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A. Policies 

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B. Responsibilities 

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1. JAC Project Manager:

1. A JAC Project Manager will be appointed for each major design and construction project where new equipment will be installed at JAC facilities, or where existing equipment will be substantially modified.
2. The JAC Project Manager is responsible for assuring that new equipment is of a safe design. In particular the JAC Project Manager shall assure that:
1. Any hazards are identified during the design process.
2. Appropriate safety standards, to ensure compliance with the law and ensure safety, are identified and followed.
3. Documentation is produced and stored which is sufficient to demonstrate safe design and that the design was correctly implemented during construction and testing.
4. Documentation is produced and issued outlining safe operations and maintenance procedures.
5. Note that appropriate liaison with external bodies or other JAC staff may be required to achieve the above. This may be particularly required where the bulk of the equipment design is performed by an external supplier in collaboration with JAC staff.

1. In the absence of a designated JAC Project Manager, the above responsibilities will fall upon the head of the relevant JAC Group.
2. The heads of groups also have particular responsibility to ensure that their staff are competent (qualified) for tasks assigned to them.

The Site Safety Advisor has particular responsibility for retaining safety certificates which show proof of testing where legal requirements exists.

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C. Design and Construction Procedures: General 

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1. Design Process

1. Design Reviews
1. Reviews which include coverage of safety shall be held at appropriate stages in the project.
2. The format of these reviews may be varied at the discretion of the JAC Project manager. A typical design review structure is:
• As early as possible in the design process a Preliminary Design Review (PDR) should include an examination of all relevant safety issues. This will include identification of hazards which could be mitigated by design, including the use of appropriate national consensus codes.
• Prior to completion of the design a Critical Design Review (CDR) should include assurance that all safety issues have been dealt with satisfactorily and that no new issues now exist.
• Where appropriate, 'Acceptance Test' criteria shall include demonstration that any necessary safety criteria have been met.
2. Design Activity
1. The JAC Project Manager should assure that the design is performed by competent (qualified) persons.
2. The Design Engineer shall use good engineering practice, and shall determine and follow applicable codes and standards, analyze the design for hazards, and take appropriate steps to eliminate hazards or reduce the risks to an acceptable level.
3. The Design Engineer shall identify relevant design, material or construction codes and specify these as part of the design, where appropriate.
4. Where safety critical calculations are required they shall be checked by another qualified person and then retained for the life of the item.
5. Equipment shall be designed to allow safe access for maintenance or repair. This shall include the ability to provide for safe lock-out and tag-out of all energy sources. See also Chapter 13 of this manual for information.
Note: the term Design Engineer is used throughout this chapter to designate the competent (qualified) person - usually a professional engineer - responsible for the overall development of the concept and detailed design. This phrase is used to avoid confusion over differing common usage for the phrase 'Designer' . (e.g. in UK use often designates a senior engineer with design authority and in the US often designates a draftsperson with little design authority).
3. Documentation
1. Documentation, including drawings, shall be maintained at a level adequate to demonstrate safe design. The retention of design information in a retrievable format is the responsibility of the JAC Project Manager. The JAC documentation system for design information is as described in Appendix 3 to this Chapter.
2. Equipment with more than one energy source (e.g. electrical and hydraulic power) will require a written procedure for lock-out and tag-out. The JAC Project Manager shall assure that any new written procedures required are incorporated into Chapter 13, Appendix 3 of this manual.
3. Where materials are introduced to JAC facilities the JAC Project Manager shall ensure that Material Safety Data Sheets are made available as described in Chapter 6.

1. Note that this section is not concerned with safe workshop practices (which are covered in Chapter 8) but rather with ensuring that any safety critical design requirements are met during the construction process.
2. For all in-house JAC work technicians and construction workers shall use approved work practices and produce a quality product that meets design and code requirements where specified.
1. JAC use a policy of self certification and inspection, whereby technician is responsible for assuring that items are constructed and installed as specified by the design drawings. The JAC Project Manager shall arrange for inspection of contract work where required.
2. Where the design requirements cannot be met, the Design Engineer must be consulted for an approved solution.
3. Note that JAC technicians have considerable experience and are encouraged to highlight areas where design flaws may exist, or where alternative manufacture techniques would have merit.

1. For safety critical equipment a description of tests required before first use, and any routine inspection requirements, shall be provided by the design engineer as part of the design package.
2. Before releasing any equipment for general use the appropriate tests and commissioning procedures - as specified in the design of the equipment - shall be performed. These will be witnessed by a competent person, and relevant documentation made.

1. Where relevant, legal requirements shall be met in the design of equipment. In this context, some relevant legislation includes:
1. The UK "Provision and Use of Work Equipment Regulations 1998", UK HSE
2. The UK "Workplace (Health, Safety and Welfare) Regulations 1998", UK HSE
3. The Hawaii Uniform Building Code (UBC).
2. Where practicable, relevant national consensus codes shall be used for the design of equipment. Some useful codes are identified where appropriate in the specific Procedures sections below.
3. In addition to national consensus codes, the JAC Project Manager shall draw to the attention of the equipment design engineer the environment at the Joint Astronomy Centre's sea level and Mauna Kea facilities for which items must be designed. (See Appendix 2 to this Chapter).

 

 
 
 
 
 
 
 

Notes:

1. See also the note in Chapter 1.F regarding JAC policy for international equivalent codes.
2. Compliance with local codes in the country of manufacturer is the responsibility of the supplier, wherever the equipment is used in that location prior to shipment to JAC.

1. Lifting Equipment

1.1 Description

1. Lifting equipment is particularly critical to human and equipment safety. Many items used at JAC facilities must be handled with lifting equipment for transport, loading and assembly as well as when mounting onto the telescopes or any off-telescope test rigs. It is therefore important that the lifting gear is safe, complies with the law and with relevant professional codes of practice.
2. Lifting equipment includes the lifting device (e.g. crane), the lifting tackle between the crane hook and the load, attachment points to the load, as well as the load itself.
3. Note that this section is not concerned with safe lifting practices (which are covered in Chapter 8.C) but rather with ensuring that any safety critical design requirements are met during the design and construction process.

1. Lifting Devices
1. JAC must be able to demonstrate legal compliance for all parts of the lifting system, regardless of the source of supply.
2. Where practicable, lifting equipment shall be specified and purchased from qualified commercial suppliers. These shall be compliant with the appropriate codes and shall be supplied with the appropriate documentation.
3. General Design
• The design shall comply to a national consensus code and shall be safe.
• The design environment is as laid out in Appendix 2 to this Chapter. The key features for design of lifting equipment are:
• Potentials for corrosion in a tropical environment when in Hilo.
• Possible low-temperature when at the summit of Mauna Kea.
• Lifting eyebolts shall have a preferred size metric thread.
• Lifting equipment supplied with instruments shall have been designed with over-capacity to allow for weight growth due to future upgrades to the instrument. This is in addition to the normal safety reserves, allowance for errors in estimating equipment mass and any allowance for proof testing in the design codes. The minimum allowance for a growth in mass is 25% (e.g. a 200kg instrument shall have lifting equipment designed on the assumption that in 5 years time the instrument may mass 250kg).
4. Non-compliant equipment
• Should JAC find that supplied equipment was not compliant with an appropriate national consensus code, the options would be to either reject the equipment, or to arrange for retroactive certification at the supplier's cost.
• Note that retroactive certification will not be possible where design or construction documentation are not available where required.
5. Below the Hook Lifting Devices:
• For a description of Below the Hook Lifting Devices see the latest issue of ASME B30.20.
• In addition to compliance with the selected code, JAC require that these devices have been proof tested to at least 125% of the marked Safe Working Load.
• In addition to compliance with the selected code, JAC require that these devices are delivered with the following:
• Have marked on it: the Safe Working Load marked in lb. or kg.; the equipment identification number (drawing number, serial number or similar); the date of manufacture; the manufacturer's name and the lifting device's mass if greater than 15kg.
• Markings in "ton(ne)s" in any form are unacceptable.
• Manufacturing support documentation shall be supplied to cover, where appropriate: evidence of proof testing; instructions for use; and manufacturing documentation including material supply certificates, material cast certificates and approved welder certification.
2. Design of Instruments and other Equipment which will be lifted.
1. In designing equipment for use at the JAC, consideration of lifting operations shall be given. Note that this section is particularly applicable to instruments and electronics racks from external supply sources.
2. All equipment shall have a mechanical body or framework with sufficient integrity to survive transport, operational and handling loads and remain safe. Note that per UK LOLER-98 4.b the [JAC] "shall ensure that every part of a load or anything attached to it and used in lifting is of adequate strength."
3. All equipment should be designed such that it may be safely prepared for lifting.
4. In particular JAC requires:
• Assurance that the lifting points on all equipment are safe. This shall be verified before any lifting takes place at JAC facilities.
• The maximum (measured) mass and the approximate location of the centre of gravity of all instruments must be provided to JAC before acceptance.

1. Where relevant, legal requirements shall be met in the design of lifting equipment. This includes the UK HSE Lifting Operations & Lifting Equipment Regulations 1998 (LOLER-98).
2. Relevant national consensus codes shall be used for the design of lifting equipment, such as:
1. ASME B30 "Safety Standard for cableways, cranes, derricks, hoists, hooks, jacks and slings".
2. BS 2573:Part 1:1983 "Rules for the design of cranes".

2. Load Bearing Structures

2.1 Description

1. Load Bearing Structures are critical to human and equipment safety. They include any items which bear or anchor the weight of personnel, or which carry loads where the load falling would create an unsafe condition for personnel.
2. Note that this section is not concerned with the safe working practices (which are covered in Chapter 8) but rather with ensuring that any safety critical design requirements are met during the design and construction process.

1. Where practicable, load bearing structures will be specified and purchased from qualified commercial suppliers. These shall be compliant with the relevant codes, and shall be supplied with appropriate documentation.
2. Compliance with local county ordinances may require the drawing of permits to modify existing buildings.
3. Design calculations for the structure shall have been made and checked where required to demonstrate safety.
4. Testing requirements shall be specified by the Design Engineer where required.
5. The design details shall include appropriate markings, which may include:
1. Safe floor loading markings.
2. The equipment serial number and the date of manufacture.

1. Where relevant, legal requirements shall be met in the design of load-bearing structures. In this context some relevant legislation includes:
1. The requirements of OSHA and the Hawaii UBC where applicable.
2. The UK "Workplace (Health, Safety and Welfare) Regulations 1992", UK HSE
3. Note that where these codes do not apply due to the unique design features of the JCMT or UKIRT facilities, JAC practice shall remain to voluntarily comply with the spirit of these codes wherever practicable.
2. Relevant national consensus codes shall be used for the design of load-bearing structures, such as:
1. BS 5950:1:1990 "Structural use of steelwork in building".
2. BS 8118:1:1991 "Structural use of aluminium".
3. BS 7608:1993 "Code of practice for fatigue design and assessment of steel structures"
4. BS 5378:1:1980 "Safety signs and colours".
3. Appropriate specifications will be made for:
1. Material type and any requirement for material certificates.
2. Weld procedures, materials and geometry.
3. Welder qualification for load bearing weldments.
4. Tests required.
4. Following construction the structure shall be inspected and tests performed as required. In particular all anchor points for personnel fall protection equipment shall be load tested to meet the requirements of OSHA.

3. Personnel Accessways

3.1 Description

1. Personnel Accessways include walkways, doorways, stairways, ladders and associated handrailing. For full definitions see the relevant code provisions.
2. Temporary accessways and scaffold must also comply with safe design requirements

1. The design of personnel accessways shall be compliant with relevant codes, and shall be supplied with all appropriate documentation.
2. Note that personnel accessways are also Load Bearing structures and as such are also covered by section D.2 above.
3. Temporary accessways and scaffold shall also be designed in accordance with the appropriate codes and shall be constructed by competent persons using equipment suitable for the task.

1. Where relevant, legal requirements shall be met in the design of personnel accessways. In this context some relevant legislation includes:
1. The requirements of OSHA and the Hawaii UBC where applicable.
2. The UK "Workplace (Health, Safety and Welfare) Regulations 1992", UK HSE

Note that where these codes do not apply due to the unique design features of the JCMT or UKIRT facilities, JAC practice shall remain to voluntarily comply with the spirit of these codes wherever practicable.
2. Relevant national consensus codes shall be used for the design of personnel accessways, such as:
1. BS 6180:1982 "Code of practice for protective barriers in and about buildings".
2. BS 5395:1985 "Code of practice for the design of industrial type stairs, permanent ladders and walkways".

4. Instrument and Cryogenic Systems

4.1 Description

1. This section outlines the JAC requirements for safe design and construction of instruments with their associated cryogenic and vacuum equipment.
2. JAC does not normally design or build instruments in house, but does often interact with or overwatch external design activities.
3. In addition, JAC routinely provides in-house design and construction of interfaces, distribution piping and valve systems. Occasional repair or retrofit to existing equipment is also performed where required.
4. A typical instrument in use at the JAC consists of several components:
1. The main instrument body, or "Dewar". A Dewar is a vessel isolated by vacuum, highly reflecting walls and radiation screens used to achieve and maintain cryogenic temperatures. Whilst primarily a vacuum vessel, a positive pressure may occur at certain times eg: when warming up in some fault conditions.
2. Insulation provided by a combination of vacuum, radiation shields and insulation layers.
3. Cryogenic cooling provided by a combination of cryogens and cooling machines (e.g. Joule-Thompson or Gifford-MacMahon closed cycle coolers). The cryogens are usually liquid Nitrogen or Helium (though may be gaseous or even solid in some areas of the instrument at some times in the process).
4. A "window" of material transparent at the appropriate wavelengths. This is often optimized for optical properties and is frequently the weakest and most vulnerable part of the vacuum vessel.
5. The internal instrument components including electronic, electrical and mechanical devices.
6. External mechanical mounting interfaces to the telescope and handling gear.
7. Supporting electronics, mounted nearby or remotely.
8. Supporting software package(s).
9. Service distribution lines and equipment for electrical power, electronic control, vacuum, coolant or cryogens as required.
10. Supporting documentation.
5. Note that this section is not concerned with the safe cryogen or vacuum handling practices (which are covered in Chapter 5) but rather with ensuring that any safety critical design requirements are met during the construction process.

1. Where practicable equipment shall be specified and purchased from qualified commercial suppliers. These shall be compliant with the appropriate codes and shall be supplied with all appropriate documentation.
2. The equipment design shall be safe at the pressures and temperatures which may be encountered. This should include conditions encountered in normal usage, or when cooling down or warming up, or in certain fault or blockage conditions. Equipment from commercial supply sources shall where possible be rated for the design environment encountered at JAC facilities.
3. Overpressure relief mechanisms shall be provided in all appropriate locations.
4. When designing venting arrangements, consideration shall be given to avoiding possible hazards to personnel.
5. Instruments should also comply with the provision for Manual Handling (section D.5) and Ergonomics (section D.6).
6. For dewars, particular attention shall be given to:
1. Appropriate design of vacuum and pressure vessels, incorporating appropriate safety reserves. This shall include a review of the implications of failure of the window (or other vulnerable points) on the dewar integrity, especially any catastrophic loss of vacuum or pressure; or any potential for spillage or warm up of cryogens.
2. Design of the window material, which must include review of a documented analysis of the window design process, including:
• The window design drawings.
• The material properties.
• The strength calculations and/or experimental tests performed in selecting the design.
• The expected safety reserves against failure at JAC sea level and Mauna Kea facilities.
• Documentation of any safety precautions, guards or working practices required to enhance safety.
3. Appropriate design of vessels containing hazardous materials such as liquid cryogens.
4. Specification of materials appropriate for use at cryogenic temperatures where applicable.
5. Venting capacity, for example upon initial contact of cryogens with the warm system shall be adequate for safety.
6. The stresses from thermal contraction and expansion of the inner shell and support members.
The above requirements must be met and approved in writing by the JAC Chief Engineer prior to final acceptance or operation of any instrument at any JAC facility.
7. For Piping and Distribution Systems particular attention shall be given to:
1. Appropriate design for the type of fluid.
2. Any risks which might arise from system leaks, in particular hazardous chemicals exposure or risk of fire.

1. Codes:
1. Where relevant, legal requirements shall be met in the design of equipment. In this context, some relevant legislation includes:
• The UK Simple Pressure Vessels (safety) Regulations 1994.
2. Equipment supplied shall comply to a relevant national consensus codes, such as :
• Section VIII of the ASME Boiler and Pressure Vessel Code
• BS 5500:1991 "Unfired fusion welded pressure vessel".
• BS EN 1012-1 1997 "Compressors and vacuum pumps. Safety requirements".

Note that, although not strictly applicable, there are some useful provisions in the UK HSE document :"Design and Construction of vacuum insulated road tankers used for the carriage of non-toxic deeply refrigerated gases: Road Traffic (Carriage of Dangerous Substances in Road Tankers and Tank Containers) Regulations 1992".
2. Testing
1. Prior to acceptance by JAC all cryogenic systems, particularly the dewar assembly, shall have passed a thermal shock test (initial cool down to operational temperatures) with no loss of integrity.
2. All vacuum vessels shall have passed a pump-down test (in operational configuration, to operational vacuum) with no loss of integrity prior to acceptance by JAC.
3. Consideration shall be given to the need to perform over-pressure tests of equipment.
4. Following receipt at JAC the equipment integrity should be re-verified to ensure that no damage has occurred during transit. Note that in addition to visual inspection, the initial vacuum pump down test will generally act as a suitable detection technique for structural flaws such as warpage of seal faces or through-thickness cracks.

5. Manual Handling Requirements

5.1 Description

1. In many cases human effort is required to move or position equipment, with or without mechanical assistance. One useful definition of manual handling is:
"Manual Handling means any transporting or supporting of a load (including the lifting, putting down, pushing, pulling, carrying or moving thereof) by hand or by bodily force" (UK Manual Handling Operations Regulations 1992, UK HSE).
2. Manual handling has a variety of associated hazards, including the risk of injury from falling objects, attempting to lift dangerously heavy or awkward objects, or muscular injury through repetitiously lifting objects in an un-ergonomic manner.
3. Where practicable, the need for manual handling of equipment or components should be minimized. To this end, the manual handling implications should be reviewed as early as possible in the design process, and also considered during subsequent reviews and testing.

1. All items which require manual handling should be designed to comply with good manual handling practice.
2. Some design guidelines to consider, include:
1. Modules designed for manual handling (lifting and carrying) should in general weigh no more than 20kg, and preferably less than 15kg.
2. Adequate handholds should be provided for safe lifting. It should be clear whether the handholds are for use with only the sub-module to which they are attached or to a higher level (heavier) assembly.
3. The mass should be clearly labeled, if more than 15kg, and a note made on the centre of gravity where this is not in an obvious location.
4. Any special hazards should be clearly identified, in particular:
• Sharp edges.
• Risk of static electrical shock, with grounding points provided where required.
• Any items which are not secure in particular orientations.
5. Appropriate written procedures and training should be provided which describe the recommended handling technique, in particular where:
• Special hazards exist,
• Multi-person lifts are required,
• Special handling equipment is required.
3. Special handling equipment should be provided where appropriate.
4. The equipment should be designed such that it may be easily accessed for manual handling, for example to:
1. Remove or secure fixing points and handling equipment.
2. To lift components safely, preferably in a vertical direction with a single lift.
3. Pick up or place down components without risk of trapping fingers, etc.

1. Where relevant, legal requirements shall be met in the design of equipment requiring manual handling . In this context some relevant legislation includes:
• The UK "Manual Handling Operations Regulations 1992".
2. Where practicable, relevant national consensus codes shall be used for the design of equipment requiring manual handling.

6. Access and Ergonomic Requirements

6.1 Description

1. The equipment shall be designed such that it may be safely accessed at all stages of assembly, test, installation, use, maintenance and repair.
2. In general, good ergonomic design practice for ease of installation, use and maintenance is preferred where practical.
3. The review process must include a check that no unsafe ergonomic hazards exist.

1. The equipment shall be designed such that it may be safely accessed, and that appropriate provisions exist for lock-out and tag-out of all energy sources during:
1. Routine maintenance including inspection, greasing, testing, cryogenic fills, tuning, calibration.
2. Troubleshooting of electrical or mechanical problems in-situ.
3. Repair.
2. There shall be no requirement to work in areas without rapid means of egress.
3. Adequate provisions must exist for lock-out and tag-out of all energy sources during maintenance and repair.
4. The design and layout should allow safe handling of hazardous substances (e.g.. cryogenic or high voltage electrical equipment).
5. In cases where there is no safe access to a side of equipment (e.g.. due to walls or other structures) the design should be such that no access is required to this side. Alternatively, the equipment should be provided with the capability to roll-out or similarly move, such as to allow safe access.
6. Hazards from exposed or moving machinery shall be eliminated or suitable guards provided.
7. Consideration should be given to good ergonomic practice to facilitate installation, maintenance and assembly. This is particularly useful given the cold, arduous, environment in which much work is performed at the JAC.

1. Where relevant, legal requirements shall be met in the ergonomic design of equipment.
2. Equipment ergonomics should comply to relevant national consensus codes.

1. Electronic And Electrical Equipment

1.1 Description

1. This section covers all electrical and electronic equipment, including energy storage and distribution systems.
2. Note that this section is not concerned with safe electrical work practices (which are covered in Chapter 12) but rather with ensuring that any safety critical design requirements are included during the construction process.

1. All designs and construction standards shall be compliant with relevant codes listed below, and the installation shall be supplied with all appropriate documentation.
2. Where practicable, equipment will be specified and purchased from qualified commercial suppliers.
3. The design shall include appropriate provisions for lock-out and tag-out of all energy sources during maintenance and repair.
4. Where necessary, the equipment shall be adequately designed to function safely in the Mauna Kea design environment. This is described in Appendix 2, and the key areas of concern for electrical equipment include:
1. High altitude (particularly de-rating of cooling and hence power capabilities).
2. Low temperature and icing.
3. Water ingress to the JCMT or UKIRT facilities, including up to 1" of standing water in the basements of either building.
5. When purchases of major electrical or electronic equipment are being made, consideration should be given to including the requirements set out in Appendix 1 to this chapter.

1. Where relevant, legal requirements shall be met in the design of electrical and electronic equipment. In this context, some relevant legislation includes:
1. The UK Electrical Equipment (Safety) Regulations 1994.
2. The UK Provision and Use of Work Equipment Regulations 1992.
2. Where necessary, in conjunction with modifications:
1. Local county electrical permits will be drawn for installation or construction work.
2. Only licensed personnel will be permitted to install or modify electrical equipment.
3. Electrical and electronic equipment should comply to relevant national consensus codes, such as:
1. The American National Electrical Safety Code.
2. The US National Electrical Code (NEC) handbook, latest issue.
3. Equipment listing requirements are explained in Appendix 1.
4. Testing of new or modified systems shall be as directed by the design engineer .

1. Safety Relevant Software

1.1 Description

1. UKIRT and JCMT design practice is that software is not relied upon to provide protection of personnel. Wherever protection is required it is provided by hardware interlocks.
2. The design of the hardware interlock shall comply to the relevant portions of this manual, and shall be such that it cannot be over-ridden or bypassed by any software. The hardware interlock may be mechanical or electrical and examples include emergency stops, locking pins and lock-out systems.
3. Software, however, remains a major component in the control of a large and complex telescope facility, and as such the design shall be reviewed to ensure that it does not constitute an added hazard.

1. For new software projects, or updates to existing software the JAC Project Manager shall arrange for appropriate design reviews.
2. Consideration shall be made as to whether the software meets the design practice outlined in section F.1/1/1/1 above. This review shall confirm that :
1. The software is not relied upon to provide protection of personnel.
2. Wherever protection is provided by hardware interlocks, the interlocks cannot be overridden by any other system.

When testing the software, particular attention shall be given to the interaction of the software under test with other systems or staff and appropriate safety precautions taken.

1. Description

1. The JAC has a significant amount of equipment designed and constructed prior to the release of this document. This includes the telescopes themselves, instruments and support equipment, and the equipment age encompasses a range of original manufacture dates, in some cases earlier than 1979 or as late as 1997.
2. Additionally, several instruments currently under construction for supply to JAC were specified and designed prior to release of this document, with original design review dates as early as 1990. Much of the hardware for this equipment is now in the late stages of design and manufacture and is scheduled to arrive at JAC over a range of dates from mid 1997 to 2000.
3. JAC undertakes an active safety management process which aims to continually improve staff safety. If in the course of this process existing equipment is found which is believed to be unsafe, this section shall be used as a basis for review of the situation and corrective action.

1. Existing equipment at the JAC facilities is subject to regular review by processes including Safety Tours and Risk Assessment (Chapter 1 section A2j), and the ongoing awareness and duties of the JAC's staff under safety legislation. Certain equipment, such as lifting devices, are also subject to statutory inspection schedules.
2. Where equipment is found which is thought to be unsafe then a review of the equipment shall be arranged by the JAC Chief Engineer who shall have sole discretion to withdraw it from service until the review has been held.
3. The review shall cover:
1. A description of the equipment.
2. Why it is thought to be unsafe, e.g. due to deficient design, deficient construction practices, deficient supporting documentation, or a changed legal requirements since the date of manufacture.
3. A risk assessment of the hazard posed in order to place the review into an appropriate safety context.
4. An assessment of the work required to rectify the deficiency in order to establish practicality.
5. A "Sentence" of the equipment shall be made which takes into account all the above factors.
6. The Sentence shall be one of the following:
• To approve the equipment as safe without reservations.
• To approve the equipment for use, provided that certain rectification work is performed before use, such as appropriate:
• Design calculations
• Proof testing
• Retrofit modifications.
• To permit the temporary continued use of the equipment. In this event:
• A date shall set by which the equipment must be replaced.
• The equipment shall be suitably marked with the phrase "DO NOT USE AFTER <DATE>".
• To condemn the equipment. In this event:
• The equipment shall be suitably marked with the phrase "CONDEMNED AS UNSAFE".
• The JAC Chief Engineer shall arrange for immediate disposal.
• The review should also consider whether any similar equipment might be in use at any JAC site that, by analogy, might also require investigation.
• A record of the Review and the resulting Sentence shall be retained by the Site Safety Advisor.

1. Work in progress at supplier sites is subject to existing design review processes, to final acceptance tests as described elsewhere in this chapter, and to the ongoing awareness and duties of the supplier under safety legislation.
2. As early as possible, following publication of this document, the JAC Project Manager shall ensure that the ongoing work is reviewed for compliance with the requirements of this chapter.
3. Where items are not in compliance the JAC Project Manager shall, where practicable, require that the appropriate design or construction work be performed prior to acceptance of the equipment by JAC.

Appendix 1: Guidelines for the Purchase of Major Electrical or Electronic Equipment

General

This Appendix is included for information and where applicable, as a set of guidelines to major equipment purchases.

Electrical materials and equipment shall be UL- or FM- tested, with label attached, for the purpose intended, whenever such products are available. Where there are no UL- or FM- Listed products of the type, testing and certification by another nationally recognized testing agency may be acceptable. The prior written approval of the JAC Chief Engineer is required in all such cases. Installation methods shall be in accordance with the manufacturer's instructions. with NFPA 70, and with other applicable requirements.

On-site acceptance testing shall be required for each major electrical system. Tests shall be specified to demonstrate that each function and important parameter is implemented. Specific criteria shall be included to determine pass/fail acceptance. Copies of test results shall be submitted for approval.

Wiring Systems

• Raceways that penetrate fire-rated assemblies shall be non-combustible. The complete installation shall be suitably sealed to maintain the established fire ratings as defined in UL Building Materials Directory and UL 1479. Raceways embedded in masonry for concrete shall be 3/4 inch minimum and shall be adequate in number and capacity for the initial and projected facility requirements.

Conductors

• Conductors for interior electrical systems shall be copper, except that aluminum conductors size No. 4 AWG and larger may be used. Conductors for poser and lighting branch circuits shall be not smaller than No. 12. Power and lighting conductors shall be 600-volt, Type THHN,THWN. Termination of aluminum conductors on copper or aluminum pads shall comply with IEEE 141.

Receptacles

• Receptacles shall comply with general grade and a GFCI protected receptacle shall be used in compliance with NFPA 70.

• Lightning protection systems shall comply with NFPA 78. Lightning protection systems shall be considered for buildings over 50 feet in height, and for building containing valuable equipment.

• Motors shall comply with NEMA MG-1, except that hermetic refrigerant motor compressors shall comply with UL 984.

Motor enclosures shall be drip-proof for indoor dry locations and totally enclosed or totally enclosed fan-cooled for outdoor or other wet locations.

Motors shall be designed for continuous service at 40 degrees C ambient temperature. Motors shall operated at full capacity, with a voltage variation of plus or minus 10 percent of the nameplate voltage. Motor characteristics shall be selected to avoid excessive acceleration time for motors driving large masses and starting under load.

Motor Control

• Control equipment shall comply with the NEMA ICS standards and UL 508

Control devices shall be of adequate voltage and current rating for the duty to be performed. Pilot control circuits shall operate with one side grounded, at no larger than 120 volts. Where control power transformers are required, they shall be located inside the associated motor starter housing, shall be protected against faults and overload by properly sized overcurrent devices, and shall be of sufficient capacity to serve all the devices connected to them with out overload.

Lighting Systems

• Interior lighting systems shall comply with IES Lighting handbook. Lighting power budget shall be determined in conformance with ASHRAE standard 90. Exit and emergency lighting systems shall comply with NFPA 101 and NFPA 110.

• Fire alarm and supervisory systems shall comply with NFPA 71, NFPA 72A,B,C,D,E,F,G,H, NFPA 1221 and ANSI C2 and appropriate for the location.

Appendix 2: Environmental Conditions for Equipment in use by the Joint Astronomy Centre

1. The aim of this document is to summarize design environment information for the use of equipment design engineers at the JAC or supplier organizations.
2. Detailed information has been provided for the telescope sites on Mauna Kea, with lesser detail being provided for the Hilo Base facility.
3. The ranges here are based partly upon codes and standards where these apply, and partly upon operating experience on Mauna Kea over ~15 years. In particular survival ranges may be non-conservative on longer time spans dependent upon the assumed probability of excursion.
4. Reference to appropriate standards and site surveys may provide better detail on extreme limits or statistical range data.
5. In general the "Operating" conditions apply with the telescope configured for observing, the "Survival" conditions with it closed up and shut down. Thus telescope based equipment may presume the protection of the telescope enclosure to some degree (e.g. against wind, snow, debris).
6. The symbol "xx" denotes missing information. Where information is provided for only one of JCMT or UKIRT it may usually be used as a guideline for the other site. Any parties with referenced data or educated opinions are welcome to contact the JAC Chief Engineer.
7. The notes marked "r" below provide specific reference material, those marked "d" provide some discussion based on JAC design experience and/or relevant references.

Table 1: JAC Environmental Conditions

Vibration and Earthquake notes            References            Design Notes         Misc Design Notes

1. Earthquakes probably provide the worst case vibration loading on most equipment, in addition to the basic overload or lateral "g" loading situation for which equipment should be designed. A variety of loading information, some of it contradictory, has previously been available at the JAC due to varying dates of adoption. The current U.S.geological Survey rating for Hawai'i was updated to UBC Zone 4 in 1997, per r17. This provides for a  0.4g lateral / 0.4g horizontal.
2. Spectral contents and duration data may also be available for some of these reference sources.
3. For observing regimes on telescope instruments the vibration environment is highly location specific and the JAC should be consulted closely in designing for such conditions.
4. For information older codes applied at JAC included:Definition is  is available as noted below.

• UBC Zone III (r3)
• 0.3g lateral, 0.1g vertical (r1)
• 0.4g, any direction (r6,r9)
• UBC Zone IV earthquake (r6,r9)
• 0.3g any direction (r10)

• r1 Mauna Kea Specification MT02.
• Depression temperature minimum quoted in JCMT Carousel manual, cross referenced to MT02.
• Earthquake: 0.3g max lateral, 0.1g vertical. Frequency 1-10Hz simple harmonic. 20 sec duration
• r2 Based on r1, page xx
• quoting 100 Tonne snow load on roof (at ~ 30 m diameter )
• r3 Based on r1, page xx
• quoting UBC Zone III. UBC details are , see xx.
• r4 Based on r1, page xx.
• Upper temperature will depend upon direct solar heating. Ambient air rarely exceeds 16&deg;C
• r5 Based on Current practice. See Chapter xx, section xx of this manual
• 64 kph based upon current practice.
• Note that though r1 quotes a design limit of 80kph this is rarely attainable due to gust resonance of festoon cables, roof and doors.
• r6 Gemini Environmental Design Requirements ICD-G0013 Rev B.
• Seismic base acceleration: 0.4g, 0,5-100Hz. Any axis.
• r7 Per UKIRT web page.
• For position the coordinate system is believed to be Geodetic, Old Hawaiian Datum.
• This differs from the standard Geodetic, North American Datum (1927) updated to1983, by a predicted amount 341m N, 291 m W (translation of coordinate grid from OH to NA'83).
• The altitude refers to the dome floor, interpolating from the source map contours.
• The reference altitude is not stated: this is conventionally the local mean sea level.
• Contours were derived by (revised) photogrammetry in 1978.
• r8 CFHT Observers' Manual - Section 5 - SITE CHARACTERISTICS Web based.
• 15mm/year figure is suspect as contradicted by MT02, which contains a 'real' map with the figure 15"/yr.
• Mauna Loa slope (at solar observatory) figures (see r16)
• for RAIN are for 21" max rainfall in year, 8" max rainfall in 1 day
• for SNOW are for 4.5" max snowfall in year, 3" max snow depth.
• r9 Seismic Risk of the Summit Area of Haleakela Volcano, Dr. A.S.Furumoto, Hawaii Institute of Geophysics
• Probability of Magnitude 7 earthquake by 2034: ~40%
• Recommended design load for Mauna Kea 0.4g lateral /0.4g vertical
• r10 ANSI/ASCE 7-95 Minimum Design Loads for Buildings and other structures
• r11 source: Anecdotal: Tribune Herald Volcano Update article (?)
• The Big Island of Hawaii was updated to UBC IV in 1990's
• r12 not used
• r13 UKIRT Dome Performance Requirements Specification UKIRT 4 (Issue 1), 22.May.75
• Section 2.1 (b) quotes: ice load 146 kg.sq.m horizontal surfaces, 293 kg.sq.m vertical surfaces.
• r14 Merz & Mclellan Calc Sheet , UKIRT Job No. 184-015. May.87
• 160mph quoted as measured at site. 104% factor applied for site roughness & height constraints.
• r15 NOAA Western Regional Climate Centre, online data. http://www.wrcc.sage.dri.edu/index.html
• r16 JCMT GPS clock readout, 02.Feb.98 six satellite lock, non-differential.
• r17 US Geological Survey web page: Hawaai Earthquake hazards http://hvo.wr.usgs.gov/earthquakes/hazards/
• r18 : per IfA aerial survey map

Typical grid convergence for the Old Hawaiian coordinates is 0 00 30.
Typical scale factor for the Old Hawaiian coordinates is 0.99996675.
Last updated September 22, 1998 Richard Wainscoat rjw@ifa.hawaii.edu

• d1 Note that a "3second gust" wind speed implies a peak wind speed found by averaging data over a three second interval. It does not imply that the high wind condition will only last for 3 seconds (!). ASCE-7-95 and later standards are tending to quote 3 second gusts as the older "fastest mile" data (how long a packet of wind would take to travel one mile) is no longer widely collated. Note also that the wind loadings may take appropriate account for the reduced air density, and hence reduced air mass.
• d2 For outside enclosures, care should be taken to ensure no penetration - particularly of windows and doors - by missile damage is likely to occur (or that the building is designed to survive loss of outer shell integrity)
• d3 "Wind Loading on large astronomical telescopes" F.Forbes Kitt Peak Observatory & G.Gabor Lawrence Berkeley Labs, Iniversity of California. Undated (but post 1979). provides site wind spectra for UKIRT.
• d4 No observing should occur during precipitation or in cloud/fog. However, both UKIRT and JCMT do experience some water ingress due to leakage or delays in closing up due to hardware faults or slowness in closing during intermittent good-bad weather. JCMT has experienced pooling of water up to 1" deep in certain basement areas. Condensation on, or leakage onto, all exposed surfaces may occur from time to time.
• d5 In most snow or ice conditions, JCMT cannot be opened until all ice and snow is removed from the door and roof trackways. Attempts to open before removing the ice generally leads to ripped brush seals, damaged flashing and the potential for overload or derailing of roof and doors. Additionally, any snow or ice left on non-moving surfaces (mainly on the roof) will lead to water ingress problems upon melting so must also be removed.
• d6 UKIRT is vulnerable to icing of the main dome brush seals, which may take several days to thaw. Attempts to rotate before the ice thaws generally leads to ripped brush seals, damaged flashing and the potential for overload of the dome motors.
• d7 Based on a 2hr transit time from Hilo to Mauna Kea.

Consideration should be given to several effects of high altitude when designing all equipment. This includes:

1. Atmospheric Composition effects
• ozone and ultraviolet may degrade certain polymers
• humidity is generally lower than at sea level, though may vary on short timescales. This may cause dimensional and strength changes in polymers and adhesives
• cure times of adhesives, grouts, and cements are often reduced by a combination of cold and reduced partial oxygen pressure.
2. Low Air Pressure
• low vapor pressure may promote out-gassing of volatiles from polymers, greases and oils.
• reduced atmospheric pressure will affect pressure vessel design, and consideration to potential change of pressure on ascent from sea level should be given
3. Lower Air Density affects:
• reduced convective cooling due to reduced air density impacts electrical equipment's ratings for power dissipation, delivered power and life.
• air conditioning calculations are also impacted including, convective cooling coefficients, fan power ratings, mass flow calculations, and cooling power of ambient air.
4. Low temperature
• Equipment may remain 10-15degC cooler than a typical as-manufactured shop-floor environment, and thus precision tolerances may need to be calculated to allow for operation at lower temperature.
• Low temperature Ductile-Brittle transition may promote early fracture of some materials, including some construction steels.
• reduced ductility of polymers may occur.
• Grease and oil viscosity will be reduced.
5. Low humidity
• Electrostatic discharge hazards often exist in times of low humidity.
• The dry cinder soil also hinders grounding and special grounding layouts are in use at UKIRT and JCMT.
6. Users
• Reduced oxygen levels, in conjunction with cold temperatures and long, unusual work hours will degrade the physical and mental abilities of most workers.
• Consideration should always be given to keeping mechanisms, labels and instructions simple, robust and easy to understand.
7. Corrosion and Debris:
• The Mauna Kea does not generally promote corrosion, unless equipment is exposed to rain, standing water or condensation. Volcanic dust is however pervasive, and the dust may be highly abrasive. Neither JCMT nor UKIRT are by any means 'clean room' environments, and conditions are more typical of a workshop than a laboratory.
• The Hilo environment is severely corrosive. The atmosphere is warm and moist, promoting rusting of most steels and mold growth on organic materials. Equipment may be exposed to salt spray in transit by sea. Volcanic gases and byproducts also pervade the atmosphere.
8. Vibration:
• Some data exists at JAC, although tending to be very location/instrument specific. Contact the relevant JAC project manger for information if required.
9. Packing and Transportation environments
• The packing and transportation environment are often severe and should be considered in designing equipment. Precise details will depend on shipping environment and route. Outline information is available, for example in the US Government MIL-STD-810E. The Gemini Environmental Requirements ICD-G0013-B document quotes:
• altitude 0 to 15,500m
• temperature (inside packing) -25&deg;C to +71&deg;C
• Temperature shock +/- 35&deg;C
• Relative Humidity 0-100% (condensing)
• Wind speed 0-67 m/s
• gravity orientations: any axis
• Shock : 15g peak accel. any axis

Vibration: PSD 0.015g&sup2;/Hz 10 to 40 Hz and 0.00015g&sup2;/Hz 500 Hz

Appendix 3: The JAC Engineering Documentation System

The JAC Engineering documentation system for design information: is as follows

1. Drawing information for JCMT, UKIRT and JAC facilities is located in several locations, each with an appropriate indexing system.
1. Drawings in electronic format are located on central disk space(s) maintained by the computer services group. Access to these files is restricted to authorized persons, generally Design Engineers and JAC Project Managers.
2. Drawings in hardcopy format are located in the Drawing Storage Room at JAC Hilo, or in other locations designated by the JAC Project Manager.
3. Duplicate copies of hardcopy drawings are located for reference purposes at the UKIRT and JCMT sites.
2. JCMT design information is located in the following areas:
1. The JCMT Documentation index <http://www.jach.hawaii.edu/JCMT/pages/technical.html> which consists of several sections for
1. Design documents from the original design of the JCMT
2. Operational notes including technical descriptions and procedures for current systems.
3. Technical reports, such as feasibility studies and detailed investigations of existing phenomena.
4. Software design and documentation notes.
2. Other information storage is the responsibility of the Project Manager. Information is generally located at the Hilo base office of the appropriate Design Engineer(s). There is no overall index.
3. UKIRT design information is located as designated by the UKIRT Technical Manager or the JAC Project Manager or Design Engineer as appropriate. There is no indexing system.