USSR STATE STANDARD

OCCUPATIONAL SAFETY STANDARDS SYSTEM

INDUSTRIAL EQUIPMENT
GENERAL SAFETY REQUIREMENTS

GOST 12.2.003-91

Official Edition

USSR STATE COMMITTEE FOR PRODUCT QUALITY MANAGEMENT AND

STANDARDS
Moscow
 UDC 658.382.3:006.354 Group T58
USSR STATE STANDARD

Occupational Safety Standards System

INDUSTRIAL EQUIPMENT GOST
General Safety Requirements 12.2.003 – 91

OKSTU (All-Union Classification Code of Standards and specifications) 0012

Date of Introduction 01.01.92

This Standard applies to industrial equipment used in all areas of the national economy
and establishes general safety requirements, which shall be the basis for establishing safety
requirements in Standards, specifications, operation and other designer documents for the
particular groups, types, models (grades) of industrial equipment.
The Standard does not apply to industrial equipment that is a source of ionizing radiation.

1. GENERAL PROVISIONS

1.1. Industrial equipment shall ensure the safety of working people during installation (or
dismounting), putting into operation and operation both in case of autonomous use, and in the
structure of technological complexes provided that the requirements (conditions, rules)
established in operational documentation are observed.
Note. The operation of the equipment includes, in general, use for its designated purpose, maintenance and
repair, transportation and storage.
1.2. The safety of an industrial equipment design shall be ensured as follows:
1) the choice of principles of operation and design, power sources and performance of
energy resources, parameters of working processes, control system and its components;

Official Edition
© Standards Publishing House, 1991
This Standard may not be reproduced in full or in part, reprinted or distributed without
permission of Gosstandart of the USSR
p. 2 GOST 12.2.003 – 91

2) minimization of consumed and accumulated energy during operation of the equipment;

3) the choice of accessories and materials used for manufacture of designs and also
applied during operation;
4) The choice of manufacturing processes;
5) The use of protection means for operators, built into a design, and also means of
information, warning about the origin of dangerous (including fire and explosion risks)
situations *;
6) The reliability of a design and its components (including duplication of separate control
systems, means of protection and information, whose failure may cause dangerous situations);
7) The use of means of mechanization, automation (including automatic control of
working process parameters), remote control and monitoring;
8) The potential to use means of protection, which are not included in the design;
9) The observation of ergonomic requirements;
10) The limitation of physical, nervous and psychological burdens for the operators.
1.3. Safety requirements for particular groups, types and models (grades) of industrial
equipment shall be established on the basis of the requirements of this Standard, taking the
following into account:
1) Features of a function, modification and operating condition;
2) Test results, and also analysis of dangerous situations (including fire and explosion
risks) which took place during operation of analogous equipment;
3) Requirements of the Standards establishing permissible values of dangerous and
harmful manufacturing factors;
4) Research and development works and also analysis of means and methods for ensuring
security, using the best world analogs;
5) Safety requirements established by international and regional Standards and other
documentation for analogous groups, types, models (grades) of industrial equipment;
6) A forecast of possible dangerous situations for newly developed or upgraded equipment.
Safety requirements for a technological complex shall also take into account possible
dangers caused by combined operation of units of the industrial equipment, which form a
complex.
* A dangerous situation is a situation, the origin of which may cause the effects of dangerous and harmful
manufacturing factors to harm the operators.
 GOST 12.2.003 – 91 p. 3

1.4. Each technological complex, and industrial equipment used autonomously, shall be
completed with operational documentation containing the requirements (rules) for preventing
the origin of dangerous situations during installation (or dismounting), when placing the
equipment into operation, and during operation. General requirements for the contents of
operational documentation regarding safety are given in the Appendix.
1.5. Industrial equipment shall meet safety requirements for the entire period of operation,
if a customer observes all the requirements established in the operational documentation.
1.6. Industrial equipment shall not pollute the environment by the effluent of harmful
substances or harmful microorganisms during operation, in amounts exceeding permissible
the values established by Standards and Sanitary Standards.

2. GENERAL SAFETY REQUIREMENTS

2.1. Requirements for a design and its separate components

2.1.1. The materials for a design of industrial equipment shall not cause dangerous or
harmful effects to the human organism under all stipulated modes of operation and
established operating conditions, or cause fire and explosion risks.
2.1.2. The design of industrial equipment shall eliminate loads to parts and assembly units
that may cause a breakdown dangerous to operators under all established operation modes.
If the origin of loads that can cause a breakdown of separate parts or assembly units
dangerous to operators is possible, industrial equipment shall be provided with devices
preventing the origin of destructive loads. Parts and assembly units shall be protected or
located so that their destruction shall not create situations causing injury.
2.1.3. The design of industrial equipment and its separate parts shall eliminate the
possibility of their falling, tipping over and displacement of their own accord during all
established operating and installation (or dismounting) conditions. If the necessary steadiness
cannot be reached because of the shape of the industrial equipment, the weight distribution of
its separate parts and installation (of dismounting) conditions, and the means and methods of
fixing shall be stipulated, and the operational documentation shall contain corresponding
requirements.
p. 4 GOST 12.2.003 – 91

2.1.4. The design of industrial equipment shall eliminate the possibility of falling or
throwing parts (for example, instruments, blanks, machined parts, chips) dangerous to
operators, and also an effluent of greasing, cooling and other working fluids.
If the use of protection enclosures, which are not included in the design, is necessary for a
specified purposes, the operational documentation shall contain corresponding requirements
for them.
2.1.5. Moving parts of industrial equipment, which are a possible source of injures, shall
be protected or located so that the opportunity of touching them by operators is eliminated, or
other means (for example, two-handled control) preventing injuring are used.
If the functional purpose of moving parts dangerous for man does not allow the use of
protection enclosures or other means preventing operators from touching moving parts, the
design of the industrial equipment shall provide a signaling system, warning or equipment
start-up, and also the use of signal colors and safety symbols.
Controllers for emergency stop (braking) shall be installed in immediate proximity to
moving parts, which are out of the range of operator vision, if operators may be in the danger
zone of moving parts.
2.1.6. The design of clamping, gripping, elevating and loading devices or their drives shall
eliminate the opportunity of a danger origin if power is cut off, in full or in part, of its own
accord. It shall also eliminate any change in the condition of these devices of their own accord
when the power supply is restored.
2.1.7. The structural members of industrial equipment shall not have sharp corners, edges,
burrs and rough surfaces, which may injure working people, if the functional purpose of these
members does not require them. In the latter case, the protection of workers shall be
stipulated.
2.1.8. Parts of industrial equipment (including pipelines of hydraulic, steam and pneumatic
systems, safety valves, cables etc.), the mechanical damage of which may cause an origin of
danger, shall be protected by enclosures or be located so that their accidental damage by
operators or by means of an technical maintenance is prevented.
 GOST 12.2.003 – 91 p.5

2.1.9. The design of industrial equipment shall eliminate the weakening or disconnection
of assembly units attachments and parts of their own accord, and also eliminate the
displacement of moving parts beyond the limits stipulated by the design, if it may cause a
dangerous situation.
2.1.10. The industrial equipment shall be fire-safe and explosion-safe under stipulated
operating conditions.
Means and methods for ensuring fire-safety and explosion-proofing (for example,
prevention of formation of fire- and explosive atmosphere, exclusion of formation of ignition
sources and explosion initiation, warning, fire-extinguishing systems, emergency ventilation,
air-tight jackets, emergency draining of combustible fluids and leakage of combustible gases,
placing the industrial equipment or its separate parts in special locations) shall be established
in the Standards, specifications and operational documentation for particular groups, types,
models (grades) of industrial equipment.
2.1.11. The design of industrial equipment powered by electrical energy shall include
devices for ensuring electrical safety.
Means for ensuring electrical safety (for example, an enclosure, grounding, neutral
earthing, insulation of current carrying parts, protective cut-off etc.) shall be established in
Standards, specifications and operational documentation for particular groups, types, models
(grades) of industrial equipment, taking maintenance conditions and performances of
electrical energy sources into account.
2.1.11.1. Industrial equipment shall be manufactured so that accumulation of static
electricity charges in an amount dangerous to operators is eliminated, and the possibility of
fire and explosion is also eliminated.
2.1.12. Industrial equipment operating under non-electrical energy (for example,
hydraulic, pneumatic, steam power) shall be manufactured so that all dangers caused by these
types of energy are eliminated.
The specific measures for exclusion of danger shall be established in the Standards,
specifications and operational documentation for particular groups, types and models (grades)
of industrial equipment.
p. 6 GOST 12.2.003 – 91

2.1.13. Industrial equipment which is a source of noise, ultrasound and vibration, shall be
manufactured so that the noise, ultrasound and vibration does not exceed permissible levels
established in Standards, under stipulated conditions and modes of operation.
2.1.14. The industrial equipment, the operation of which is accompanied by an effluent of
harmful substances (including non-fire-safe and explosive) or harmful microorganisms, shall
include built-in devices for their removal or allow the connection of removal devices which
are not included in the design of the industrial equipment.
The device for harmful substances and microorganism removal shall be manufactured so
that the concentration of harmful substances and microorganisms in a working area, and also
their effluent into the environment, does not exceed the values established in Standards and
Sanitary Standards. The cleaning and neutralization of the effluent shall be carried out where
necessary.
If the combined removal of different harmful substances and microorganisms is
dangerous, their separate removal shall be ensured.
2.1.15. Industrial equipment shall be manufactured so that the effect of harmful radiation
on operators is removed or limited to safe levels.
When laser devices are used, it is necessary:
to eliminate unintended radiation;
to shield laser devices so that health dangers to the operator are eliminated.
2.1.16. An industrial equipment design and its location shall eliminate contact of its
combustible parts with any substances that may cause a fire or an explosion, and also
eliminate the possibility of operator contact with hot or overcooled parts, or his being in
immediate proximity to such parts, if it may cause injury, overheating or overcooling of the
operator.
If the purpose of the industrial equipment and the conditions of its operation (for example,
the use of equipment outside of industrial locations) may not eliminate in full operator contact
with its overcooled or hot parts, the operational documentation shall contain requirements
concerning the use of individual protection means.
 GOST 12.2.003 – 91 p. 7

2.1.17. The design of industrial equipment shall eliminate the danger caused by sputtering
hot materials or substances being treated or used during operation.
If the design does not ensure the exclusion of such danger in full, the operational
documentation shall contain requirements concerning the use of protective means, which are
not included in the design.
2.1.18. Industrial equipment shall be supplied with local illumination, in case there is a
danger of eyestrain or other types of danger if there is no is the illumination.
The performance of local illumination shall comply with the character of operation, which
it is necessary for.
Local illumination, its performance and locations shall be established in Standards,
specifications and operational documentation for particular groups, types and models (grades)
of industrial equipment.
2.1.19. The design of industrial equipment shall eliminate errors during installation, which
may be a source of danger. In a case when this requirement may be observed in part only, the
operational documentation shall contain the installation procedure, number of inspections and
tests eliminating the possibility of dangerous situations because of installation errors.
2.11.19.1. Pipelines hoses, wires, cables and other connecting components and assembly
units shall have markings in accordance with wiring diagrams.
2.2. Requirements to operator’s workstations
2.2.1. The design of an operator’s workstation, its dimensions and relative position of
elements (control, means of information representation, auxiliary accessories etc.) shall ensure
safety during use of industrial equipment for its designated purpose, maintenance, repair and
cleaning, and also meet the ergonomic requirements.
It is necessary to have fire-fighting means and other means used in emergency situations
at the operator’s workstation, as established in Standards, specifications and operational
documentation for particular groups, types and models (grades) of industrial equipment.
If a cabin is included in an operator’s workstation for protection from the effects of
dangerous and harmful manufacturing conditions, its construction shall provide the necessary
protective functions, including the creation of optimum microclimatic conditions,
convenience of execution of working operations and optimum vision of industrial equipment
and the surrounding space.
p. 8 GOST 12.2.003 – 91

2.2.2. The dimensions of an operator’s workstation and placement of its elements shall
ensure the execution of working operations in convenient working poses and not hamper the
motions of the operator.
2.2.3. The possibility of working operation execution in a sitting position or changing
sitting and standing positions shall be stipulated when the operator’s workstation is being
designed, if the execution of operations does not require the continuous movement of the
operator.
The design of a chair and feet support shall meet the ergonomic requirements.
If the placement of an operator’s workstation causes the necessity of operator movement
between floors, the design shall provide platforms, ladders, handrails and other devices, the
dimensions and construction of which shall eliminate the possibility of the operators falling
and ensure convenient and safe execution of working operations including maintenance
operations.
2.3. Requirements for control s ystems
2.3.1. The control system shall ensure reliable and safe operation of industrial equipment
under all stipulated operation modes and during all external actions stipulated by the
operating conditions. The control system shall eliminate dangerous situations caused by the
violation of the sequence of controlling operations by the operators.
Inscriptions, schemes and other means of information concerning the necessary sequence
of controlling operations shall be marked on the operator’s workstation.
2.3.2. Control systems of industrial equipment shall include means of emergency braking
and emergency stop (cut off), if their use may decrease or prevent danger.
The necessity of including specified means in the control system shall be established in
Standards and specifications for particular groups, types and models (grades) of industrial
equipment.
2.3.3. The control system shall include auto-control normalization of operational modes or
auto-controlled stop, depending on the complexity of control and monitoring of operational
modes of industrial equipment, if the violation of an operational mode may cause a dangerous
situation.
 GOST 12.2.003 – 91 p. 9

A control system shall include signaling means and other means of information, warning
about violations of industrial equipment operation that could result in dangerous situations.
The design and placement of warning signs shall ensure correct, reliable and prompt
perception of the information.
The necessity of including means of auto-control normalization of operation modes or
auto-control stop into a control system shall be established in Standards and specifications for
particular groups, types and models (grades) of industrial equipment.
2.3.4. The control system of a technological complex shall eliminate the origin of danger
as a result of combined operation of all units of industrial equipment included in the
technological complex, including in cases of failure of any single unit.
2.3.5. The control system of separate units of industrial equipment, which is included in a
technological complex, shall have devices to block the start of operations of the technological
complex or to stop it if necessary (for example, before finishing maintenance).
2.3.6. The central control panel of a technological complex shall be equipped with a
signaling system, mnemonic diagram or other means of information representation
concerning violations of normal operation of all units of industrial equipment constituting a
technological complex, means of emergency stop (cut off) of the entire technological
complex, and also its separate units, if the emergency stop of separate units will not cause the
aggravation of the situation.
2.3.7. The central control panel shall be located and equipped so that the operator can
check if there are people in dangerous zones of the technological complex, or a control system
shall be made so that the operation of the technological complex is impossible if there are
people in the danger zone. There shall be a warning signal, the duration of which shall allow a
person being in a danger zone to leave it or to prevent operation of the technological complex.
p. 10 GOST 12.2.003 – 91

2.3.8. Control system command devices (further –controls) shall meet the following
requirements:
1) they shall be easily accessible and freely distinguishable, marked with inscriptions,
symbols or other means where necessary.
2) they shall be designed and placed so that their involuntary movement is impossible, and
so that accurate, reliable and unambiguous manipulation shall be ensured, including cases
when an operator is using personal protection means;
3) they shall be placed taking into account the effort required for movement, sequence and
frequency of use, and also the significance of functions;
4) they shall be made so that their shape, dimensions and contact surfaces corresponded
with the means of grasping (fingers, hand) or pressing (finger, palm, foot);
5) they shall be located outside of a danger zone, except for controls whose functional
purpose (for example, controls of a robot moving during its adjustment) requires the operator
to be in a danger zone; in this connection, additional safety measures (for example, lowering
the speed of moving parts of the robot) shall be provided.
2.3.9. The industrial equipment may be placed into operation for the first time, or restarted
after stopping, only by manipulation of the start-control.
This requirement does not apply to restart of industrial equipment which works in an auto-
control mode, if restart after a stop is stipulated by this mode.
If a control system has several controls which place the industrial equipment or its
separate parts into operation, and a violation in the sequence of their use may cause dangerous
situations, the control system shall include devices to eliminate such situations.
2.3.10. The emergency stop control shall remain in a position corresponding to stop after
cut off, before it is returned to its initial position by the operator; resetting shall not cause the
start of the industrial equipment.
The emergency stop control shall be red in color, and differ from other controls in shape
and dimensions.
2.3.11. If there is a switch for the operation modes of industrial equipment in a control
system, each switch position shall correspond to one mode only (for example, regulating
mode, monitoring mode, etc.) and shall be fixed safely in each position, if fixing will prevent
a dangerous situation.
 GOST 12.2.003 – 91 p. 11

If increased protection for the operator is required under some modes of operation, the
switch shall carry out the following functions under these modes:
to block the possibility of automatic control;
to ensure the movement of members, when continuous effort of a worker is applied to a
movement control only;
to stop operation of dependent equipment, if its operation may cause additional danger;
To eliminate operation of parts of industrial equipment, which are not involved in the
realization of the selected mode;
To reduce speeds of moving parts of industrial equipment which are involved in the
realization of the selected mode.
2.3.12. Dangerous situations, including the following, shall not take place if the power
supply is disconnected in full or in part and then restored, and also if there is damage in a
power supply control circuit:
the start of equipment of its own accord, when the power supply is restored;
omission of a stop command, which has already been given;
falling and ejection of loose parts of industrial equipment and articles fixed to them (for
example, blanks, instruments, etc.);
the lowering of efficiency of protective devices.
2.4. Requirements for protection means included in a design, and signaling
devices
2.4.1. The design of protection means shall ensure monitoring capabilities if they carry out
their functions before the start or during operation of the industrial equipment.
2.4.2. Means of protection shall carry out their functions continuously during operation of
the industrial equipment or if there is a dangerous situation.
2.4.3. The operation of protection means shall not stop before the operation of the
corresponding dangerous or harmful manufacturing factor is stopped.
2.4.4. A failure of one protective means or its element shall not stop the normal operation
of other means of protection.
2.4.5. Industrial equipment that includes means of protection that must be switched on
before starting operations or be cut off after stopping operations, shall have devices ensuring
such a sequence of operations.
p. 12 GOST 12.2.003 – 91

2.4.6. The design and location of protection means shall not limit the technological
performance capabilities of the industrial equipment and shall ensure the convenience of
operation and maintenance.
If the design of protective means does not ensure all technological performance
capabilities of the industrial equipment, the requirements for ensuring protection for the
operator shall have priority.
2.4.7. The shape, dimensions, strength and rigidity of a protective enclosure, and its
location in relation to protected parts of the industrial equipment shall eliminate the
possibility of the protected parts affecting the operator and throwing (for example, of
instruments, processed parts).
2.4.8. The design of a protection enclosure shall:
1) eliminate the possibility of the enclosure moving of its own accord from a position
ensuring protection of the operator;
2) allow the opportunity of its moving from a position ensuring protection of the operator
only with the help of tools, or to block operation of the industrial equipment, if the protection
enclosure is in a position which does not ensure its protective functions;
3) ensure the ability of the operator to carry out stipulated operations, including
monitoring the operation of protected parts of the industrial equipment, if necessary;
4) not cause additional dangerous situations;
5) not reduce labor productivity .
2.4.9. The danger warning signaling devices shall be made and located so that their signals
are easily distinguishable and audible under industrial conditions for all persons who are
potentially in danger.
2.4.10. The parts of the industrial equipment which are dangerous shall be painted with
bright colors and marked out with a corresponding safety sign, in accordance with effective
Standards.
2.5. Requirements for design facilitating safet y during mounting,
transportation, storage and repair
2.5.1. If the use of hoisting means is necessary during installation, transportation, storage
and repair, places for connection with hoisting means and the weight to be lifted shall be
marked on the industrial equipment and its separate parts.
 GOST 12.2.003-91 p. 13

2.5.2. The places for connecting hoisting means shall be chosen taking the center of
gravity of the equipment (and its parts) into consideration so that the possibility of damaging
the equipment during lifting and movement is eliminated and a convenient and safe approach
to it is ensured.
2.5.3. The design of the industrial equipment and its parts shall ensure the possibility of
their reliable fixing on a vehicle or in a packing container.
2.5.4. Assembled units of industrial equipment that may move of their own accord during
loading (or unloading), transportation and storage shall have means for fixing in the defined
position.
2.5.5. The industrial equipment and its parts, which are stipulated to be moved manually,
shall be supplied with means (for example, with handles) for movement or have a shape
convenient for grasping by hand.
p. 14 GOST 12.2.003 – 91

APPENDIX
Recommended

GENERAL REQUIREMENTS FOR OPERATIONAL DOCUMENTATION

REGARDING THE ENSURANCE OF SAFETY OF INDUSTRIAL EQUIPMENT

1. The contents of the operational documentation of industrial equipment shall be defined

by the purpose, design features and operating conditions established in Standards and
specifications.
2. The operational documentation shall establish the requirements (rules), which shall
eliminate dangerous situations (including fire and explosion risk) during the mounting (or
dismounting), putting into operation and operation of the industrial equipment, and also
contain requirements defining the use of means that are not included in the design, and
methods for protecting the operator.
3. In general, the operational documentation regarding safety shall contain the following:
1) specifications for equipment, instruments and devices, ensuring safety during all
stipulated operations of installation (or dismounting), starting operation and maintenance;
2) Rules of installation (or dismounting) and means of preventing possible errors which
may result in dangerous situations;
3) Requirements for placing industrial equipment in industrial locations (on industrial
platforms) ensuring convenience and safety during use of equipment for its designated
purpose, maintenance and repair, and also requirements for providing locations and platforms
with protective means which are not included in the design of the industrial equipment;
4) Real levels of noise, vibration, radiation, harmful substances, harmful microorganisms
and other dangerous and harmful industrial factors, introduced by the industrial equipment
into the environment;
5) The procedure of putting the equipment into operation and ways of preventing possible
errors which may result in dangerous situations;
6) Limiting conditions for exposure (temperature, atmospheric pressure, humidity, solar
radiation, wind, ice formation, vibration, impacts, earthquakes, corrosive gases,
electromagnetic fields, harmful radiation, microorganisms, etc.) and effects of the industrial
environment, at which the security of industrial equipment is preserved;
7) Rules for equipment control under all stipulated operation modes and operator actions if
there are dangerous situations (including fire and explosion risks);
8) Requirements for staff concerning the use of individual protection means;
9) Means of timely failure detection in built-in protection means and the operations of
workers in these cases;
10) Rules and means for the safe execution of maintenance;
11) Rules for transportation and storage, which ensure conformity of the industrial
equipment to safety requirements;
12) Rules for ensuring fire- and explosion-safety;
 GOST 12.2.003 – 91 p. 15

13) Rules for ensuring electrical safety;

14) A prohibition against the use of industrial equipment or its parts for undesignated
purposes, if it would be dangerous;
15) Requirements concerning the teaching of operators (including training) and also age
requirements and other limitations;
16) Safety rules for biological, chemical and radioactive decontamination.
4. The operational documentation may contain other requirements (rules), and some of the
requirements (rules) listed in clause 3 may not be included into documentation, if they do not
comply with features ensuring safety for the particular type, kind, or model of industrial
equipment.
p. 16 GOST 12.2.003 – 91

DETAILS

1. DEVELOPED AND SUBMITTED by the USSR State Committee for Product

Quality Management and Standards, and the USSR Council of the Universal
Confederation of Trade Unions
DEVELOPERS
V. G. Versan, Cand. Sci. (Econ.); N. T. Timofeeva, Cand. Sci. (Tech.); V. B. Ochlyand;
T. A. Alecseeva; V. V. Dyakov, Dr. Sci. (Tech.); I. P. Stabin, Dr. Sci. (Tech.);
O. M. Kasatkin
2. APPROVED AND INTRODUCED by Decree No. 807 of the USSR State Committee
for Product Quality Management and Standards, dated 06.06.91
3. Review period and frequency: 1997.
4. IN PLACE OF GOST 12.2.003 – 74

Editor V. M. Lisenkina
Technical Editor O. N. Nikitina
Proof-reader R. N. Korchagina