise specified, push buttons that perform a cycle stop shall be non-lockable. 5.10.9 Foot pedal control devices that initiate a hazardous motion shall be fully guarded, require full foot insertion for proper operation and incorporate positive opening snap action contacts. Risk assessment shall determine their use. 5.10.10 Two hand trip devices shall not be used.
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5.10.11 Pressure sensitive mat devices and controllers shall have an SRP/CS Cat 3 rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design and shall: [ANSI B11.19] a. not create a hazard. b. detect a minimum object sensitivity of 80mm (3.25in) including joints between adjacent mats. c. indicate its status to persons within its sensing surface. d. not have its response time or sensitivity be affected by ambient light, temperature or humidity. e. include supervisory control over programmable settings. 5.10.12 Optical presence sensing devices shall have an SRP/CS Cat 4 rating as described in ISO 13849- 1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design and be approved and shall: [ANSI B11.19] a. not create a hazard. b. detect a minimum object sensitivity of 32mm (1.25in). c. indicate its status to persons within its sensing field. d. not have its response time or sensitivity be affected by ambient light, temperature or humidity. e. supervisory control over programmable settings. 5.10.13 Unless otherwise specified, an optical area scanner shall have an SRP/CS Cat 3 rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design and shall: [ANSI B11.19] a. not create a hazard. b. have a documented object sensitivity at full range. c. indicate its status to persons within its sensing field. d. not have its response time or sensitivity be affected by ambient light, temperature or humidity. e. supervisory control over programmable settings. 5.10.14 Interlock devices used with moving barriers shall: [RIA 15.06] [ANSI B11.19 Explanatory] [CSA Z432.4] have a key, actuator or plug that is not easily duplicated be secure and tamper resistant have a minimum SRP/CS rating of Cat 3 as described in ISO 13849-1:2008 Safety of Machinery- Safety related parts of control system – General Principles for design. 5.10.15 An enabling device shall incorporate three position switches with positive opening contacts or have a minimum SRP/CS Cat 4 rating as described in ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design that initiates a Category 0 or Category 1 stop. [RIA 15.06] [ANSI B11.19] 5.10.16 A pendant or portable teaching control device shall incorporate an enabling device. [RIA 15.06] 5.10.17 Enabling devices shall have three positions that permit motion when continuously held in the center position. [RIA 15.06] 5.10.18 Each person in the hazardous area shall have their own enabling device. [ANSI B11.19] [RIA 15.06] 5.10.19 Powered barrier locking devices shall require power to lock. Exceptions: Risk assessment. 5.10.20 Safety control devices not listed here shall require a risk assessment for use. Refer to clause 2.0 Design for Safety of this standard for approval.
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5.11 LOCATION AND MOUNTING 5.11.1 The location of operator controls shall provide an unobstructed view of the controlled equipment. [NFPA 79] Exception: Where visibility is reduced for portions of the equipment, an additional manual control shall be provided for that portion of the equipment only. 5.11.2 Operator controls shall be located: [NFPA 79] a. within normal reach of the operator, and b. away from hazards, and c. protected from excessive contamination, and d. protected against inadvertent operation, and e. provided with a legend that is durable and readable from the operator’s normal position. 5.11.3 Where multiple control stations are provided for equipment, an effective means of preventing equipment operation from more than a single control station shall be provided. [NFPA 79] Exceptions: (1) Emergency stop functions shall operate at all times. (2) Where concurrent actuation is required by all operators to initiate motion. 5.11.4 All start buttons shall be recessed or suitably guarded to prevent accidental activation. [ANSI B11.19] 5.11.5 Stop controls must be arranged within easy reach of all affected employees. [NFPA-79] 5.11.6 An emergency stop device shall be located within or adjacent to the operator control station. [ANSI B11.19] [NFPA 79] Note: Additional emergency stop devices shall be located as determined by risk assessment. [ANSI B11.19] [NFPA 79] 5.11.7 Cable operated switch devices shall utilize high tensile cable and reduced friction pulleys. 5.11.8 Cable used on cable operated switches shall be red in color. 5.12 CONDUCTORS, CONNECTORS, AND WIRING METHODS 5.12.1 Wiring methods, cables, and conductors shall meet the requirements of NFPA 79 Electrical Standard for Industrial Machinery. 5.12.2 Wiring not enclosed in conduit shall consist of multi-conductor cord or cable designated for “hard usage” with no exposed connections. Cables when used shall be compatible with the equipment environment. Exceptions: As allowed by NFPA 70 National Electrical Code. 5.12.3 Electrical connectors which could cause hazardous motion if mismatched, shall be keyed to prevent incorrect attachment. [RIA 15.06] 5.12.4 Electrical connectors which may cause hazardous motion if separated or break away, shall be designed, constructed and installed to prevent unintended separation. [RIA 15.06] 5.12.5 Conductors that remain energized when the disconnecting device is in the off position shall be identified using an orange color throughout its length or with orange markers. [NFPA-79] Exception: Conductors that remain energized on equipment other than new may be identified using a yellow color throughout its length or with yellow markers. 5.13 MUTING 5.13.1 Muting of a device used as part of a safety rated control system shall be permitted during the non- hazardous portion of the equipment cycle. [ANSI B11.19] 5.13.2 The safety rated parts of the muting control system shall have the same safety rating as the safety rated parts of the control system to be muted. [ANSI B11.19] Exception: Alternative technologies may be used if determined through a risk assessment, it can be demonstrated to be equivalent to the designated architecture of the claimed safety category. 5.13.3 Muting of a safeguarding device or control circuit shall be indicated to individuals within the area protected by the device. [ANSI B11.19]
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5.14 ALTERNATIVE SAFEGUARDING 5.14.1 Where access to the equipment may be necessary without lockout/tagout in place, the equipment shall be designed and constructed to enable alternative safeguarding methods as described here that provide equivalent and effective protection as required by 29 CFR 1910.147, ANSI/ASSE Z244.1-2003 (R2008) Control of Hazardous Energy—Lockout/Tagout and Alternative Methods, and FCA SMI-107 Control of Hazardous Energy. 5.14.2 The following tasks are considered routine, repetitive, and integral to production processes and may be considered with alternative safeguarding methods. [ANSI Z244.1] a. minor cleaning b. lubrication c. tool change or adjustment d. minor repair e. part removal Exception: Requires a determination by risk assessment. 5.14.3 Allowable work details for each of the tasks in 5.14.2 shall be defined by local plant EHS and readily available for employee review and awareness. 5.14.4 The hierarchy of alternative control methodologies listed below shall be used when selecting alternative safeguarding methods: [ANSI Z244.1] (1) Eliminate the hazard if possible (2) Substitution (3) Provide engineered controls to mitigate the hazard (4) Provide administrative controls to educate employees and identify hazards (5) Provide employees with personal protective equipment (PPE) to safely work with the hazard. 5.14.5 Affected personnel shall have exclusive control of the equipment and/or hazardous energy by the use of one or more of the following alternative safeguarding methods: [ANSI Z244.1] lock enabling device point of hazard location blocking 5.14.6 Control devices and circuits used to override safeguards as part of alternative methods shall provide an equivalent level of protection as the suspended safeguard and: [NFPA 79] [ANSI Z244.1] a. disable automatic mode. b. disable incoming external signals. c. not disable emergency stop devices and their control circuits. d. equipment motion within affected area shall be under the exclusive control of the personnel within the affected area. e. limit the motion speed, power or range of motion. 5.14.7 Alternative safeguarding methods shall have written procedures available. [ANSI Z244.1]
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6.0 MARKING AND SAFETY IDENTIFICATION 6.1 GENERAL Unless otherwise stated in this standard, marking and safety awareness shall meet the requirements of ANSI Z535 Safety Alerting Standards. 6.2 COLORS 6.2.1 Unless otherwise stated in this standard, the use of colors to identify hazards, and safeguards, shall follow ANSI Z535.1 Safety Color Code. See Appendix K Safety Color Identification for color descriptions. 6.2.2 FCA SAFETY RED shall be used to identify the following: Flammable liquid containers. Emergency stop devices. General dangerous hazard indication. Fire suppression piping 6.2.3 FCA SAFETY ORANGE shall be used to identify the following: Moving hazards. Interior of guards. MACHINE WHITE may be used for improved visibility when inspection windows are used. General warning hazard indication. Toxic or corrosive fluid piping. 6.2.4 SAFETY YELLOW shall be used to identify the following: a. Structures of safety barriers, fencing, hand railings, ladders, step edges, and balcony toeboards. b. Exterior of guards and barriers. c. Handles of manually operating tooling and safety devices. d. Bumper posts and rails. e. Outlines of aisle ways, traffic lanes, and paths of egress. f. Flammable fluid or vapor piping. Exception: FLAT BLACK may be used on mesh or wire fencing panels only. 6.2.5 Tiger stripe marking (yellow/black) shall be painted / taped in the following: Where safety pins are to be applied. Floor trip hazards. Head bump hazards Mechanical motion hazards, e.g., robot axis limits, low clearance overhead conveyors, etc. 6.2.6 SAFETY GREEN shall be used to identify the following: a. First aid equipment. b. Safety instruction signs c. Safe areas. d. Equipment emergency escape locations. e. Potable and non-potable water piping. 6.2.7 SAFETY BLUE shall be used to identify the following: Informational non safety notices. Compressed air piping. 6.2.8 Surfaces where paint is required shall be painted with an EHS approved paint. See sub-clause 3.10 Hazardous Materials for information on approved paints.
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6.2.9 Commercially colored surfaces (powder coat, anodize, etc.) that cannot be painted should utilize similar but distinct colors referenced above. 6.2.10 Additional information on proper identification of piping may be found in sub-clause 3.10 Hazardous Materials. 6.3 WARNING LABELS 6.3.1 Warning labels for electrical equipment shall be provided as required by NFPA 70 National Electrical Code, NFPA 79 Electrical Standard for Industrial Machinery and NFPA 70E Electrical Safety Requirements for Employee Workplaces. 6.3.2 Warning labels shall conform to ANSI Z535.4 Product Safety Signs and Labels. (See Appendix L Safety Labels for more information.) 6.4 SIGNAGE 6.4.1 Warning signage and placards shall conform to ANSI Z535.4 Product Safety Signs and Labels. 6.4.2 Where lockout graphic(s) are required they shall meet the requirements of ANSI Z244.1 Control of Hazardous Energy, FCA SMI-107 Control of Hazardous Energy, and shall be located as follows: a. All equipment shall have one graphic posted at the equipment main electrical panel. Exception: Equipment with a single energy source (electric, water, gas, steam, and compressed air) are not required to have a lockout graphic. b. All transfer type equipment shall have one additional graphic posted at a location on each side of the process/operation and at each interlocked barrier or console. c. All systems with multiple processes located within perimeter guarded cells, shall have one additional graphic on each side of the cell and at each interlocked barrier. d. If the energy control requirements cannot be covered in a single plan view because of system complexity, additional plan views may be produced. 6.5 VISUAL DISPLAYS Visual beacons, marquee displays and operator interface indicators shall follow the color required by NFPA-79 Electrical Standard for Industrial Machinery for the appropriate state. 6.6 ROTATING BEACONS 6.6.1 Rotary or flashing beacon may be used as an awareness device as part of secondary safeguarding method. 6.6.2 Beacons, when used shall be located to be visible from anywhere in the affected area. 6.7 HORNS 6.7.1 When an audible warning is used as part of an awareness safeguarding method, it shall a. be distinguishable from the ambient sound. [29 CFR 1910.37, 1910.165] b. have a minimum sound pressure level of 15dBA higher than the average ambient sound pressure level and 5dBA higher than the maximum ambient sound pressure level that sounds for 60 seconds or more. [NFPA 72] c. not exceed a sound pressure level of 110 dBA at the minimum hearing distance. [NFPA 72] d. be located no lower than 3m (118in) from the floor and project onto the hazard area. e. be sounded for a minimum of three seconds and end five seconds prior to equipment movement that may present a hazard. Additional time may be required as determined by risk assessment. Informational Note: 29 CFR 1910.37 titled Maintenance, safeguards, and operational features for exit routes requires alarm systems to have a distinctive signal and comply with 29 CFR 1910.165 Employee Alarm Systems. Informational Note: NFPA 72 National Fire Alarm and Signaling Code Handbook is the only consensus standard that describes audible alarm sound pressure levels. There is no standard on maximum or minimum time requirement for sounding or waiting.
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6.7.2 When an audible warning is used as part of an awareness safeguarding method, warning signs shall be displayed in the affected area to communicate the audible warning purpose. [ANSI B11.19] 6.8 DOCUMENTATION 6.8.1 Safety instructions and references within design, maintenance, and service manuals and instructions shall include the requirements of ANSI Z535.6 Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials. 6.9 SIGNAL WORDS 6.9.1 DANGER: Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury. Safety Signs identified by the signal word DANGER should be used sparingly and only for those situations presenting the most serious hazards. (ANSI Z535.1) 6.9.2 WARNING: Indicates a potentially hazardous situation which, if not avoided, will result in death or serious injury. Hazards identified by the signal word WARNING present a lesser degree of risk of injury or death than those identified by the signal word DANGER. (ANSI Z535.1) 6.9.3 CAUTION: Indicates a hazardous situation, which if not avoided, could result in minor or moderate personal injury. It may also be used without the safety alert symbol as an alternative to “NOTICE”. ANSI Z535.1) 6.9.4 NOTICE: is the preferred signal word to address practices not related to personal injury. The safety alert symbol should not be used with this signal word. As an alternative to “NOTICE”, the word “CAUTION” without the safety alert symbol may be used to indicate a message not related to personal injury. 6.9.5 Safety instructions or safety equipment location signs indicate general instructions relative to safe work practices, reminders of proper safety procedures, or the location of safety equipment. (ANSI Z535.1) 6.10 SAFETY SYMBOLS 6.10.1 Hazard Alert: This type of safety symbol conveys information primarily related to the nature of hazards, how to avoid the hazard and sometimes the consequences of not avoiding the hazard. The hazard alerting symbol should be drawn within a yellow equilateral triangle. (ANSI Z535) 6.10.2 Prohibition Symbols: This type of safety symbol conveys actions that should not be taken. This symbol consists of a red circular band with a 45° diagonal red band from upper left to lower right. The symbol contains a black image within the red band on a white background. 6.10.3 Mandatory Action Symbols: This type of safety symbol conveys actions that should be taken to avoid hazards. The symbols consist of a white image within a solid blue or black circular surround shape. (ANSI Z535) Information Symbols: This type of safety symbol is generally used on ANSI Z535.2 Environmental Safety or Fire Safety Signs, to convey equipment location, permitted actions and fire equipment location. (ANS Z535)
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7.0 OTHER SYSTEMS 7.1 GENERAL 7.1.1 Fluid circuits shall be designed and components selected, applied, mounted, and adjusted to provide uninterrupted operation, extended life and control reliable operation. 7.1.2 To reduce exposure to equipment hazards, equipment requiring inspection, adjustment should be readily accessible while the equipment is in operation. 7.1.3 Devices controlled electrically, pneumatically and/or hydraulically shall be selected and applied so that failure of the control media, or of a component, does not cause a hazard. 7.1.4 Where a hazard may result if operating pressures are exceeded, tamper-resistant (e.g., internal positive stop, nonadjustable, etc.) over-pressure protection shall be provided. 7.1.5 Pressure adjustment control devices shall incorporate a pressure gauge with the safe working pressure range indicated. 7.1.6 Pneumatic and hydraulic systems in industrial equipment ensure the sound pressure level of the equipment meet the requirements of sub-clause 3.6 Occupational Noise Hazards. 7.1.7 Fluid(s) identified in FCA ETI-103 Regulated Substance Certification Report shall be approved prior to use. 7.2 HYDRAULIC SAFEGUARDS 7.2.1 Pressure and flow control components shall be constructed in a manner that prevents adjustment outside their safe working range. The manufacturer's information plate on pressure control components shall be marked to indicate their minimum and maximum pressure limits. 7.2.2 Hydraulic devices controlled electrically, pneumatically, and/or hydraulically shall be selected and applied so that failure of the control media does not cause a hazard or damage to the equipment. 7.2.3 Circuits shall be designed, constructed, and adjusted to minimize surge pressures. The hydraulic components shall withstand existing surge pressures. 7.2.4 Where loss of working pressure could cause a hazard, means shall be provided to prevent operation under this condition. 7.2.5 Hydraulic circuits incorporating accumulators shall automatically vent the accumulator when the equipment is shut off. 7.2.6 Isolation shall prevent uncontrolled movement of the actuators in case manual overrides on associated equipment are operated. 7.3 PNEUMATIC SAFEGUARDS 7.3.1 Unless otherwise specified, pneumatic equipment shall have a main air supply line lockout valve accessible from the working level. This valve shall have provision for locking in the “off’ position and shall safely vent, where no hazard exists, all circuit pressure when in the “off’ position. 7.3.2 The main supply lockout valve shall plainly indicate whether it is in the open or closed position. Exception: A lockout valve is not required on non-actuating circuits of 30 PSI or less. 7.3.3 Unless otherwise specified, the main supply lockout valve body shall be yellow in color with red operating lever or handle. 7.3.4 Where additional lockout devices are used for local and separate pneumatic isolation, they shall be readily accessible, within sight of the disconnected equipment, and lockable in the open position only. 7.3.5 Where there is more than one source of air supply on the equipment and possible hazard or damage could result from failure of any one source, means shall be provided to protect personnel and equipment if any one source fails. 7.3.6 Exhaust ports of all pneumatic devices, except pilot exhaust, shall be equipped with a suitable muffler or silencer located to protect personnel and equipment from the exhaust air and blown particles.
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7.3.7 Unless otherwise specified, where required for safe, efficient, and economical system performance, pressure regulators shall be of the relieving type. 7.3.8 Pipe, valves, and fittings manufactured from polyvinyl chloride (PVC) shall not be used on compressed air systems. 7.3.9 Nonmetallic bowls susceptible to fracture shall be shielded to avoid hazard. Unprotected, nonmetallic bowls shall not be used. 7.3.10 Circuits shall: operate within the component manufacturer’s specifications. be protected against over-pressure. be so designed and applied that surge pressure, over-pressure, and loss of pressure do not cause hazard or damage to the equipment. 7.3.11 Receivers and surge tanks shall: a. be constructed in accordance with the American Society of Mechanical Engineers (ASME) Boiler and Pressure Vessel Code Section VIII. b. be equipped with an (ASME) approved safety relief valve set and sized to relieve at or below the tank-design working pressure. c. have a manually operated vent valve. Appropriate instructions for vent valve use shall be permanently displayed at the valve. d. be permanently marked with outstanding words reading “CAUTION PRESSURE VESSEL”. e. have safety valves, dump valves, and gages that are protected from damage by freezing. f. be so installed that all drains, handholds, and manholes are easily accessible. g. NOT be buried underground or located in an inaccessible place. Exceptions: None.
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8.0 SPECIFIC EQUIPMENT SYSTEM SAFEGUARDS 8.1 GENERAL 8.1.1 In addition to the other requirements of this standard, specific equipment shall meet the applicable requirements of this clause. 8.1.2 FCA manufacturing engineering organizations may have supplemental requirements for equipment within their authority that shall be considered part of this standard. See Appendix B FCA-NAFTA Engineering Organizations for a list of organizations with supplemental requirements. 8.2 ASSEMBLY SYSTEMS 8.2.1 Guarding openings shall be designed as small as possible. To reduce an opening size, profile guarding with 4 inch (10 cm) hand clearances shall be utilized. 8.2.2 All exposed rotating shafts, sockets, and extensions on production power tools shall be smooth, have no projections and be guarded by location or non-rotating safety sleeves without gaps. Two hand operator safety devices do not meet this requirement. 8.3 CONVEYOR SAFEGUARDS 8.3.1 Conveyors used in manufacturing equipment and systems shall meet the requirements of ANSI B20.1 Safety Code for Conveyors, Cableways, and Related Equipment. 8.3.2 Power and free floor conveyor systems designed with pedestal style pallets shall not create pinch points to the feet during transfer. 8.3.3 Conveyor crossovers with 2 or more steps shall require a hand rail over the conveyor. The hand rail shall be installed on the upstream side of the conveyor crossover in-between the stair rails. 8.3.4 Conveyor crossovers shall meet the egress requirements of this standard. 8.3.5 Conveyors that isolate workspace access shall have a crossover(s) or other equally effective means to ensure proper egress. 8.4 CRANE SAFEGUARDS 8.4.1 Overhead top running bridge cranes shall meet the appropriate requirements of ASME B30.2 Overhead and Gantry Cranes (Top Running Bridge, Single or Multiple Girder, Top Running Trolley Hoist) or ASME B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single , Underhung Hoist). 8.4.2 Overhead monorails, underhung cranes, hoists and wire rope assists shall meet the requirements of ASME B30.11 Monorails and Underhung Cranes. 8.4.3 Stacker cranes shall meet the requirements of ASME B30.18 Stacker Cranes (Top or Under Running Bridge, Multiple Girder with Top or Under Running Trolley Hoist). 8.5 METAL CUTTING EQUIPMENT SAFEGUARDS 8.5.1 Equipment and systems that utilize one or more grinding machines shall meet the requirements of ANSI B11.09 Safety Requirements for Grinding Machines. 8.5.2 Equipment and systems that utilize one or more gear or spline cutting machine tools shall meet the requirements of ANSI B11.11 Safety Requirements for Gear and Spline Cutting Machines. 8.5.3 Equipment and systems that utilize one or more multiple spindle automatic bar and chucking machines shall meet the requirements of ANSI B11.13 Machine Tools - Single- and Multiple- Spindle Automatic Bar and Chucking Machines - Safety Requirements for Construction, Care and Use. 8.5.4 Equipment and systems shall meet the requirements of ANSI B11.20 Safety Requirements for Integrated Manufacturing Systems. 8.5.5 Equipment and systems that utilize one or more turning machines shall meet the requirements of ANSI B11.22 Safety Requirements for Turning Centers and Automatic Numerically Controlled Turning Machines.
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8.5.6 Equipment and systems that utilize one or more CNC machines shall meet the requirements of ANSI B11.23 Safety Requirements for Machining Centers and Automatic Numerically Controlled Milling, Drilling and Boring Machines. 8.6 PRESS EQUIPMENT SAFEGUARDS 8.6.1 Equipment and systems that utilize one or more machine tools shall meet the requirements of ANSI B11.18 Safety Requirements for Machines Processing or Slitting Coiled or Non-coiled Metal. 8.6.2 Equipment and systems that utilize one or more mechanical power presses shall meet the requirements of ANSI B11.1 Safety Requirements for Mechanical Power Presses. 8.6.3 Equipment and systems that utilize one or more hydraulic or pneumatic presses shall meet the requirements of ANSI B11.2 Safety Requirements for Hydraulic and Pneumatic Presses. 8.7 ROBOT AND ROBOT SYSTEM SAFEGUARDS 8.7.1 In addition to the general requirements of this standard, equipment and systems that utilize one or more programmable robots shall meet the requirements of this sub clause. 8.7.2 Industrial robots or robot systems shall be installed in accordance with their manufacturers’ specifications and ANSI/RIA 15.06 Industrial Robots and Robots Systems – Safety Requirements. Exception: Regional standards in Canada govern Robots and robot systems. [CSA Z434-03]. 8.7.3 Safeguards shall prevent: the operator from being in the work envelope (program path) during robot motion, or robot motion while any part of an operator’s body is within the work envelope. 8.7.4 Access to the restricted work space by personnel shall be prevented by one or more of the following: 1. A fixed barrier that prevents personnel from reaching over, under, around or through the barrier into the restricted work space, or 2. An interlocked barrier guard that prevents access to the restricted work space except by opening an interlocked gate, or 3. Presence sensing device that detects intrusion into the safeguarded space and placed at the proper safety distance from the restricted space. 4. Awareness barriers constructed and installed so that personnel cannot approach the industrial robot’s restricted work space without sensing the presence of the awareness barrier and meeting the requirements of sub clause 4.11 Awareness Barriers. 8.7.5 Unless otherwise allowed by this standard, barrier height used on robot systems shall be no less than 1400mm (55 in) when a minimum of 900mm (35.4 in) of safety distance to the hazard is provided. Informational Note: Robot system barrier minimum height is an exception to the general requirements for barriers stated in sub clause 4.4. 8.7.6 Barrier height of 1600mm (63 in) shall be required where additional hazards are present or the safety distance to the hazard is less than 900mm. 8.7.7 Restricted space shall be established by one of the prioritized methods listed below which minimize the total distance an industrial robot can travel. [RIA 15.06] 1. installation of mechanical limiting devices and /or 2. use of industrial robot safety soft axis limiting software with risk assessment, or 3. reinforced barrier guards 8.7.8 The use of mechanical stops shall be rated at the equipment’s full speed and load capability.
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8.7.9 The restricted space limits of robot axis J1 shall be identified by one or more of the following methods in order of preference: Lockout placard identification. See SMI-107 Control of Hazardous Energy (Lockout) for placard requirements. High contrast floor markings, e.g. tiger stripes. (See 6.0 Marking and Safety Identification) 8.7.10 The safeguarded space shall be protected by perimeter barriers located outside the robot’s restricted space. 8.7.11 Unless otherwise specified, the supplier shall determine the locations and set all electrical, mechanical, and software limit stops for operating space and restricted space. 8.7.12 The equipment design layout should minimize the difference between the work envelope and the restricted space. 8.7.13 The supplier shall provide the equipment design layout of each robot work station for EHS review and approval (ref sub-clause 2.6 Project Management-Design). The equipment design layout shall provide the necessary views, sections and dimensions to install the industrial robot(s) and its associated equipment in the work station and include: any and all details, supports, units, transfer rails, etc., that are located within the industrial robot's work envelope program path, and the industrial robot(s) work envelop, including the attached EOAT (end-of-arm-tool), restricted space, safeguarded space, and maximum space. 8.8 FACILITY MECHANICAL SAFEGUARDS 8.8.1 Electrical equipment and systems including facility power supply and distribution shall meet the requirements of NFPA 70 National Electrical Code. 8.8.2 Boilers and steam generation shall meet the applicable requirements of the ANSI/ASME Boiler and Pressure Vessel Code – 2013 edition. 8.8.3 Compressor and compressor installations shall meet the requirements of ANSI/CAGI B19.1, Safety Standard for Air Compressor Systems 8.8.4 Heating, ventilation, and Air Conditioning shall meet the requirements of NFPA 90A Standard for the Installation of Air Conditioning Systems and NFPA 90B Standard for the Installation of Warm Air Heating and Air Conditioning Systems. 8.9 INDUSTRIAL TRUCKS AND MOVING PLATFORMS 8.9.1 Powered industrial trucks shall meet the requirements of FCA Safety Material Handling Engineering SMHE-109 Safety Requirements For Powered Industrial Trucks. 8.9.2 Moving work platforms shall meet the requirements of 29 CFR 1910.67 Vehicle mounted Elevating and Rotating Work Platforms and FCA SMHE-111 Safety Requirements for Vehicle Mounted and Manually Propelled Elevated and Rotating Work Aerial Devices.
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9.0 REFERENCES 9.1 ANSI PUBLICATIONS - AMERICAN NATIONAL STANDARDS INSTITUTE, WASHINGTON, DC ANSI B11.0 Safety of Machinery; General Requirements and Risk Assessment ANSI B11.1 Safety Requirements Mechanical Power Presses ANSI B11.2 Safety Requirements for Hydraulic and Pneumatic Presses. ANSI B11.09 Safety Requirements for Grinding Machines. ANSI B11.11 Safety Requirements for Gear and Spline Cutting Machines. ANSI B11.13 Machine Tools – Single - and Multiple-Spindle Automatic Bar and Chucking Machines - Safety Requirements for Construction, Care and Use. ANSI B11.18 Safety Requirements for Machines Processing or Slitting Coiled or Non-coiled Metal. ANSI B11.19 Performance Criteria for Safeguarding ANSI B11.20 Safety Requirements for Integrated Manufacturing Systems. ANSI B11.22 Safety Requirements for Turning Centers and Automatic Numerically Controlled Turning Machines. ANSI B11.23 Safety Requirements for Machining Centers and Automatic Numerically Controlled Milling, Drilling and Boring Machines. . ANSI/ASME A13.1 Standard for the Identification of Pipes. . ANSI/ASME B20.1 Safety Code for Conveyors, Cableways, and Related Equipment . ANSI/ASME B30.11 Monorails and Underhung Cranes . ANSI/ASME B30.17 Overhead and Gantry Cranes (Top Running Bridge, Single, Underhung Hoist). . ANSI/ASME B30.18 Stacker Cranes (Top or Under Running Bridge, Multiple Girder with Top or Under Running Trolley Hoist). . ANSI/ASME B30.26 Rigging Hardware . ANSI/ASME Boiler and Pressure Vessel Code – 2013 edition. . ANSI/CAGI B19.1, Safety Standard for Air Compressor Systems . ANSI/RIA 15.06 Industrial Robots and Robots Systems – Safety Requirements . ANSI/RIA TR 15.206 Industrial Robots and Robots Systems – Safety Requirements . ANSI Z136.1 Safe Use of Lasers . ANSI/ASSE Z244.1-2003 (R2008) Control of Hazardous Energy—Lockout/Tagout and Alternative Methods. . ANSI/ASSE Z359.1: Safety Requirements for Personal Fall Arrest Systems, Subsystems and Components ANSI Z434-2003 (R2013) Industrial Robots and Robot Systems – General Safety Requirements. ANSI Z535.1 Safety Colors ANSI Z535.2 Environmental and Facility Signs ANSI Z535.3 Criteria for Safety Symbols
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ANSI Z535.4 Product Safety Signs and Labels ANSI Z535.5 Safety Tags and Barrier Tapes ANSI Z535.6 Product Safety Information in Product Manuals, Instructions, and Other Collateral Materials
9.2 ASTM PUBLICATIONS - AMERICAN SOCIETY OF TESTING MATERIALS, WEST CONSHOHOCKEN, PA E1321-13 Standard Test Method for Determining Material Ignition and Flame Spread Properties. E1623-00 Standard Test Method for Determination of Fire and Thermal Parameters of Materials, Products, and Systems Using an Intermediate Scale Calorimeter (ICAL). E162-13 Standard Test Method for Surface Flammability of Materials Using a Radiant Heat Energy Source ASTM C-1055 Standard Guide for Heated System Surface Conditions that Produce Contact Burn Injuries.
9.3 CANADIAN STANDARDS ASSOCIATION, TORONTO, ON, CANADA CSA Z432.4 Safeguarding of Machinery CSA Z434 Industrial Robots and Robot Systems CSA Z460 Control of Hazardous Energy - Lockout and Other Methods CSA C22.1 Canadian Electrical Code CSA Z462 Workplace Electrical Safety Standard.
9.4 FCA NAFTA, CORPORATE AUDIT, AUBURN HILLS, MI Corporate Process Guideline ADM 059 Federal and State OSHA 9.5 FCA NAFTA, ENVIRONMENT, HEALTH, & SAFETY, AUBURN HILLS, MI ETI-102 Instructions for the Application & Requesting of Non-Production Hazardous and Potentially Hazardous Material. ETI-103 Regulated Substance Certification Report IH-06 Hearing Conservation IH-12 Basic Design and Operation Principles of Ventilation Systems IH-21 Publication of Final Rule for OSHA's PEL Project IH-26 Safety and Health Considerations for Laser Systems IH-28 Safety and Health Requirements for Work in Confined Spaces. ME-PT Machinery Equipment Specification Section 15889 Oil Mist/Dust Collection Systems MHEP-205 Internal Plant Traffic Isles SEB 410 Refrigeration and Air Conditioning Equipment Regulations SEB 705 Secondary Containment Design and Use SEB 707 Asset Removal and Shipment Procedures. SEB 802 Non-Bulk Battery Shipping Procedures SMHE-109 Safety Requirements For Powered Industrial Trucks SMHE-111 Safety Requirements for Vehicle Mounted and Manually Propelled Elevated and Rotating Work Aerial Devices
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SMI 105 Safety Inspection and Approval of Machinery & Equipment SMI-107 Control of hazardous energy (Lockout) SMI-110 Confined Spaces (cancelled, see IH-28) SMI-112 Handling of Flammable, Combustible, and Toxic Liquids SMI-115 Handling and Storage of Compressed Gas and Fuel Gas Cylinders. SMI-117 Hot Work Permits. SMI-131 Liquefied Petroleum Gas – Safe Unloading and Handling of Bulk Quantities SMI-157 Safety Fall Hazard Control Requirements SMI -161Safety Guidelines for Pedestrian Safety – Aisle, Dock, and Storage Area Identification. Sound Level Standard for Industrial Machinery and Equipment
9.6 INTERNATIONAL ELECTROTECHNICAL COMMITTEE, GENEVA, SWITZERLAND IEC [EN] 60825-1 clause 4.12 on Walk-in Workcells, 9.7 INTERNATIONAL ORGANIZATION FOR STANDARDIZATION, GENEVA, SWITZERLAND ISO 10218-2 Robots and robotic devices - Safety requirements for industrial robots - Part 2: Robot systems and integration ISO 13849-1:2008 Safety of machinery – Safety-related parts of control system – General Principles for design. ISO 13854 Safety of machinery -- Minimum gaps to avoid crushing of parts of the human body 9.8 NFPA PUBLICATIONS – NATIONAL FIRE PROTECTION ASSOCIATION, QUINCY, MA NFPA 10 Standard for Portable Fire Extinguishers. NFPA 13 Standard for the Installation of Sprinkler Systems NFPA 30 Flammable and Combustible Liquids Code NFPA 70 National Electrical Code NFPA 72 National Fire Alarm and Signaling Code NFPA-79 Electrical Standard for Industrial Machinery NFPA 70E Standard for Electrical Safety Requirements for Employee Workspaces NFPA 90A Standard for the Installation of Air Conditioning Systems NFPA 90B Standard for the Installation of Warm Air Heating and Air Conditioning Systems. NFPA 101 Life Safety Code
9.9 ONTARIO MINISTRY OF LABOR O. Reg. 332/12 Building Code O. Reg. 438/07 Product Safety O. Reg. 632/05 Confined Spaces O. Reg. 851 Industrial Establishments 9.10 OSHA PUBLICATIONS - OCCUPATIONAL HEALTH AND SAFETY ADMINISTRATION, U.S. DEPT. OF LABOR 21 CFR Chapter I, Subchapter J Part 1040.2 through 1040.11 Performance Standards for Laser Products
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29 CFR 1910 Subpart S Electrical 29 CFR 1910.22 General requirements. 29 CFR 1910.23 Guarding floor and wall openings and holes. 29 CFR 1910.24 Fixed industrial stairs. 29 CFR 1910.27 Fixed ladders. 29 CFR 1910.30 Other working surfaces. 29 CFR 1910.36 Design and construction requirements for exit routes. 29 CFR 1910.67 Vehicle mounted Elevating and Rotating Work Platforms 29 CFR 1910.66 App C - Personal Fall Arrest System 29 CFR 1910.94 Ventilation 29 CFR 1910.101 Compressed Gases 29 CFR 1910.102 Acetylene 29 CFR 1910.103 Hydrogen 29 CFR 1910.104 Oxygen 29 CFR 1910.105 Nitrous oxide 29 CFR 1910.106 Flammable Liquids 29 CFR 1910.107 Spray finishing using flammable and combustible materials. 29 CFR 1910.110 Storage and Handling of Liquefied Petroleum Gases 29 CFR 1910.124 General requirements for dipping and coating operations 29 CFR 1910.125 Additional requirements for dipping and coating operations that use flammable liquids or liquids with flashpoints greater than 199.4 *F (93 *C). 29 CFR 1910.146 Permit-required confined spaces 29 CFR 1910.147 Control of Hazardous Energy 29 CFR 1910.157 Portable fire extinguishers. 29 CFR 1910.212 Machine Guarding 29 CFR 1910.217 Mechanical power presses. 29 CFR 1910.303 Electrical General.
9.11 UNDERWRITERS LABORATORIES, NORTHBROOK, ILLINOIS UL 508A Standard for Industrial Control Panels
9.12 U.S. FDA CENTER FOR DEVICES AND RADIOLOGICAL HEALTH (CDRH) Policy Notice #37 (1985)
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10.0 GLOSSARY OF TERMS Additional definitions are located in sub-clause 1.3 Definitions. accessible – admitting close approach; not guarded by locked doors, elevation, or other effective means. [NFPA 79, NFPA 70] accessible, readily – capable of being reached quickly for operation, renewal, or inspection, without requiring those to whom ready access is requisite to climb over obstacles, or to resort to portable ladders, etc. [NFPA 79, NFPA 70] affected personnel – personnel required to operate or perform equipment maintenance under lockout/energy control. Refer to FCA SMI-107 Control of Hazardous Energy. alternating tread – step design with narrowly defined treads for separate left foot and right foot access. approved – material that meets specified criteria. autonomous maintenance – Maintenance performed by unskilled personnel. Cleaning, lubricating, inspecting, and retightening are included. barrier – a physical object that does not completely enclose a hazard, but reduces access by shape or location from the hazard. barrier, adjustable – any barrier that with the use of a tool can be adjusted for proper operation prior to equipment operation, but remains fixed during equipment operation. barrier, fixed – any barrier that is not movable or adjustable at any time except for removal with the use of a tool during equipment repair. barrier, interlocked – any movable barrier equipped with a safety rated interlock device that disables the hazardous motion if opened. barrier, movable – any barrier that can readily move without the use of a tool. The movement may be guided or unguided. category 0 stop – an uncontrolled stop by immediate removal of power to the machine actuators. [NFPA 79] category 1 stop – a controlled stop with power to the machine actuators available to achieve the stop and removal of power when the stop is achieved. [NFPA 79] category 2 stop – a controlled stop with power left available to the machine actuators. [NFPA 79] class 1- a laser considered to be incapable of producing damaging laser exposure during operation and is, therefore exempt from any control measures or other forms of surveillance. [ANSI Z136.1] class 2 – a laser that emits in the visible portion of the spectrum (0.4 to 0.7 μm), and eye protection is normally afforded by the aversion response. [ANSI Z136.1] collateral radiation – any electronic radiation except laser radiation emitted by the laser equipment during operation. controls – means mechanical, electrical, pneumatic, hydraulic means of equipment operation. cycle – a complete movement of motion or equipment from the start position through the working position ending in the start position. [ANSI B11.11] cycle stop – a control system command to stop the continuous operation of the equipment at the end of its current cycle. electromagnetic Field/Electromagnetic Radiation (EMF/EMR) floor hole – an opening measuring less than 12 inches and more than 1 (one) inch in its least dimension in any floor, platform, pavement, or yard, through which materials but not persons may fall such as a belt hole, pipe opening, or slot opening.
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floor opening – an opening measuring 12 inches or more in its least dimension, in any floor, platform, pavement, or yard, through which persons may fall such as a hatchway, stair or ladder opening, pit or large manhole. Floor openings occupied by elevators, dumb waiters, conveyors, machinery, or containers are excluded from this subpart. guard – any physical object that completely encloses a hazard. handrail - a single bar or pipe supported on brackets from a wall or partition, as on a stairway or ramp, to furnish persons with a handhold in case of tripping. hazard – a potential source of harm to a person. hazardous energy – any electrical, mechanical, pneumatic, hydraulic, chemical, nuclear, thermal, gravity, or other energy that could cause injury to personnel. hazardous Motion - motion that is likely to cause personal physical injury or damage to health. HEPA – High Efficiency Particulate Arrestance. A US Department of Energy filter designed to remove 99.97% of particulates 0.3µm and larger. interlock – an arrangement where two or more mechanisms or control devices allow or prevent the other(s) from occurring. kit – an engineered package that may include loose or assembled components that when installed into an existing system alters the “As Designed” safety controls. ladder stand – a mobile fixed size self-supporting ladder consisting of a wide flat tread ladder in the form of stairs. The assembly may include handrails. Laser Safety Officer (LSO) – FCA personnel assigned responsibility for ensuring laser welding systems meet health and safety requirements of the local installation. nip point – where two parts move together and at least one part moves in a rotary or circular motion. personal Protective Equipment (PPE) – equipment worn to minimize exposure to serious workplace injuries and illnesses such as gloves, safety glasses and shoes, earplugs or muffs, hard hats, respirators, or coveralls, vests and full body suits. Preliminary Hazard List (PHL) – A report of initial hazard assessment. Preliminary Hazard Analysis (PHA) – A report of risk caused by hazards and controls to reduce risk. presence sensing device initiation (PSDI) – A presence sensing device used to initiate as equipment start control device. refurbish – the repair of equipment or system to its original specification without modification. (ANSI/RIA 15.06 Industrial Robots and Robots Systems – Safety Requirements) remanufacture – the engineering or modification of equipment or system to a new or revised specification. (ANSI/RIA 15.06 Industrial Robots and Robots Systems – Safety Requirements) safety factor (SF) – the ratio of capacity or strength to the applied stress or expected load. safety related parts of a control system (SRP/CS) safeguarding device – A device that detects or prevents inadvertent access to a hazard. [ANSI B11.19] stop, emergency – The stopping of a machine, manually initiated, for emergency purposes. [ANSI B11.19] stop, protective – The stopping of the machine initiated by safeguarding. [ANSI B11.19]single control - a single actuating control used to initiate or maintain machine motion, located at a safe distance from the hazard. [ANSI B11.19] space, maximum – space that can be swept by the robot including EOAT. [RIA 15.06] space, restricted – portion of the maximum space restricted by limiting devices that establish limits which will not be exceeded. [RIA 15.06]
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space, safeguarded – space defined by perimeter guarding. [RIA 15.06] SRP/CS Category 3 - for category 3, the same requirements as those according to category B shall apply. Well-tried safety principles according to category 1 shall also be followed. In addition the SRP/CS of category 3 shall be designed so that a single fault in any of these parts does not lead to the loss of the safety function. Whenever reasonably practicable, the single fault shall be detected at or before the next demand upon the safety function. [ISO 13849-1] SRP/CS Category 4 - for category 4, the same requirements as those according to category B shall apply. Well-tried safety principles according to category 1 shall also be followed. In addition the SRP/CS of category 4 shall be designed such that: [ISO 13849-1] a single fault in any of these safety related parts does not lead to a loss of safety function, and the single fault is detected at or before the demand upon the safety functions, e.g. immediately, at switch on, or at end of a machine operating cycle. standard railing - a vertical barrier erected along exposed edges of a floor opening, wall opening, ramp, platform, or runway to prevent falls of persons. [29 CFR 1910.21] unintended motion - the normal motion of equipment occurring at an unexpected time.
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Index 15889...... 10, 39 environmental...... iv, 4, 5, 6, 10, 13, 32, 38 aerial ...... 37, 39 EPA...... 6 affected personnel...... 29, 42 EPATS ...... 4 alternative method ...... 6, 14, 25, 29 ETI-102...... 12, 39 ANSI B11.1...17, 18, 20, 21, 23, 25, 26, 27, 28, 32, 35, ETI-103...... 12, 33, 39 36, 38, 42, 43, 49, 55, 57, 58 Flat Black...... 67 ANSI B11.19.17, 18, 20, 21, 23, 25, 26, 27, 28, 32, 38, FM...... 7 43, 49, 55, 57, 58 foot pedal ...... 26 ANSI B30.26 ...... 21, 38 green...... 20, 30, 67 ANSI Stds....4, 8, 11, 12, 13, 14, 15, 17, 18, 20, 21, 23, ground ...... 24 25, 26, 27, 28, 29, 30, 31, 32, 35, 36, 37, 38, 39, 42, 43, hazardous material ...... 12, 52, 60 49, 55, 57, 58, 64, 67 HEPA...... 10, 43 ANSI Z136.1 ...... 11, 38, 42 hydraulic...... 14, 33, 36, 38, 42, 43, 51 ANSI Z244.1 ...... 14, 17, 29, 31, 38, 49 IEC [EN] 60825-1...... 11, 40 ANSI Z535 ...... 30, 31, 32, 38, 39, 67 IH-06...... 10, 39 ANSI/ASSE Z359.1...... 8, 38 IH-12...... 9, 13, 39 ANSI/ASSE Z590.3...... 4 IH-21...... 9, 10, 39 ANSI/CAGI B19.1 ...... 37, 38 IH-25...... 9 applicable...... iii, 1, 2, 3, 6, 9, 10, 35, 37, 50, 63 IH-26...... 11, 39 approved..v, 1, 2, 4, 6, 7, 11, 12, 13, 14, 27, 30, 33, 34, IH-28...... 13, 39, 40 42, 63, 67 Industrial Hygiene...... 9, 10, 11, 13, 39, 40 ARRS...... 4 industrial truck ...... 37 ASME standards...... 7, 12, 13, 15, 34, 35, 37, 38, 48 interlock ...... 11, 20, 21, 25, 42, 43, 63 ASTM C-1055 ...... 14, 39 ISO 10218-02...... 40 ASTM E1321-13 ...... 14, 39 ISO 13849-1...... 7, 24, 26, 27, 40, 44 ASTM E162-13 ...... 14, 39 ISO 13854 ...... 15, 40 ASTM E1623-00 ...... 14, 39 JSRA ...... 3 ASTM standards...... 14, 39 label...... 9, 13, 14, 15, 23, 65 awareness...... 15, 16, 17, 19, 21, 29, 30, 31, 32, 36 Laser...... 11, 39, 40, 43 barrier....5, 9, 11, 15, 16, 17, 18, 19, 20, 21, 27, 30, 31, Lexan...... 19 36, 37, 42, 44, 51, 53, 56, 57 lockout...6, 13, 14, 15, 29, 31, 33, 37, 38, 39, 40, 42, 49 battery...... 6, 14, 39 lubrication ...... 12, 29 Canada.iii, iv, 3, 4, 6, 7, 8, 9, 12, 13, 14, 18, 36, 39, 47, Machine White...... 67 49, 50, 52, 53, 54 maintenance..4, 5, 6, 8, 9, 12, 15, 17, 31, 32, 42, 51, 62, Canadian Ministry of Labor...... 3 64 Cat 3 ...... 26, 27 Mexico Secretaría del Trabajo y Previsión Social ...... 3 Cat 4 ...... 27 MHEP-205 ...... 8, 39 Category 0 stop...... 20, 25, 27, 42 mute...... 28 Category 1 stop...... 20, 25, 27, 42 NEMA Stds...... 67 Category 2 stop...... 20, 25, 26, 42 NFPA 6, 7, 14, 23, 24, 25, 26, 28, 29, 31, 37, 40, 42, 49 CDRH ...... 11, 41 NFPA 10 ...... 14, 40 CEPA...... 6 NFPA 13 ...... 14, 40 clearance...... 5, 9, 15, 18, 19, 23, 30, 50, 52, 53, 60 NFPA 30 ...... 14, 40 conductor ...... 24, 28 NFPA 70...... 6, 7, 14, 23, 24, 28, 31, 37, 40, 42, 49 crush ...... 16, 21 NFPA 70E...... 14, 23, 24, 31, 40, 49 CSA ...... 7, 18, 27, 36, 39, 49 NFPA 72 ...... 14, 31, 40 deviation ...... 7 NFPA 79 ...... 23, 24, 25, 26, 28, 29, 31, 42 EHS....1, 2, 4, 5, 6, 7, 11, 12, 19, 29, 30, 37, 60, 61, 63 NFPA 90A ...... 37, 40 emergency...... 25, 26, 28, 29, 30, 43 NFPA 90B...... 37, 40 EMR/EMR...... 10, 17, 42, 60 noise ...... 10, 33 enabling ...... 14, 25, 27, 29, 61 NRTL...... 7 enclosure...... 4, 9, 10, 11, 19, 23, 24 O. Reg...... 4, 7, 8, 9, 12, 13, 14, 40, 50, 52, 53, 54
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Ontario..4, 7, 8, 9, 12, 13, 14, 40, 49, 50, 52, 53, 54, 63 SEB 410 ...... 6, 39 OSHAiii, 1, 3, 7, 8, 9, 11, 12, 13, 14, 15, 17, 18, 20, 23, SEB 707 ...... 6, 39 29, 31, 37, 39, 40, 41, 44, 67 SEB 802 ...... 6, 39 PHA ...... 4, 5, 43, 60, 61, 62 SMHE-109 ...... 37, 39 PHL...... 3, 5, 43, 60 SMHE-111 ...... 37, 39 pinch ...... 16, 18, 20, 26, 35 SMI-105 ...... 5, 14 pneumatic...... 14, 16, 33, 36, 38, 42, 43, 51 SMI-107 ...... 13, 14, 29, 31, 37, 40, 42 positive opening contacts...... 26, 27 SMI-112 ...... 14, 40 PPE ...... 2, 3, 5, 6, 8, 24, 29, 43 SMI-115 ...... 12, 40 Pre-Start Health and Safety Review...... 4, 50, 63 SMI-117 ...... 14, 40 PSDI ...... 26, 43 SMI-131 ...... 12, 40 red ...... 26, 30, 67 SMI-157 ...... 8, 40 regional..3, 4, 7, 8, 9, 12, 13, 14, 18, 36, 49, 50, 52, 53, SMI-161 ...... 8 54 sound ...... 10, 19, 31, 33, 40, 60 Regional...... 3, 4, 36, 47, 49, 50 SRP/CS...... 7, 24, 26, 27, 43, 44 RIA 15.06 ...... 21, 26, 27, 28, 36, 38, 43, 44, 49 tiger stripe ...... 21, 30, 37 risk assessment.3, 4, 5, 9, 15, 16, 18, 20, 21, 22, 23, 25, TSSA...... 7 26, 27, 28, 29, 31, 36, 38, 55, 64 unintend...... 16, 23, 28, 44 Safety Green ...... 20, 30, 67 unintended ...... 16, 23, 28, 44 Safety Orange ...... 18, 30, 67 validation...... 1, 5 Safety Red...... 30, 67 verification ...... 1, 5 Safety Yellow...... 18, 19, 20, 30, 54, 67 yellow...... 18, 19, 20, 26, 28, 30, 32, 33, 54, 67 SEA...... 30
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APPENDIX A
FCA - NAFTA FACILITIES
The following FCA-NAFTA locations are included in the scope of this standard.
(BVAP) Belvidere Stamping and Assembly Plant (DEP) Dundee Engine Plant (CAAP) Conner Avenue Assembly Plant (ITP1) Indiana Transmission Plant 1 (JNAP) Jefferson North Assembly Plant (ITP2) Indiana Transmission Plant 2 (SHAP) Sterling Heights Assembly Plant (KTP) Kokomo Transmission Plant (SSP) Sterling Stamping Plant (KCP) Kokomo Casting Plant (TAC) Toledo Assembly Complex (MEC) Mack Engine Complex (WTAP)Warren Truck Assembly Plant (TTP) Tipton Transmission Plant (WSP) Warren Stamping Plant (TEC) Trenton Engine Complex (ATD) Autodie Tool and Die (TMP) Toledo Machining Plant (METD) Mt. Elliot Tool and Die (CPG) Chrysler Proving Grounds Chelsea (WCMA) WCM Academy Warren (APG) Chrysler Proving Grounds Arizona (CTC) Chrysler Technical Center Auburn Hills Chrysler Group Transport Detroit Chrysler Florida Evaluation Center Naples Chrysler Group Transport Toledo Baltimore Transformation Center Maryland
(BAP) Brampton Stamping and Assembly Plant CPK Interior Products Guelph (ECP) Etobicoke Casting Plant CPK Interior Products Belleville (WAP) Windsor Assembly Plant CPK Interiors Port Hope FCA Canada Windsor Chrysler Group Transport Windsor
(STAP) Saltillo Truck Assembly Plant (SNEP) Saltillo North Engine Plant (SVAP) Saltillo Van Assembly Plant (SSEP) Saltillo South Engine Plant (SASP) Saltillo Stamping Plant (TAP) Toluca Assembly Plant Chrysler de Mexico (TSP) Toluca Stamping Plant WCM Academy Saltillo Chrysler Group Transport Mexico FCA Mexico Center for Research, Development and Testing of Automotive Engineering, Cuajimalpa
22 Mopar Parts Distribution Centers across the United States, Canada, and Mexico. 12 Regional Business Centers
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APPENDIX B
FCA - NAFTA ENGINEERING ORGANIZATIONS
The following FCA-NAFTA engineering organizations may have supplemental requirements that are considered part of this standard.
Facility Engineering Authority Powertrain and Component Operations CTC Manufacturing Engineering Powertrain (ME-PT) Stamping Plant Operations CTC Advance Stamping Manufacturing Engineering (ASME) Assembly Plant Operations CTC Manufacturing Engineering – Body In White Stamping and Assembly Conveyors CTC Manufacturing Engineering – General Assembly Conveyors Mopar Parts Distribution Centers Centerline Mopar Facilities All buildings and grounds CTC Manufacturing Engineering – Building Construction Assembly Plant Paint Operations CTC Manufacturing Engineering – Paint Operations
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APPENDIX C
REGIONAL REQUIREMENTS
The industry consensus standards and their regional counterparts that are considered part of this standard are listed in Table C1 Regional Industry Standards. It is not implied that the associated standards are identical. Only that their scope is similar and should be used when the appropriate regional standards apply.
Table C1 Regional Standards FCA Listed Standard Regional Standard ANSI B11.19 Performance Criteria for Safeguarding CSA Z432-04 Safeguarding Machinery ANSI/RIA 15.06 Industrial Robots and Robots Systems CSA Z434 Industrial Robots and Robot Systems – Safety Requirements ANSI Z244.1 Control of Hazardous Energy - CSA Z460 Control of Hazardous Energy - Lockout Lockout/Tagout and Alternative Methods and Other Methods NFPA 70 National Electrical Code Ontario Electrical Safety Code (OESC) - CSA C22.1 Canadian Electrical Code NFPA 70E Standard for Electrical Safety Requirements CSA Z462 Workplace Electrical Safety Standard. for Employee Workplaces National Recognized Approvals Ontario Electrical Safety Authority
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APPENDIX C (CONT’D)
REGIONAL REQUIREMENTS
The regulatory requirements identified in this standard are listed in Table C2 Regional Regulatory References. The list is not all inclusive. The user should be familiar with all regional regulatory differences when applicable.
Table C2 Regional Regulatory References Sub clause Reference The province of Ontario Canada may require a Pre-Start Health and Safety Review. [O. Reg. 851, s. 7] 2.2 See Appendix H Pre-Start Health and Safety Review Checklist for more information. The province of Ontario Canada requires testing laboratories to be accredited by the Standards Council 2.12 of Canada. [O. Reg. 438/07] The province of Ontario Canada requires railings to be a minimum of 36 inch (910 mm) to 42 inch (1070 mm). [O. Reg. 851, s. 11] 3.3 The province of Ontario Canada requires a 5 inch (125 mm) high toe board. [O. Reg. 851, s. 14] The province of Ontario Canada allows fixed ladders or stairs for daily activities. [O. Reg. 851, s. 19] The province of Ontario Canada requires a minimum of 36 inch (900mm) access. [Ontario Building 3.4 Code] The province of Ontario Canada governs access to confined space. [O. Reg. 851, s. 138], and air quality 3.5 [O. Reg. 851, s. 128] 3.11 The province of Ontario Canada governs compressed gases. [O. Reg. 851, s. 49], 3.12 The province of Ontario Canada governs explosive and combustible materials. [O. Reg. 851, s. 63] 3.14 The province of Ontario Canada governs access to confined space. [O. Reg. 632/05] The province of Ontario Canada requires ventilation where flammable liquids are dispensed. 3.16 [O. Reg. 851.s. 138] The province of Ontario Canada requires cages on ladders extending higher than 5m (16.5feet) Appendix [O. Reg. 851, s. 18]. D6 The province of Ontario Canada requires cages to extend from 2133mm (84 in.) to a point 36 inch (900mm) above the exit landing. [O. Reg. 851, s. 18]. Appendix The province of Ontario Canada allows a minimum of 81 in (2050mm) vertical clearance to an overhead D7 hazard. [Ontario Building Code]. The province of Ontario Canada allows a railing minimum of 34 in (865mm) to a maximum of 38 in Appendix (965mm). [Ontario Building Code]. D8 The province of Ontario Canada requires a minimum of 5 in (125mm) toeboard height. [O. Reg. 851, s. 14]. Appendix The province of Ontario Canada requires a minimum of 2 in (50mm) handrail clearance. [Ontario D9 Building Code]. The province of Ontario Canada allows a maximum of 9 feet (30 feet) between ladder platforms [Ontario Building Code]. Appendix Where stairs are used to ascend heights greater than 20 feet (3.7m), regional regulations in Canada D11 require landing platforms. [Ontario Building Code]. The province of Ontario Canada allows a minimum of 36 in (900mm) to a maximum of 42 in (1070mm) above the landing surface. [O. Reg. 851, s. 18].
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APPENDIX D
BALCONIES, PLATFORMS, LADDERS AND STAIRWAYS
D.1 PURPOSE D.1.1 To identify the minimum requirements of the U.S. Department of Labor for industrial machinery and provide supplemental FCA requirements to them for the design and construction of permanent elevated balconies, platforms, catwalks, ladders, and stairways used with manufacturing equipment. D.1.2 It is not the intent of this appendix to override the U.S. Department of Labor minimum safety requirements. D.2 SCOPE D.2.1 This appendix applies to all permanent elevated balconies, platforms, catwalks, ladders, and stairways used with manufacturing equipment in FCA facilities. D.2.2 This appendix does not apply to barriers used at floor level, ladder stands, mobile scaffolds, or balconies, platforms, catwalks, ladders, and stairways not part of the industrial equipment. D.3 GENERAL D.3.1 All balconies, platforms, catwalks, ladders, and stairways shall meet the appropriate requirements of the following U.S. Department of Labor standards: 1910 Subpart D - Walking-Working Surfaces 1910.21 - Definitions. 1910.22 - General requirements. 1910.23 - Guarding floor and wall openings and holes. 1910.24 - Fixed industrial stairs. 1910.27 - Fixed ladders. 1910.30 - Other working surfaces. D.3.2 Requirements of U.S. Department of Labor standards are identified by reference to the respective paragraph with brackets e.g. [ ]. D.3.3 Where conflicts arise between the U.S., state and local Department of Labor organizations and this document, the most restrictive requirement shall apply. D.4 LOADING Balcony, platform, and catwalk load ratings shall be conspicuously and permanently displayed.
D.5 ACCESSIBILITY D.5.1 Balconies, platforms, and catwalks shall be designed to provide adequate space around equipment and allow the surface to be kept clean from fluids and debris that may create a hazard under normal operating or maintenance, or inspection conditions. [22(b)] D.5.2 Balcony shall be designed and constructed to provide safe accessibility to all electrical, hydraulic and pneumatic installations. D.5.3 Safety railings on balconies may be removable with the use of a tool to provide safe access for heavy and bulky equipment. D.5.4 Where personnel may be exposed to hazardous conditions that prevent access to the exit of the balcony, platform or catwalk, an alternate access point with similar accessibility shall be provided. D.5.5 Alternating tread design shall not be used for ladders or stairways. D.6 LADDERS D.6.1 Ladders shall be designed and constructed to support a single concentrated load of 90kg (200 lbs.) at any location and the expected normal live load(s) (including the weight of the ladder) in multiples of the single concentrated load located at the point of greatest stress. [27(a)] D.6.2 The distance between ladder rungs, cleats, or steps shall not exceed 300mm (12 in.), and shall be uniform throughout its length. [27(b)]
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D.6.3 The clear width of rungs shall be no less than 400mm (16 in.). [27(b)] D.6.4 Ladder rungs shall be constructed of a slip resistant material and be no smaller than 19mm (3/4 in.) in diameter. [27(b)] D.6.5 Ladders shall be designed and constructed to prevent slipping off the either end (R/L) of the rung. [27(b)] D.6.6 Ladders shall be installed at a pitch between 75 degrees and 90 degrees to the horizontal. [27(e)] D.6.7 The distance to any object behind the rungs shall be no less than 178mm (7 in.) [27(c)] Note that regional regulations in the province of Ontario Canada allow a minimum of 6 in (150mm) clearance. [Ontario Building Code]. D.6.8 Cages shall be required on all ladders extending higher than 6.1m (20 feet). [27(d)] Note that regional regulations in the province of Ontario Canada require cages on ladders extending higher than 5m (16.5feet) [O. Reg. 851, s. 18]. D.6.9 Cages shall extend from a point between 2133mm (84 in.) and 2438mm (96 in.) to a point 1067mm (42 in.) above the upper exit platform or floor of the ladder. [27(d)] Note that regional regulations in Canada require cages to extend from 2133mm (84 in.) to a point 36 inch (900mm) above the exit landing. [O. Reg. 851, s. 18]. D.6.10 The lower edge of the cage shall be flared open a minimum of 100mm (4 in.) or portion of cage opposite the ladder carried to the base. [27(d)] D.6.11 Cages shall be no less than 685mm (27in) in width and between 685mm (27in) and 711mm (28in) in depth. [27(d)] D.6.12 Cages shall incorporate vertical bars at 40 degree maximum spacing around the perimeter. [27(d)] D.6.13 Ladder handrails shall measure between 770mm (30 in.) and 860mm (34 in.) vertically from the top rail to the leading edge of the ladder rung. D.6.14 The minimum distance to any object in front of the rungs or steps shall be no less than 762mm (30 in.) Exception: Where cages are used. D.6.15 Any protruding hazard within 762mm (30in) of the center of the rungs or steps shall be fitted with deflector plates placed at an angle of 60 degrees from the horizontal. [27c] D.7 STAIRWAYS D.7.1 Fixed stairways shall be provided for access from one platform or level to another where [24(b)]: Access to those levels is required daily, or Employees may be exposed to hazardous materials, caustics, acids, etc., or Carrying of hand tools or equipment is required. D.7.2 Stairways shall be design and constructed to provide the greater of 453kg (1000 lbs.) or five times the expected normal live load minimum. [24(c)] D.7.3 Stairway angle shall be no less than 30 degrees and no more than 50 degrees measured from the horizontal with 40 degrees preferred. [24(e)] D.7.4 Stairway treads shall be constructed from a slip resistant material (e.g. Grip-Strut). [24(f)] D.7.5 Stairway rise height and tread width shall be uniform including any stairway foundation step. [24(f)] D.7.6 Stairway platforms shall be 762mm (30 in.) in length minimum. [24(f)] D.7.7 Stairway width shall be no smaller than 560mm (22 in.). [24(d)] D.7.8 Steps shall be clear of obstructions throughout their entire width. [23(d)] D.7.9 Stairways shall be no wider than 2210mm (87in.). D.7.10 Stairways shall be straight. Winding stairways shall not be used. [24(b)] D.7.11 Vertical clearance above any stair tread to an overhead obstruction shall be at least 2135mm (84 in.) measured from the leading edge. [24(i)] Note that regional regulations in the province of Ontario Canada allow a minimum of 81 in (2050mm) vertical clearance to an overhead hazard. [Ontario Building Code]. D.7.12 Stairways with four or more risers shall be equipped with:
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D.7.13 Handrails or railing on both sides, [23(d)] [24(h)] or D.7.14 Handrail on one side and a barrier on the other. [23(d)] [24(h)] D.7.15 Where only one handrail is supplied, it shall be located on the right side descending where possible. [23(d)] [24(h)] D.7.16 The location of ladders and stairways shall be coordinated with the FCA Specifying Authority and receiving plant layout. D.7.17 Unless otherwise specified, the underside of stairway structures shall be covered with a removable debris pan. The pan when used shall have a noncorrosive finish and provide a minimum of 25mm (1 in.) of clearance between step tread and the pan surface. D.8 RAILING D.8.1 All balconies, platforms, catwalks, or other floors at an elevation four feet or greater above the surrounding balcony, platform, catwalk, or other floor shall be guarded by a standard railing on all exposed sides, except where there is a ladder or stairway. [23(c)] D.8.2 Railing top rails shall be smooth throughout their length. [23(e)] D.8.3 The ends of railings shall not extend beyond the terminal posts. [23(e)] D.8.4 Railings shall incorporate a horizontal intermediate rail throughout their length, located between 480mm (19in.) and 530mm (21 in.) from the top rail. [23e] D.8.5 Horizontal railings shall measure no less than 1066mm (42 in.) from the upper surface of the top rail to the floor, or platform. [23(e)] D.8.6 Stair railings shall measure between 770mm (30 in.) and 860mm (34 in.) vertically from the top rail to the leading edge of the stair tread. [23(e)] Note that regional regulations in the province of Ontario Canada allow a railing minimum of 34 in (865mm) to a maximum of 38 in (965mm). [Ontario Building Code]. D.8.7 Railings shall be equipped with solid toeboards no less than 100mm (4in.) above the floor or platform. [23(e)] Note that regional regulations in the province of Ontario Canada require a minimum of 5 in (125mm) toeboard height. [O. Reg. 851, s. 14]. D.8.8 Railings and toeboards shall be removable with the use of a tool to provide safe access for heavy and bulky equipment. D.8.9 Railings and their mountings shall withstand a 90kg (200 lb.) load applied at any point in any direction. [23(e)] D.9 HANDRAILS AND GRAB RAILS D.9.1 Handrails shall be attached directly to a wall or partition with brackets from the underside of the handrail to provide a smooth surface along the top of the handrail. [23(e)] D.9.2 Handrails shall be no less than 40mm (1-1/2 in.) nominal diameter. [23(e)] D.9.3 Handrails and grab rails shall be mounted to provide a minimum of 75mm (3 in.) clearance between the handrail and the adjacent wall, barrier, or object. [23(e)] Note that regional regulations in the province of Ontario Canada require a minimum of 2 in (50mm) handrail clearance. [Ontario Building Code]. D.9.4 The distance measured between handrail mountings shall be no greater than 2438mm (96 in.). [23(e)] D.9.5 Handrails, grab rails, and their mountings shall be designed and constructed to withstand a 90kg (200 lb.) load applied at any point in any direction. [23(e)] D.9.6 Grab rails and handles shall not be less than 3004mm (12in.) in length. [23(e)] D.9.7 Grab bars shall not extend beyond the climbing side of the ladder which it serves. [27(c)] D.10 MOVEABLE BARRIERS Movable walls, barriers, gates, or railings and their attachments shall be designed, constructed and mounted to withstand a 90kg (200 lb.) load applied at any point in any direction. [23(e)] D.11 LANDINGS D.11.1 Where ladders are used to ascend heights greater than 20 feet (6.1m), landing platforms shall be provided. Each adjacent ladder shall be offset. [27(d)] Note that regional regulations in the province of Ontario Canada allow a maximum of 9m (30 feet) between platforms. [Ontario Building Code].
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D.11.2 Where stairs are used to ascend heights greater than 12 feet (3.7m), regional regulations in the province of Ontario Canada require landing platforms. [Ontario Building Code]. D.11.3 Where adjacent offset ladders are used, landing platforms shall be provided at each offset. [27(d)] D.11.4 Landing platforms when used shall be equipped with standard railings and toeboards. [27(d)] D.11.5 Landing platforms when used shall be no smaller than 609mm (24 in.) wide and 762mm (30 in.) deep. [27(d)] D.11.6 Where ladders are used to gain access to a landing, one rung of the ladder shall align with the landing surface. [27(d)] D.11.7 Ladders rails and rungs shall extend one rung beyond 1066mm (42in) above the landing surface. [27(d)] Note that regional regulations in Canada allow a minimum of 36 in (900mm) to a maximum of 42 in (1070mm) above the landing surface. [O. Reg. 851, s. 18]. D.11.8 Horizontal grab bars when used, shall be installed on the same spacing as the ladder rung spacing. [27(d)] D.11.9 Vertical grab bars when used, shall be installed on the same spacing as the ladder side rail spacing. [27(d)] D.12 FLOOR AND FLOOR OPENINGS D.12.1 Balcony, platform, and catwalk floors shall provide a clear and flat surface without projections. D.12.2 Floor openings and their covers and attachments shall not project above the surrounding floor. D.12.3 Ladder floor openings shall be guarded by a railing and toeboard on all exposed sides except for the ladder entrance. The ladder entrance shall be protected by either a hinged gate or an offset entrance to prevent direct entry into the opening. [23(a)] Chain shall not be allowed. D.12.4 Stairway floor openings shall be guarded by a railing and toeboard on all exposed sides except for the stairway entrance. [23(a)] D.12.5 Hinged floor opening covers shall not be used. D.12.6 Floor holes (see Glossary) shall be covered. [23(a)] D.13 PAINTING Handrails, railings, toeboards, and leading edge of step treads of balconies, platforms, catwalks, ladders, and stairways shall be painted or otherwise identified with SAFETY YELLOW. (See Appendix F Safety Color Identification for more information.)
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APPENDIX E
SAFETY DISTANCE
Safety distance determination shall follow the requirements of ANSI B11.19 Performance Criteria for Safeguarding. Safety distance (Ds) is determined with the following generalized equation:
Ds = K(T) + Dpf (1)
Where: Ds safety distance K maximum speed of movement including hand, arm, walking, running and twisting motions T stopping time of hazardous motion K minimum of 63in/sec (1.6m/sec) constant, unless otherwise identified by risk assessment,
T = Tr + Tc + Ts + Tspm (2)
Where: Tr Response time of safeguarding device Tc Responds time of control system (relays, controllers, etc.) Ts Response time of actuator (valves, motor drives, brakes, etc.) Tspm Stop time performance monitor delay Dpf depth penetration factor for use only with detection and control safety devices. Travel distance before detection.
Fig. E1 Depth Penetration Factors
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Dpf are listed in table E1 for common sensing barriers and operator controls.
Table E1 Common Sensing Barrier Depth Penetration Factors (Dpf) Ref Description Min Height (h) Min Dpf A. Vertical electro-opticalw/ 600mm(24 in) max beamspacing 900mm(36in) 1200mm(48in) B Vertical electro-optical w/ 600mm (24 in) max beam spacing 1200mm(48in) 900mm(36in) C Vertical electro-optical w/ 30mm (1.25 in) beam spacing 1400mm (55in) 80mm (3.2in) D Horizontal electro-optical See Equation3 1200mm(48in) E Single operator control device N.A. 2000mm (78in) F Twohandoperator control N.A. 0
h = 15(S – 50) (mm) (3) h = 15(S – 2) (in)
Where: h height of top of barrier S barrier minimum object sensitivity
Fig. E2 represents the depth penetration factors from Table E1 Depth Penetration factors.
Depth Penetration Factor Horizontal Distance 2.0 1.8 1.6 1.4 1.2 1.0 0.8 0.6 0.4 0.2 0.0 2000 1200 K(T) 900 Dpf 1400 55 1200 47 E 1000 39 800 31 600 24 400 16. 200 8.0 A B C 79 47 39 31 24 16 8 0
Fig E2 Depth Penetration Factor
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The dimensions in Fig.E3 Guard Opening vs Distance are used to determine safe distance from a potential hazard.
Note: Fig. E3 is taken from ANSI B11.19 ANNEX D.
Fig. E3 Guard Opening vs Distance
The dimensions listed in Tables E2 (Low Risk) and E3 (High Risk) represent the most common barrier heights in use. Where a risk analysis indicates additional height requirements, the full table(s) in ANSI B11.19 ANNEX D should be consulted.
Where the actual hazard height and available safe distance are known: Locate the height of the hazard in the left column and find the available safe distance to this hazard in the body of the table. The selected column will indicate the required minimum barrier height at the top. Where the preferred barrier height and height of the hazard are known: Locate the height of the hazard in the left column and the required minimum barrier height at the top. The intersection of column and row will indicate the minimum required safe distance to this hazard in the body of the table.
Fig E4 Barrier Height vs Hazard Reach represents the four most common barrier heights and their safe distance profiles for low risk and high risk scenarios..
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Table E2 Common Barrier Height vs Reach-Low Risk Height of Barrier in meters (in) Height of Hazard 1.0 (39) 1.2 (47) 1.4 (55) 1.6 (63) 1.8 (71) in meters (in) Horizontal Safety Distance to Hazard 2.5 (99) 0 0 0 0 0 2.4 (95) 0.1 (4) 0.1 (4) 0.1 (4) 0.1 (4) 0.1 (4) 2.2 (87) 0.6 (24) 0.6 (24) 0.5 (20) 0.5 (20) 0.4 (16) 2.0 (79) 1.1 (43) 0.9 (36) 0.7 (28) 0.6 (24) 0.5 (20) 1.8 (71) 1.1 (43) 1.0 (39) 0.9 (36) 0.9 (36) 0.6 (24) 1.6 (63) 1.3 (51) 1.0 (39) 0.9 (36) 0.9 (36) 0.5 (20) 1.4 (55) 1.3 (51) 1.0 (39) 0.9 (36) 0.8 (32) 0.1 (4) 1.2 (47) 1.4 (55) 1.0 (39) 0.9 (36) 0.5 (20) 0 1.0 (39) 1.4 (55) 1.0 (39) 0.9 (36) 0.3 (12) 0 0.8 (32) 1.3 (51) 0.9 (36) 0.6 (24) 0 0 0.6 (24) 1.2 (47) 0.5 (20) 0 0 0 0.4 (16) 1.2 (47) 0.3 (12) 0 0 0 0.2 (8) 1.1 (43) 0.2 (8) 0 0 0 0 1.1 (43) 0.2 (8) 0 0 0
Table E3 Common Barrier Height vs Reach-High Risk Height of Barrier in meters (in) Height of Hazard 1.0 (39) 1.2 (47) 1.4 (55) 1.6 (63) 1.8 (71) in meters (in) Horizontal Safety Distance to Hazard 2.7 (106) 0 0 0 0 0 2.6 (102) 0.9 (36) 0.8 (32) 0.7 (28) 0.6 (24) 0.6 (24) 2.4 (95) 1.1 (43) 0.1 (4) 0.9 (36) 0.8 (32) 0.7 (28) 2.2 (87) 1.3 (51) 0.6 (24) 1.0 (39) 0.9 (36) 0.8 (32) 2.0 (79) 1.4 (55) 0.9 (36) 1.1 (43) 0.9 (36) 0.8 (32) 1.8 (71) 1.5 (59) 1.4 (55) 1.1 (43) 0.9 (36) 0.8 (32) 1.6 (63) 1.5 (59) 1.4 (55) 1.1 (43) 0.9 (36) 0.8 (32) 1.4 (55) 1.5 (59) 1.4 (55) 1.1 (43) 0.9 (36) 0.8 (32) 1.2 (47) 1.5 (59) 1.4 (55) 1.1 (43) 0.9 (36) 0.7 (28) 1.0 (39) 1.5 (59) 1.4 (55) 1.1 (43) 0.8 (32) 0 0.8 (32) 1.5 (59) 1.3 (51) 0.9 (36) 0.6 (24) 0 0.6 (24) 1.4 (55) 1.3 (51) 0.8 (32) 0 0 0.4 (16) 1.4 (55) 1.2 (47) 0.4 (16) 0 0 0.2 (8) 1.2 (47) 0.9 (36) 0 0 0 0 1.1 (43) 0.5 (20) 0 0 0
Note: Tables E2 and E3 are excerpts taken from ANSI B11.19 ANNEX D.
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Fig. E4 Barrier Height vs Hazard Reach
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APPENDIX F
PRELIMINARY HAZARD LIST
The following checklist is a generalized Preliminary Hazard List (PHL) described in clause 2.0 Design for Safety, for use in design as part of an analysis for safety methods. Answering Yes to any question requires safety design criteria and proper safeguarding to be identified. FCA EHS involvement is required where indicated.
Preliminary Hazard Analysis No Yes EHS 3.2 CONSTRUCTION HAZARDS Will equipment or building construction or demolition be required on site. Y 3.3 WALKING AND WORKING SURFACES Are platforms, balconies, ladders, or stairways required? Y Walking surfaces are flat and free of any trip hazards? Adequate electrical clearance is available? 3.4 FACILITY HAZARDS/EGRESS Ceiling height is a minimum of 7 ft. 6 in.? Access doors or limited space openings are used? Y 3.5 AIR QUALITY AND VENTILATION Ventilation is required? Y 3.6 OCCUPATIONAL NOISE HAZARDS Sound levels of the equipment will exceed the required maximums? Audible alarms will be used? 3.7 NON-IONIZING RADIATION (ELECTROMAGNETIC-EMR/EMF) HAZARDS Will non-ionizing radiation be used? Y 3.8 LASERS Lasers greater than Class 1 exposure will be used? Y 3.9 ERGONOMIC HAZARDS Is an employee load or unload station used? Y 3.10 HAZARDOUS MATERIALS Hazardous materials will be used? Y paint 3.11 COMPRESSED GASES Flammable or non-flammable gas will be used? Y Compressed air
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Appendix F
Preliminary Hazard List Example (Cont’d)
Preliminary Hazard Analysis (cont’d) No Yes EHS 3.12 SPRAY FINISHING USING FLAMMABLE AND COMBUSTIBLE MATERIALS Flammable materials will be sprayed? Y 3.13 DIPPING, COATING, AND SPRAYING Will liquid filled tanks be used? 3.14 CONFINED SPACE HAZARDS Restricted or limited egress or poor ventilation? Y 3.15 CONTROL OF HAZARDOUS ENERGY Hazardous energy will be available? Enabling pendant required? Y 3.16 ELECTRICAL HAZARDS Equipment arc flash hazards? Production arc flash hazards? Y 3.17 FIRE SAFETY HAZARDS Will flammable liquids be used? Y Will a heating source (flame, induction, electric) be used? Y Will equipment be isolated from facility fire protection systems? Y 3.18 THERMAL SURFACES (BURNS) Will steam or other medium above 54°C (134°F) be used or in close proximity? Will heat producing devices be used (transformers, heaters, etc.)? 3.19 OVERHEAD HAZARDS Are there overhanging loads? Will overhead conveyors be used or in close proximity to the equipment? Y Will overhead material handling with parts over walking surfaces be used? Y 3.20 MOVING HAZARDS Will rotating shafts, walking operations, pallet handling, other moving equipment be used? 3.21 POINT OF OPERATION HAZARDS Personnel will place any part of their body within the point of operation? Y 3.22 UNINTENDED MOTION Will vertical or horizontal motions where the load can drive or move them be used?
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APPENDIX G
PRELIINARY HAZARD ANALYSIS (Normative)
A Preliminary Hazard Analysis (PHA) worksheet is used to develop design solutions to potential hazards.
Mode: The end failure state. i.e. fall from platform. Effect: What happens as a result of the mode occurring. i.e. body injury Cause: What defect can cause the mode to occur. i.e. no railing and no safety harness. Hazard: What is the potential harm. i.e. fall. FMRI: Final Mishap Risk Index; Mishap Risk Index from Table J1 Mishap Risk Index after the Recommended Action is implemented to mitigate the hazard. IMRI: Initial Mishap Risk Index; Mishap Risk Index from Table J1 Mishap Risk Index before the Recommended Action is implemented to mitigate the hazard. Action: Activity required to mitigate the hazard. i.e. add railings and/or fall arrest system.
When performing the (task), the user could be injured (effect) by the (hazard) due to the (mode) presented by the (cause).
Table G1 Mishap Risk Index Severity I II III IV Probability (Catastrophic) (Critical) (Marginal) (Negligible) A (Frequent) I-A (H) II-A (H) III-A (S) IV-A (M) B (Probable) I-B (H) II-B (H) III-B (S) IV-B (M) C (Occasional) I-C (H) II-C (S) III-C (M) IV-C (L) D (Remote) I-D (S) II-D (M) III-D (M) IV-D (L) E (Improbable I-E (M) II-E (M) III-E (M) IV-E (L)
Category (H)igh (S)erious (M)edium (L)ow
Fig. G1 PHA Partial Example illustrates documenting the example above.
PHA Example Task Equipment inspection & maintenance from elevated platform. No. Mode Effect Cause Hazard IMRI Action FMRI 1 No railing Fall I-C Add railing IV-C Fall from platform Body injury 2 No safety harness Fall I-C Add fall arrest system IV-C
Fig. G1 PHA Partial Example
Additional columns should be included for implementation status, responsibilities, comments, etc., as needed. There may be multiple, causes, effects, or hazards for each mode.
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APPENDIX H
PRE-START HEALTH AND SAFETY REVIEW CHECKLIST
The following checklist is used described in clause 2.0 Design for Safety, for use in design as part of an analysis for safety methods. Answering Yes to any question shall require a Preliminary Health and Safety Review to be completed and an FCA – EHS approved engineering firm to review and approve with a letter of conformity.
Table H1 Preliminary Health and Safety Review Checklist Item Applicable Provisions Circumstance No Yes 1 Subsection 22 (1), (2) and (4) Flammable liquids are located or dispensed in a building room or area. 2 Sections 24, 25, 26, 28, 31 and Any of the following apply: 32 1. Safeguarding devices that signal the apparatus to stop, including but not limited to: a. safety light curtains and screens, b. area scanning safeguarding systems, c. radio frequency systems and capacitance safeguarding systems, d. safety mat systems, e. two hand control systems, f. two hand tripping systems, and g. single or multiple beam systems, or 2. Barrier guards that use interlocking mechanical or electrical safeguarding devices. 3 Clause 45 (b) Materials, articles or things are placed or stored on a structure that is a rack or stacking structure. 4 Section 63 A process involves a risk of ignition or explosion that creates a condition of imminent hazard to a person. 5 Section 65 The use of a dust collector involves a risk of ignition or explosion that creates a condition of imminent hazard to a person. 6 Sections 87.3, 87.4, 87.5 and A factory produces aluminum or steel or is a foundry 88, subsections 90 (1), (2) and that melts material or handles molten material. (3), and sections 91, 92, 934, 95, 96, 99, 101 and 102 7 Sections 51 and 53 The construction, addition, installation, or modification relates to a lifting device, traveling crane or automobile hoist. 8 Sections 127 and 128 A process uses or produces a substance that may result in the exposure of a worker in excess of any occupational exposure limit set out in Regulation 833, 835, 836, 837, 838, 839, 840, 841, 842, 843, 844, 845 or 846 of the Revised Regulation of Ontario, 1990
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APPENDIX J
RISK ASSESSMENT EXAMPLE
Risk Assessment Report Plant: FCA – Warren Stamping Equipment: Hood Assembly System Application: Welding and Material Handling Assessment Type: Detailed Data Source: On site, maintenance, & operator personnel. Risk Scoring System: ANSI B11TR3 Two Factor Author: John Smith Contributors:
Initial Risk Final ID User/Task Hazard Risk Level Risk Level Status Assessment Reduction Assessment Mechanical Moderate 1 Operator/ Load Low Gloves Minor Negligible Complete Cutting Unlikely Operator/ Mechanical Moderate Minor 2 Negligible Gloves Negligible Complete Remove Rejects Cutting Remote Remote Presence Operator/ Catastrophic Catastrophic 3 Entanglement High Sensing Low In-Process Remove Rejects Likely Remote Stop Equip. 4 5
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APPENDIX K
SAFETY COLOR IDENTIFICATION
The following safety colors are approved for use as described in this standard. (PROPOSAL)
Table K1 Safety Colors
COLOR RAL ANSI *NPVP SAFETY RED 3020 Traffic Red 7.5R 4/14 Safety Red 7.5R 4/14
5YR 6/15 Safety Orange SAFETY ORANGE 2011 Deep Orange 3.75YR 6/14 (OSHA)
SAFETY YELLOW 1018 Zinc Yellow 5Y 8/12 Safety Yellow 3.75Y 8.5/12
SAFETY GREEN 6024 Traffic Green 7.5G 4/9 Safety Green 7.5G 4/8
SAFETY BLUE 5017 Traffic Blue 2.5PB 3.5/10 Safety Blue 2.5PB 3/10
FLAT BLACK 9005 Jet Black N 1.5/ Safety Black N 0.75/
MACHINE WHITE 9010 Pure White N 9/ NEMA White 5Y 9/1
Notes: ANSI safety colors listed above are taken from ANSI Z535.1 Safety Colors and utilize the Munsell color notation system. The use of ANSI color identification and RAL color identification codes are not interchangeable. A single color notation system should be used on the entire equipment or system. *NPVP color designations above are Chrysler/FCA legacy colors that are acceptable when used in refurbished or existing equipment and utilize the Munsell color notation system. The Munsell is internationally recognized color notation system. RAL color notation is a Central European Color Standard.
Munsell color chips are available from:
Munsell Color 4300 44th Street SE Grand Rapids, MI 49512
RAL color chips are available from:
Color Harzen, Netherlands at http://www.ralcolor.com/
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APPENDIX L
SAFETY LABELS
Fig, L1 Safety Label Contents
Fig, L2 Safety Sign Format Alternates
Fig. L3 Safety Alert Symbols
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Fig, L4 Safety Symbol Surround Shape
Fig, L5 Common Safety Symbols
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APPENDIX M
EQUIPMENT DESIGN LAYOUT EXAMPLE
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