Attachment_2_-_75D-07.0-06_EHS_Requirements_for_Large_Equipment_Purchases.pdf

75D-07.0-06 EHS Requirements for Large Equipment Purchases

EHS Requirements for Large Equipment Purchases Revision: #2

Table cell intentionally left blank Document Control Number: 75D-07.0-06 Date: 07/17/15

PROC. Responsible Organization: Office of Environment, Health and Safety Table cell intentionally

Table cell intentionally left blank Approved By: Neal Mohlmann Signature:

1.0 Purpose:

To define the requirements for purchased equipment at the DCF.

2.0 Scope:

Applies the acquisition of large equipment at the DCF.

3.0 Roles and Responsibility:

3.1 The EMS Facility Management Representative is responsible for:

Communicating with OEHS Program Managers to assure that boiler plate specifications are kept up to date.

3.2 CORs are responsible for:

Communicating the specifications of this procedure to contractors (as applicable); and

Communicating with the EMS Facility Management Representative when these boilerplate requirements need to be changed.

3.3 Contractor Personnel are responsible for:

Following these requirements; and

Communicating with their COR when there is uncertainty about these specifications.

4.0 Requirements and Specifications

4.1 Environmental, health and safety requirements:

All equipment delivered to the BEP shall be designed to minimize all risks of injury to BEP employees. All equipment shall be in full compliance with government and commercial safety and health regulations and requirements.

The following are specific safety and environmental requirements for major production machinery for the BEP.

Attachment 2 - 75D-07.0-06

4.2 General safety

Equipment shall be designed to prevent injury to operation and maintenance personnel at all times. It shall be equipped with service access equipment; such as, catwalks, access platforms, access ladders, lifts, and other equipment for operation and maintenance. Fixed stairs shall be provided in compliance with OSHA 29 CFR 1910.24, Fixed Industrial Stairs. All catwalks, access platforms, access ladders, lifts, hoists, and any other equipment that are furnished, shall be built and tested to comply with American National Standards Institute (ANSI) and the Occupational Safety and Health Administration (OSHA) standards.

4.3 Noise Level

The maximum noise produced by the operation of the equipment at full production rate shall not exceed 85 decibels A-weighted sound level (85 dBA) when measured at 914 mm (3 feet) distance along the plan view of the equipment and at an elevation of 1,524 mm (5 feet).

4.4 Machine Guarding

All covers and safety guards shall be interlocked with the equipment’s controls to prevent its operation while any cover or guard is open or absent. Covers and guards shall be manufactured for easy removal by Bureau personnel to facilitate removing mechanical and electrical parts for repair. All rotating and reciprocating parts shall be guarded as specified by OSHA regulation 29 CFR 2910.212. All equipment and service access panels shall be guarded as required by applicable portions of OSHA Regulations.

4.5 Mechanical Entrapment Response Procedures

The manufacturer shall provide mechanical entrapment response procedures for the emergency release of persons trapped in machinery. Training on the procedures shall also be provided. This requirement applies to equipment that has any potential entrapment point(s) where hands, fingers or any other body parts could become caught between moving parts.

4.6 Sharp Edges

All sharp edges and corners, which present personnel hazards, shall be guarded or padded.

4.7 Heated Surfaces

Equipment shall be designed to prevent heated surfaces from causing burns to personnel during operation.

4.8 Prohibited Materials

Some materials shall not be used in the equipment. These materials are noted in 75D-07.0-07 Restricted Materials at DCF.

4.9 Hazardous Emissions

Operation of the equipment shall not result in worker exposure to airborne contaminations exceeding current maximum allowable concentrations established by (OSHA) and the American Conference of Governmental Industrial Hygienists (ACGIH) standards. When the standards differ, the most stringent shall apply.

4.10 Interlocks

An electrical interlock shall be provided to prevent accidental starting with the mechanical lock engaged.

4.11 Hazard Communication

Safety Data Sheets (SDS) for all supplied and specified chemicals that are part of the process shall be supplied by the contractor to the COTR. The SDS shall comply with OSHA, as listed in standard 29 CFR 1910.1200, with particular emphasis on paragraphs (g) and (i). All MSDS and package labeling must be in English.

4.12 Overload Protection

Equipment shall be provided with overload protection and power factor correction devices to prevent damage to components and operating personnel.

4.13 Safe Ready

All control stations shall include a "safe-ready" collar. Upon turning the collar to the safe position, it shall be impossible to start the system from any other station.

Console shall indicate that the particular interlock including emergency stop buttons causes the system to start or not.

4.14 Emergency Stop

Emergency stop buttons shall be provided at strategic locations to minimize the time required to reach them. Emergency stop buttons shall stop the system within one (1) second so as to reduce damage to the system and injury to personnel. Emergency stop buttons shall be of the pronounced mushroom type, red in color. Emergency stop buttons shall remain activated with a blinking red light once depressed until manually reset.

4.15 Inching Interlock

Whenever an inching of the equipment occurs, only the control station from where the inch was performed shall be able to cause the equipment to move until the safe-ready is activated and deactivated. The equipment shall be designed such that the use of “cheaters” to override the interlock function is not necessary.

4.16 Energy Isolation

Disconnect or lockout devices shall be provided and identified with signage for all sources of energy on the equipment; this includes electrical, hydraulic, pneumatic, and kinetic sources of energy. All isolating devices (levers, breakers, valves, etc.) for all associated energy sources (electrical, hydraulics, pneumatics, gravity, etc.) shall be identified by a color coded tag which indicates the type of energy source, the magnitude of the energy and an ID number. All isolating devices shall be capable of being locked out with a standard locking device and/or padlock. Stored sources of energy such as, pneumatic and hydraulic forces shall be automatically bled and returned to a zero energy state when an interlocked device (i.e. a guard or a door) is opened.

4.17 UV Curing/Exposing Equipment

All equipment with ultraviolet radiation systems shall be designed such that no operator is exposed at or above permissible threshold levels established by the

ACGIH.

4.18 Hydraulic & Pneumatic Systems

All hydraulic and/or pneumatic systems shall have functional isolation, i.e., when part of a system is operating, no other part of the system shall be adversely affected by pressure drop, flow transients, etc. All hydraulic and pneumatic equipment employed in the system shall conform to the Joint Industrial Council (JIC) standards. Hydraulic and pneumatic pumps shall be energy efficient.

4.19 Laser Systems

All equipment with laser systems shall comply with the latest version of the Laser Institute of America’s ANSI-Z136.1 standard, American National Standard for Safe Use of Lasers, and 21 CFR 1040 and shall be designed such that no operator is exposed at or above permissible threshold levels established by the

ACGIH.

4.20 Illumination

Large equipment (such as printing presses) with covered work stations such as impression cylinder, wiping roller, inking-in areas, etc., shall be illuminated to 20 foot-candles of luminance by the equipment manufacturer, in accordance with the latest version of ANSI RP-7.

4.21 Industrial Ventilation

Equipment which emits airborne contaminants which exceed permissible exposure concentrations as established by OSHA, ACGIH and National Institute of Occupational Safety and Health (NIOSH) shall be equipped with local exhaust ventilation (LEV). LEV shall be designed in accordance with the ACGIH Industrial Ventilation: A Manual of Recommended Practice for Design, (latest edition). All industrial ventilation system parameters and design shall comply with the OSHA Ventilation Standard, 29 CFR 1910.94.

4.22 Material Handling Assistance

The equipment shall include ergonomic lifting aids for any lifting of more than 32 pounds by the operators.

4.23 Environmental Protection Requirements

All equipment, materials, and processes must meet or exceed standards in the regulations and executive orders listed below. Other environmental regulations, executive orders and guidance may also be applicable. The environmental protection requirements focus on emissions, discharges, and waste products impacting air, water, and land.

a. References Federal Regulation: Environmental Protection Agency, EPA Clean Air Act, as Amended;

40 CFR 403 - General Pretreatment Regulations for Existing and New Sources of Pollution

40 CFR 433 – Metal Finishing Point Source Category

40 CFR 261 – Identification and Listing of Hazardous Waste

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle A, Air Quality Regulations

District of Columbia Municipal Regulations (DCMR), Title 20, Subtitle E, Hazardous Waste Regulations

District of Columbia Municipal Regulations (DCMR), Title 21, Water and Sanitation, Chapter 15, Discharges to Wastewater System Regulations

P.L. 102-486, Energy Policy Act of 1992, October 24, 1992

40 CFR Part 247, Comprehensive Guideline for Procurement of Products Containing Recovered Materials, May 1, 1996

Executive Order 13693 - Planning for Federal Sustainability in the Next Decade,” March 19, 2015

b. Air Pollution Control

The DCF is in a non-attainment area for Volatile Organic Compounds and

2.5 Particulate Matter (PM 2.5). Any equipment to be installed in either the DCF or the WCF must meet Lowest Achievable Emissions Rate (LAER) standards in accordance with EPA and District of Columbia regulations.

Maximum Achievable Control Technology (MACT) standards may also be applicable to control the emissions of any Hazardous Air Pollutants that result due to the installation of new equipment or change in the method of operations of existing equipment.

The Contractor shall identify potential source locations of air pollutant emissions from the equipment. Equipment must be designed so that pollutants can be captured and ventilated to air pollution control devices. If emission capture and control are required, the Contractor may be required to propose and provide a design and equipment for capture and control of the pollutant in question.

Check box

BEP check as appropriate for this solicitation

Contractor IS required to propose and provide a design and equipment for capture and control of pollutants.

Contractor IS NOT required to propose and provide a design and equipment for capture and control of pollutants.

Third Party Performance Test— A compliance test which demonstrates that the equipment and/or air pollution control device (APCD) meets the applicable EPA or DC performance requirements may be required. If required, the compliance test must be performed according to a test plan that uses approved EPA methods and be submitted to the Office of Environment, Health and Safety (OEHS) for approval prior to the test.

Check box BEP check as appropriate for this solicitation:

Table cell intentio left b nally lank

Contractor IS required to perform third party compliance testing to demonstrate equipment and to meet emission performance requirements.

Contractor IS NOT required to perform third party compliance testing to demonstrate equipment and meets emission performance requirements.

Construction Permits—The DC Air Quality Division is required to review all equipment that may reasonably be expected to emit air pollutants prior to installation. The contractor must provide sufficient information to the Bureau so that the OEHS can prepare an application to install the equipment and

APCD.

Equipment and the associated control devices may not be installed until the District of Columbia issues a Construction Permit to do so. Note that it takes a minimum of 6 months from the time of submission of the permit application to receive a permit to construct.

Interlocks and Standby Mode—All APCDs will be interlocked with the operating equipment to prevent operation without emission capture. The Contractor is responsible for coordinating with Bureau representatives, including OEHS to establish the parameters that warrant a shutdown of equipment. Standby Modes shall be established for periods when equipment is not operating. The Contractor shall document the parameters established and include this information in the operation and maintenance manuals.

c. Wastewater

Information shall be provided to the OEHS through the COTR on the characteristics of all effluents (liquids which can be pumped or gravity flow liquids) that will come from the equipment, either regularly or intermittently, including routine or scheduled maintenance work. This information will be used to determine the feasibility and method of treating the effluents either in the Wastewater Pre-Treatment Plant or requiring that the materials be handled through the Solid/Hazardous Waste Program.

d. Energy, water, and materials usage programs

The Contractor shall make every effort to provide the most energy and water efficient equipment to the Bureau. The contractor shall furnish all information to document the energy and water usages for the system, including all calculations. The Contractor shall comply with:

P.L. 102-486, Energy Policy Act of 1992, October 24, 1992 Executive Order 13693 - Planning for Federal Sustainability in the Next Decade,” March 19, 2015 40 CFR Part 247, Comprehensive Guideline for Procurement of Products Containing Recovered Materials, May 1, 1996.

e. Fluorescent Bulbs

All lamping shall be suitable for low mercury in addition to having low energy consumption.

f. Solid Hazardous Waste

Equipment that generates non-liquid wastes (wastes which cannot be pumped or which do not flow by gravity) either continuously or intermittently, including scheduled or routine maintenance work, in addition to normal operation must be designed to allow for removal of the waste in an ergonomic manner and to allow the operator to transfer the waste into a 55 gallon drum – 1A1, 1A2, or other appropriate container, as needed.

Information shall be provided as to the specific quantity, nature and characteristics of the non-liquid waste generated so that a waste determination may be performed by OEHS in accordance with 40 CFR 261 – Identification and Listing of Hazardous Waste.

5.0 Related Documents

5.1 75D-00.0-08 Operational Control

5.2 75D-07.0-07 Restricted Materials at DCF

REVISION PURPOSE OF REVISION

EFFECTIVE

DATE

1 Changed Doc numbers 04/18/14 2 Updated Executive Orders and MSDS to SDS 07/17/15