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Rensselaer Formula MotorsportHybrid

Shop Rules
Team Leaders
Advisor: Kaitlyn Lounsbury (518)526-5805 ### #### Formatted: Tab stops: 6.5", Right

Team Leader: Tim Rice (339###)203-2234) ### ####

Facilities and Safety Manager: Henry Chickering (508)740-2499
Advisor: Casey Goodwin…………………………………………………………..###-###-####
Team Manager: Ben Peacock…………………………………………………….802-779-1850
Chief Mechanical Engineer: Kyle Pollard………………………................425-463-5452
Chief Electrical Engineer: Jordan Yamada..…………………………………808-227-7625
Rules & Safety Officer: Chris Lamplough…………………………………...978-793-9195
Manufacturing Expert: Larry Oligny………………………………………..…518-428-5006
Shop Manager: Costas Metropoulos………………………………………..… 908-391-9909 Commented [H1]: and the rest of em too

Last updated on February 21, 201520 December, 2016 Commented [LKR2]:

Table of Contents Commented [KL3]: Insert Table of Contents

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General Emergencies and Injuries

Report all injuries and emergencies to team leaders. If leaders are not immediately available,
report to other shop members., and if present, team leaders of the team. If an injury or hazard
needs prompt attention:
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Call Public Safety at campus phone: (518) 276- 6611 Formatted: Font: 12 pt
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Use emergency action by calling: 911
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In case of fire or hazardous chemical spill evacuate the premises immediately and call public Formatted: No underline
safety. Formatted: Normal, Indent: Left: 0.25", No bullets or
numbering
Evacuation is the goal - fire extinguishers are intended for shop egress only.
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1. a. Do not attempt to move an injured person unless there is imminent danger to life. Formatted: Font: 4 pt, Font color: Black
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2. b. Do not attempt to clean up any blood or bodily fluids, under any circumstances. Call Formatted: Normal, Indent: Left: 0.25", No bullets or
numbering
Ppublic Ssafety. and ESS (###-###-####)
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Commented [H4]: I don’t even know what this stands for lol
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3. c. First-aid kits and fire extinguishers are locatedlocalized in the shop and it is good
practice to become familiar with their locations.

4. d. The eye wash and shower station is located in the hallway of the JEC. There is no local
eye wash or shower station in Ricketts.outside of the cage. When facing the cage door it is to
your right. The shower is painted bright orange.

5. e. If a harmful situation seems present when entering the shop (excessive vapors, smoke,
heat, smells, etc.) leave immediately and do not attempt to remedy the situation. Contact the
appropriate authorities listed above.

Following an emergency or injury, incurred or avoided, the Rules & Safety Officer (RSO), Casey Commented [H5]: What is my title?

Goodwin, and Bill MielkeHenry Chickering must be notified. If the injury requires medical Formatted: Font: Not Italic
attention, Aa Rensselaer Incident Report must be generated and submitted within 24 hours of Formatted: Font: Not Italic
the injury being sustained. Additional near-accidents should be logged internally with the RSO. Commented [H6]: title
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Disclaimer

It is the responsibility of every team member to read and abide by these rules. A member is not allowed
to work in a Formula HybridBumstead Garage shop until he or she has completed the SOE and MANE
Safety quizzes, and submitted the 100% scores to the team Safety Manager. submitted the “Formula
Hybrid Shop Rules Acknowledgement” to the Rules & Safety Officer, and RPI has a record of his or her
completion of the Core Engineering & Architecture Lab Training quiz. This These will be made available
through LMS and must be completed at the beginning of each semester. It is the responsibility of the
member to contact the Safety Manager to obtain the quizzes.

Team members entering Bumstead Garage agree to follow the rules laid out in this Manual, posted
outside of the Cage area, in accordance with SOE, MANE, and EH & S.

At any point in time, if a team member is acting unsafely, they may be removed from the Shop by a
member of Team Leadership.

If any repeated work requires supervision from the team advisor or a faculty member, the supervisor
may give permission, at his or her discretion, to a highly proficient team member to operate
without supervision. This process must be recorded in writing before the work may begin
independently. Both parties must document the agreement through the Rules & Safety Officer
by signing a Supervision Clearance Form. Even if a form is filed, the work is never allowed to be
done alone. A second team member always must be present for all work being conducted.

General Safety Practices

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The following rules apply to any and all work done in the shop. Any person(s) not following proper
safety practices must amend their behavior or will be asked to leave.

a. NEVER work in the shop alone – working with a partner prevents accidents. Always work
with an experienced team member or your sub-team leader if available. The Shop will
only be opened with two people present. One or more of which are required to be a
current or former team leader.

b.a. DO NOT OPERATE ANY MACHINES if your abilities are impaired for any reason (personal
illness, lack of sleep, drugs or alcohol).
c.b. Use of tobacco products, alcohol, and illegal substances is prohibited in and on the grounds
surrounding the shop areaBumstead garage.
d.c. Cell phone use is permitted in shop areas, but not allowed while operating a machine or
power tool. If you must take a call, just turn off the machine.
e.d. Long hair, loose clothing, neckties, dangling jewelry, hoodie strings or headphone
cords must be removed or pulled back when in the shop.
f.e. Safety glasses with side shield protection must be worn in the shop area at all
times. Persons not wearing safety glasses will be asked to leave. Glasses with OSHA
approved (shatterproof) lenses and side shields are permitted.
g.f. Open-toed shoes (high heels, sandals, flip-flops) are not allowed in the shop. Only closed-
toed shoes are allowed. Shoes with open tops (ballet flatstoms) may be subject to this Commented [H7]: I need more examples of this, but shoes
where the toes are closed but you can still see the top of the foot.
rule at the discretion of the ME. Its clearly a violation of the intent of the “closed toed shoes” rule

h.g. Hearing protection is strongly recommended for louder projects. Commented [H8]: title

i.h. Wear gloves when appropriate – for heat or cut protection. Gloves are never appropriate
when operating a rotating tool or machine, including a grinding wheel, mill, or lathe.
j.i. The use of a respirator is strictly regulated. No work should be planned that requires the
use of a respirator. Note that an N95 particle mask is considered a respirator under the
Rensselaer Respiratory Protection Program.
k. The use of bottled (pressurized) gas is controlled. All work using pressurized gas requires
the supervision or approval of the team advisor or a faculty member.
l. The use of an open flame (soldering, brazing, blow torches) in the shop is prohibited – it
is permitted only in the welding area of the student shop, JEC 1012.
m.j. Be aware of your surroundings and peers to avoid bumping into someone working
a machine; , no running in the shop.
n.k.A 2-prognged outlet or transfer attachment is never appropriate for a 3-pronged hookup,
as this eliminates the ground needed for the tool or appliance.
o.l. Heavy-duty (outdoor) extension cords are permitted if inspected and the casing is intact
(no cuts or exposed wiring), and may not be used longer than 1 day (not permanent).

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p.m. Light-weight (indoor) extension cords may not be used, under any circumstances.
q.n. Computers and other electronics may be plugged into surge protector strips for
extended times.
r. All tools, soldering irons, appliances, etc. must be unplugged before leaving the shop.
s.o. If a medical supply or first-aid item is low, empty or missing, inform a member of the
leadership or ME.the Rules & Safety Officer. Commented [H9]: title

Cleanliness and Shop Courtesy

a. Regulatory codes require an open shop floor and 36” of free space around circuit
breakers. When leaving the shop, ensure the floor is free of clutter and that no items are
left in or around the taped zones for circuit boxes. A clear path to the breakers must be
maintained at all times.
b. All flammable or combustible liquids, aerosols, paints, or organic compounds must be
stored in the marked cabinets.
c. Do not vandalize shop furniture/items, treat all tools as if they were your own –
replacement affects everyone else using the tool. Report a broken tool to the Shop
Manager so it can be replaced. He will perform the necessary tag-out to remove the tool Commented [H10]: title
from service. Commented [H11]: lol

d. If the shop is missing a tool or runs out of a material, inform the Shop Manager. also gendered wording wOAh
Commented [H12]: title
e. All tools and materials should be returned to their designated locations when work is
finished.
f. All non-Rensselaer Formula Hybrid tools must be returned and accounted for at the end
of each day. This includes any tools from the Snap-On set, which must be signed in and
out at the beginning and end of its use. Only three (3) tools from the set may be signed
out to a single individual at any time. Commented [H13]: we need to formalize a policy here

g.f. Calipers are precision measuring devices, not tools, and should always be cleaned and put
away when they are no longer in use.
h.g. Drill bits go back in the correct drawer, use calipers to measure the bit from land
to land (the shank of the bit is not the size of the hole it drills) if you’re not sure of size. If
a drill bit will not fit in the right slot, sand down burrs or ask someone else to..
i.h. If you do not know where a tool goes, ask a team member.
j.i. Tools do not belong in pockets and should not leave the shop.
k.j. Clean up work stations before your departure at the shop at the end of the day. If you
must leave while working, place a note with your name and contact information, and
clean any peripheral areas as best as possible..

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l.k. Shop cleanups are scheduled at the discretion of the Rules & Safety Officer or Shop
Manager. While attendance can’t be demanded, a full team effort saves time for Commented [H14]: title
everyone else and leads to fewer cleanups in the long run.Attendance is mandatory for
all full members. If a full member cannot attend a shop cleanup they should contact
(email, slack, text) the shop manager with the reason why they cannot attend. Commented [H15]: title

m.l. Doing personal or school projects at the shop is encouraged, but keep in mind that
team members working on race car projects have priority on machines and shop space.
Members are expected to spend the majority of their time in the shop working on projects
for the team. If a member is in violation of this they may be asked to leave. Commented [H16]: how do say better

n.m. Backpacks and coats should not be left in the shop. Leave them outside the cage
or in the office area.
o.n. Liquid spills may present a slip danger. Due to this, NO FOOD OR DRINK IS
ALLOWED in the any shop areas.

Machines and Power tools

Unless you have been fully trained by our team, do not attempt to use the machines or adjust
them in any way. If you want to be trained on machines, ask the manufacturing expert for time
to learn.someone to train you.

Many hazards exist in a machine shop. You are expected to exercise caution at all times, and think
before every action. Your behavior affects the entire team.

a. Machine usage is restricted. Ask the Rules & Safety Officer or Manufacturing Expert to be
vertical mill or lathe certified.
b. Do not use machinery or power hand tools without the proper training. All training must
be conducted by the manufacturing expert according to a set of predetermined check offs
(completion of ENGR 1300 Engineering Processes should prepare you well). If you don’t
know how to use a machine very well ask an experienced team member - accident
prevention begins with knowing your limits. Additionally, there are safety lessons
produced by the MANE department for further information. Commented [H17]: this isnt how we do it
its basically "recieve informal training and then rip it. ask questions
c.a. A machine may not be left running unattended. Turn off machines when leaving. as you have them"

d.b. Do not distract people operating machines, which include speaking to them. If you But idk if thats okay with anyone else....
Its better than what you get in processees so I dont really think its
must talk, bring machinery to a complete stop first. wrong

e.c. Only one person is allowed to operate a machine at a time. Additional assistance, such as Commented [H18]: this seems a bit overkill...
spraying coolant on a part, is allowed if the assistance is wanted by the machine operator. Commented [H19]: this is needed sometimes so having it say
"only one person" seems like it could get us in trouble over bullshit
f.d. Powered projects or operating projects may not be left running alone. Should long-term
also the wording is a bit funky
testing be required, it must be arranged in advance of the planned work. The work must
be discussed on a case-by-case basis, and given permission from Casey GoodwinHenry
Chickering. Additionally, Bill Mielke MUST be notified for a safety review. Commented [H20]: me i guess?

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g.e.When using any machinery or power tool, including the lathe, mill, or drill press, do not
put your hand in the proximity of the rotating machinery or work piece until it has stopped
spinning
h.f. Manufacturer-recommended safety precautions and machine-specific practices must be
followed when operating certain power tools. This includes using guards for open-disk
rotating machinery, such as an angle grinder.
i. Fabrication or modification of pressure vessels by student, staff, or faculty is not allowed.
Use of commercially available pressure vessels within their manufacturer-rated
operational range is allowed. with the supervision or approval of a faculty member (see
last page). Commented [H21]: what does this mean for us?

j.g. Fabrication or modification of rotating components (e.g. flywheels, tires used as
launchers) with stored energy over 100J is NOT allowed without special permission from
the team advisor or Bill Mielke.
we run the shop on our own with little to no faculty overview so idk
how to handle these kind of statements because they clearly dont
apply to us but if they are expected to exist i dont want to get
screwed
Commented [H22]: see comment H18, same applies here.
also no bill
also i did this to the Nth degree for my IED project and the
professors didn't give a flying fuck. pretty funny how they had no

Welding idea what was going on

Unless you have been fully trained by our team, do not attempt to use the welder or adjust it in any way.
If you would like to be trained to weld, ask the manufacturing expert for time to learn.the pertinent team
member.

a. Welder usage is restricted. Ask the Rules & Safety Officer or Manufacturing Expert to be
weld certified. Commented [H23]: again no certification, we do the training
tho...
b. NEVER weld when you are alone at the shop "Ask a team welder for training with a MIG or TIG welder."

c.a. Always weld with the fume hood on.

d. The use of a particle mask is recommended when welding for an extended period of time
(to prevent the excess inhalation of tungsten from grinding electrodes).
e. At the very least, you must wear a glove on your filler-rod hand, and a protective mask. Commented [H24]: I dont like the glove thing because you can
weld safely without a glove when tig'ing
f.b. Do not weld while wearing polyester, nylon or other plastic-based fabrics, as they may
mig should have gloves for splatter lol
melt to the skin and produce burns. This includes tennis shoes or other footwear made of
these materials, leather boots or shoes are recommended.
g.c. Never bother someone who is welding. This is dangerous not only to them but everyone
in the fabrication area. Wait till their mask is up to ask them a question.
h.d. Do not watch weld arcs, or their immediate reflections, without eye protection of
at least shade 10 (as dark as a welding mask). Failure to protect your eyes will result in
their damage or loss.
i. Welders must audibly give a warning when they are about to weld and another warning
letting people know that they are about to stop. (e.g. Flame on/Flame off)

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j.e. Do not handle or move any welding equipment or piece (object being welded on) without
explicit instruction to do so from their fabricator. They could be hot or fragile.
k.f. Carbon fiber conducts electricity and is poisonous when burnt. Special precautions must
be followed when welding near carbon fiber. Ask an experienced welder for further
information.
l.g. Coated metals are not allowed to be welded in the shop (e.g. galvanized, zinc coated).
Thoroughly remove the coating if you wish to weld them.
m.h. Do not weld any component (or car) that is wired or instrumented in any way. This
will lead to damage to expensive components, or catastrophic and dangerous cross-
grounding.
n.i. If you empty an argon tank, tell the Shop Manager or team welder. Commented [H25]: title

o.j. Once you have finished with the welder, untangle all of the cables and wrap them up
neatly away from traffic areas.
p.k.Shut off welder, completely close argon tank, and turn off fume hood when done welding.
q.l. If you have been fully trained by our team, you are welcome to practice welding under
the following circumstances:
a) The welder you are using is not needed to work on race car components
b) We are not rationing welding supplies (tungsten, filler rod, argon) Commented [H26]: these are lifted directly from our "posted
on the cage" shop rules, funny.

Chemical
a. You should know how to use a chemical safely and dispose of it properly whenever using
one. Review the specific SDS and Laboratory Chemical Hygiene Plan for proper disposal
procedures. The right time to figure out how to prepare for and use a chemical is before
ordering it. The Rules & Safety Officer must be notified prior to purchase. or Team Commented [LKR27]: title

Manager must sign off on chemical purchases, and the team advisor must be notified.
b. Safety Data Sheets (SDS) are available on line through MSDSonline
at www.msdsonline.com. A copy of the sheet is also available in the shop.
c. All chemicals must be clearly labeled by content, written in their full name in English. An
abbreviated, chemical formula or molecular structure label does not satisfy this
requirement.
d. Volatile, flammable, and other toxic or odor-producing chemicals must be stored in the
designated cabinets. While their storage is permitted in Ricketts, their use is restricted to
the fume hood in JEC 2332 (paint booth).
d.
e. Do not drain-dispose any chemical without first consulting Environmental Health & Safety
(EH&S).

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f. To reiterate, no chemicals should be used that require the use of a respirator.

g. Oil soaked rags or rags with any type of solvent are to be disposed of in proper containers.
Do NOT dispose of these items in regular trash containers.
h. Hazardous or regulated materials such as batteries, computer components, and chemical
reagents must be disposed of properly. Notify the Rules & Safety Officer if dealing with Commented [H28]: title

their disposal.
i. All chemical and material hazards, including spills and incidental events, are to be dealt
with in accordance with the Hazardous Materials Contingency Plan drawn up by
Rensselaer. A copy of this is available in Ricketts 001. Commented [H29]: we need to get a copy of this I guess

Composites
In addition to being subject to the Chemical policy above composites have the following rules:

a. Do not begin a layup before presenting its purpose and your plan to the Chief Electrical
or Mechanical Engineer. It is a lengthy process, so be sure to schedule a time and location Commented [H30]: titles?
Design Leads ?
to work. When leaving a layup, provide a note that includes: contact information, and
timeframe expected for the composite to set, your expected return time, and any other
important notes about the layup..
b. Any paint or chemical compounds requiring mixing and/or the use of a respirator requires
approval or supervision of a shop staff member. Please contact Sam Chiappone or Dave Commented [H31]: again with the "we run our own shop"
thing
Digulio for assistance.
Can I just delete this whole section?
c.b. When working with resin, wear eye protection, gloves, long pants and long sleeves. Check
the SDS of the resin before use to ensure proper Personal Protective Equipment (PPE),
and always work in an area with good ventilation.
d.c. Be aware of the pot life of the resin you are working with, and proceed accordingly.
Always mix resin and hardener to the proper ratio, if you do not know the ratio, consult
its data sheet, the manufacturer, or a team leader.
e.d. When cutting/sanding cured layups, always work under an engineering controlled
particle hood, wear eye protection, and cover any exposed skin (clothing or baby powder
should work for most materials). It is also helpful toAlways wet out the sanding surface
to cut down on freed dust particles.
f.e. Clean mixing cups, reusable mixing sticks and spatulas properly after each layup.
g.f. If a material is running low or is out (gloves, carbon, resin, bagging, peel ply, etc.), notify
the Shop Manager. Commented [H32]: title

Painting

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In addition to being subject to the Chemical policy above painting has the following rules:

a. No spray paint is allowed in the shop. All painting is to be done in the paint booth (with
the ventilation system turned on) regardless of application method. The paint booth is
located in the Design Lab Fabrication and Prototyping Area, JEC 2332. Commented [H33]: uhhh....

b. Liquid paints or oil-based paints are permitted only with proper ventilation. Ricketts 001
is not a properly ventilated area.

Electronics
a. To reiterate, safety glasses must be worn at all times, including soldering. Avoid flicking
the soldering iron to remove excess material.
b. When working on high voltage (24V or greater) all members of the shop must be aware
and keep their distance. This is very much similar to when members are welding.
c. High voltage work must be approved by the team advisor or Bill Mielke. When charging
or testing anything using high voltage an experienced person (team advisor or faculty
member) must supervise the work.. Commented [H34]: again with the "we run our own shop
thing"
d. High voltage gloves and rubber mats must be used at all times when working on exposed
high voltage elements and accumulators. Commented [H35]: we dont have these, the "one hand" rule
(H) works perfectly well here. also dont be an idiot applies.
e. Synthetic fiber-based clothing (such as polyester) may not be worn when working with
high voltage. Additionally, conductive jewelry (rings and watches) must be removed.
f. You must ground your lines before working with high voltage systems.
g. Do not work on electronic circuits when power is on, unless it is absolutely necessary and
under the approval or supervision of the team advisor or faculty member. Low power
analog and digital circuitry (i.e. ≤ 250 mA) is the ONLY exceptions to this rule provided the
power supply or battery is fused at 1 amp or less. Commented [H36]: this sounds reasonable but IDK if you could
consider troublehsooting the car harness to be in violation of this
h. Use the one- handed rule (only one hand touching circuit at any given time) when working given that sometimes you do it when the car is on and when the car
is on you can draw like 200,000 mA of current when you are
on active circuits. Electric currents of less than 50-100 milliamps can cause death. running the starter motor.

i. A battery may not be left charging alone, for any reason. No exceptions.
j. Batteries and power supplies must be fused appropriately to ensure safety of the
operator.
k. All batteries must be manufacturer labeled and their battery chemistry (type) listed. Lead-
Acid batteries must be of the sealed, non-spill, "gel cell" or "AGM" type – ALL Liquid
electrolyte lead acid batteries are prohibited from the shop. Commented [H37]: this is unreasonable because we have
multiple of these batteries
l. Any batteries not of the standard consumer type (e.g. AA, AAA, C, D, 9v, 6v lantern
battery, etc.) must be approved by the team advisor or a faculty member. This includes also i guarantee the Hyster has a liquid battery because an AGM
battery would be stupid expensive for something like that ($200 vs
the Lithium-based battery types: “Lithium”, “Li-po”, “Li-Ion”, “Lithium-Polymer”, “MnO2- $75 or less)
Li”, etc. Commented [H38]: again, we run our own shop and make our
own educated decisions. this seems unreasonable

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m. Never charge a battery without first knowing the specific precautions and procedures to
take for its chemistry and power source. NEVER attempt to charge a non-rechargeable
battery.
n. Capacitors (electrolytic and large) hold their charge for several hours. Be sure they are
discharged with an insulated clip lead before working on the circuit.
o. Semiconductors and other circuit components may become hot when in use, exercise
caution when removing them from an operational circuit.

Faculty
Please contact Sam Chiappone if you have questions relative to the policies, testing process, or
projects outside of the scope of these rules set forth in correspondence with the School of
Engineering laboratory safety rules. Commented [H39]: we are kinda doing this on our own

also Chiappone doesnt really have oversight over us I dont think

we are a huuuuge gray zone lol

Kaitlyn Lounsbury – Team Advisor, Associate Advancement Officer

Location: , Heffner Alumni HouseHAH 2nd Floor, 3002.03
Email: Lounsk2@rpi.edu
Office: (518) 276-4132 ####
Cell: (518) 526 5805

Randy McDougall – [What is his position?],Technical Manager, Safety Specialist

Location: Safety Specialist, JEC 1201
Email:mcdour@rpi,edu
Office: (518) 276-2391 ####

Leon Golinski – Maintenance Mechanic, Lead/On-Site CaretakerPhys Plant Welder and Caretaker
Location: Bumstead Garage, 2368 Burdett Ave.of Bumstead
Email: golinl@rpi.edu
Office: (518) 276-6238
Cell: (518) 376 0792

Casey Goodwin – Team Advisor, School of Engineering, CII 7th Floor

csgoodwin@rpi.edu ###-###-#### Formatted: Font color: Hyperlink

Sam Chiappone - Manager of Fabrication & Prototyping, School of Engineering, JEC 3004/3018

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chiaps@rpi.edu (518) 276-8295

Bill Mielke – Technical Manager, Safety Specialist, JEC 1201

mielke@rpi.edu office: (518) 276-6881 cell: (518) 728-9249

Judy Corbett – Safety Specialist, Environmental Health & Safety

corbej3@rpi.edu (518) 276-2281 Commented [H40]: Should judy be on this list

David Digiulio – Technical Support, Composite Consultant, JEC 2204

digiud@rpi.edu

Scott Yerbury – School of Engineering, Machining Consultant, JEC 3004/3018

yerbus@rpi.edu (518) 276-8290 Commented [H41]: they never agreed to do any consulting...

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