K.S.R.

COLLEGE OF ENGINEERING, TIRUCHENGODE – 637 215

(AUTONOMOUS)

M.E. / M. Tech. DEGREE END SEMESTER EXAMINATION, NOV / DEC - 2021

Third / M.E. / Industrial Safety Engineering

IS20371 – Safety in Textile Industry

(Regulations 2020)

ANSWER KEY WITH SCHEME OF EVALUATION

PART A –– (10 x 2 = 20 Marks)

1. • Operators must pay attention to safety, the machine is activated, hands can't get near
rotating parts when adjustments are required, you must first stop, after adjustment,
adjustment must confirm that the hand is out of the danger zone until after reboot.

• The operator can't wear gloves while working, the sleeves should not be too long, women
hair long operations have to tie up. (2 Marks)
2. • Mechanical irritant effects of the eyes,
• nose and skin,
• Obstructive lung disease (e.g. asthma, bronchitis),
• Other chronic effect (cough, dyspnoea, loss of lung function) (2 Marks)
3. • Fixed guards
• Fixed limited access guards
• Fixed adjustable access guard
• Interlock guards
• Automatic guards (2 Marks)
4. • Human eye
• Very noisy
• Catastrophic failure of HP steam pipes (photo) can cause personnel injury through hearing
damage
• Corrosion of pipe walls by acidic contaminants (2 Marks)
5. Depending on the substrate, a number of chemicals and application methods are employed to
achieve optimum bleaching effect, however, it is also imperative to remove and get rid of the
excess and leftover bleaching agent from the textile goods before subsequent wet processing.
(1 Marks)
• Establish a welcoming atmosphere and ensure courteous, reliable service from
all the staff of the department.
• Ensure a high standard of cleanliness and general upkeep in all areas for which
the department is responsible. (1 Marks)
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6. Textile industry consumes a large number of chemicals in the processing and manufacturing of
textiles, especially the wet processing of textiles. There are many accidents arising each year
from the exposure to chemicals used in textile mills. Thus it is important have a chemical
safety program implemented in a factory to prevent accidents and minimise the risks of
chemical hazards. There are numerous health and safety issues that are associated with
processes such as fiber synthesis, weaving, wet processing (desizing, scouring, bleaching,
dyeing and finishing) and laundry operations
(1 Marks)
• Eye irritation, Skin burns, respiratory problems from chemicals such a Hypochlorite,
Caustic soda, Ammonia, Acids, Solvents.
• Dusting (causing asthma), carcinogenic amines, allergens from dyes, reducing agents, acids
and alkalis. (1 Marks)
7. • Medical masks,
• Respirators,
• Gloves,
• Gowns and eye protectors,
• Face shields. (2 Marks)
8. Noise pollution impacts millions of people on a daily basis. The most common health problem
it causes is Noise Induced Hearing Loss (NIHL). Exposure to loud noise can also cause high
blood pressure, heart disease, sleep disturbances, and stress. These health problems can affect
all age groups, especially children. Many children who live near noisy airports or streets have
been found to suffer from stress and other problems, such as impairments in memory, attention
level, and reading skill. (2 Marks)

9. Strong and effective Environmental, Health and Safety (EHS) written policies are the
foundation for a successful and sustainable EHS program. The written EHS program is
generally comprised of several policies that establish the minimum requirements for your
company. (2 Marks)

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 10. Hazardous wastes can take the form of solids, liquids, sludges, or contained gases
• Improper hazardous-waste storage or disposal frequently contaminates surface water
and groundwater supplies as harmful water pollution and can also be a source of
dangerous land pollution.
• Ionising radiation from isotopes and X-ray machines
• Toxic wastes are poisons, even in very small or trace amounts. They may have acute
effects, causing death or violent illness, or they may have chronic effects, slowly
causing irreparable harm.
• Acid rain, also called acid precipitation or acid deposition, precipitation possessing a pH
of about 5.2 or below primarily produced from the emission of sulfur dioxide, and
nitrogen oxides, from human activities, mostly the combustion of fossil fuels.
(2 Marks)

PART B –– (5 x 16 = 80 Marks) / (5 x 12 = 60 Marks)

11. (a) This Industry has got highest numbers of functionaries houses right from Blow Room to Carding,
Spinning, Winding, Warping, Sizing, Weaving , Grey Checking, (*Desizing, Bleaching &
scouring, Dyeing, Finishing etc. known as wet Processing Zone where Chemicals are used). In
every house there is one or another, low or high hazardous aspect persists. Apart from these,
there are Polyester Manufacturing units, garment manufacturing units who also create hazards in
different circumstances depending on their manufacturing area. There are organised and
decentralised sectors and certain matters are common i.e. Noise, water, air pollution.
(8 Marks)
Safety Measures:
• Every industry should keep fire extinguishers as a safety measure.
• The machine must be switched off, with the plug removed, and must be stationary before
any cleaning or repair work is started.
• Never use a machine with damaged covers, cables, switches, etc. Report the damage at
once. Never try to repair it yourself.
• Proper adjustment of the eye guard should be checked before work starts. Safety glasses
should be used.
• Ensure placing lighting fixtures in a way that the light should fall on the working surface
from the left side or from the front. This promotes better visibility.
• Provide even floor surfaces with slip resistance so the operators do not slip.
• Free the work surface and floor off debris (pronounced as day-bree) and other waste to
avoid tripping and falling.
(8 Marks)

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 (b) Health hazards associated with various units are:
Production and ginning unit: Physical injuries in fingers, back, and eye, arm/shoulder, leg and
head injuries include direct costs (medical compensation) and indirect costs (down time and loss
of productivity). (4 Marks)
Yarn manufacturing unit: The manufacturing unit involves machineries having higher rotary
and travelling speeds. These speeds can cause noise pollution resulting in headache and
dizziness. Also, the workers and supervisors regularly engage themselves in processing and
spinning of cotton with these machines. Continuous inhalation of cotton dust result in lung
diseases and their symptoms involve tightening of chest, coughing and shortness of breath.
(4 Marks)
Synthetic fiber production unit: A large amounts of solvent vapors are released when the
filaments arise from the spinnerets by means of spinning. There is a high probability of cancer
and heart diseases in such cases which can further result in fatalities. (4 Marks)
Dyeing and printing: Dyeing is a physical affinity between the dye and the fiber of the fabric.
Flammable solvents are used in the processes, leading to fire hazards. Workers deal with
dangerous levels of chlorine on a daily basis and can cause lung edema. Usage of organic
solvents result in dermatitis (skin disease). (4 Marks)

12. (a) During the weaving process warps ends of the beam undergoes various tension and abrasion. To
withstand these tension and abrasion size paste is applied on warp ends such that those will
become hard and flexible. The ingredients of size pest are -Starch, antistatic, agent, antifungal
agent, smoothening and hardener agent. The viscosity of size pest is maintained as per
requirement of size take-up by warp sheet. The warp sheet is passed through size box and
squeezed in the squeezing rollers to remove excess pest on warp sheet. This warp sheet is then
dried on the range of drying cylinders and wound on the beam which is known as weavers beam.
This is the longest machine in the weaving department where the coatings are applied on the
cotton/blended yarn to make it ready for the next stage i.e. weaving. (6 Marks)

In this department, the hazardous areas are heat, dust generation and slippery floors. The main
causes of heat generations are
(i) Sow Box tempt (90 degree C)
(ii) Drying Cylinder
(iii) Improper ventilation etc. (5 Marks)
Dust generates mainly from Creel zone and that too depending on type of yarn.
Prevention from heat: Proper exhaust of steams by ducting system, Air circulation, machine
maintenance etc. Regular precautions and housekeeping will prevent slippery floors.
(5 Marks)

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 (b) Information, Instruction & Training for Employees
An employer who undertakes work that may expose any of his employees to substances hazardous
to health must provide that employee with information, instruction and training.
The information, instruction and training provided by the employer must be suitable and sufficient
for the employee to know the risks to health created by such exposure and the precautions which
should be taken. (6 Marks)
The employer should provide information to employees that includes at least the following:
• The nature and degree of risks to health which can arise from exposure, including any
factors that could increase risk (e.g. smoking)
• The control measures adopted, the reasons for these and how to use them properly
• Where appropriate the reasons for any personal protective equipment or clothing, and the
jobs where these are necessary
• Where appropriate exposure monitoring procedures, including arrangements for access to
results and notification if a maximum exposure limit is exceeded
• Where appropriate the role of health surveillance, who must attend for health surveillance
procedures, and arrangements for employee access to individual health records and the
collective results of health surveillance.
In addition, the employer must provide employees at the workplace concerned with information
on the results of any exposure monitoring at the workplace and the collective results of any
health surveillance undertaken there. (10 Marks)

13. (a) Chemicals Hazardous

Hazardous substances include:
• Substances used directly in work activities (e.g. adhesives,
solvents, cleaning agents);
• Substances generated during work activities (e.g. fumes from
soldering and welding);
• Naturally occurring substances (e.g. dust); and
• Biological agents such as bacteria and other micro-organisms. (5 Marks)
Examples of the effects of hazardous substances include:
• Skin irritation or dermatitis as a result of skin contact,
• Asthma as a result of developing an allergy to substances used at work,
• Losing consciousness as a result of being overcome by toxic fumes,
• Cancer, which may appear long after the exposure to the chemical that caused it, and
• Infection from bacteria and other micro-organisms (biological agents).
(5 Marks)
Safety Protocol on Factory Floor

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 • Record Keeping
• Protective Gear
• Training
• Environment
• Lifting and Carrying Heavy Objects (6 Marks)
(b) Bleach is a chemical that is diluted and used as a cleaning agent to kill bacteria, fungi and viruses.
(i) Handling bleach requires caution and care because it’s corrosive, which means it can irritate or
burn the skin and eyes, according to the Canadian Center for Occupational Health and Safety.
When mixed with certain chemicals or cleaners, bleach can create toxic gases that may cause lung
damage and even death. (2 Marks)
Employers should take precautions to help keep workers safe from bleach-related hazards,
CCOHS notes, including:
• Substitute a less-hazardous product when possible.
• Teach workers how to safely use and store bleach and what to do in case of an emergency.
• Follow the manufacturer’s instructions on the label or Safety Data Sheet.
• Never use bleach in a container that doesn’t have a legible label.
• Know how to properly dilute bleach. For example, always pour bleach into water – never
the other way around.
• Never mix bleach with other products, particularly other cleaners that contain ammonia.
• Work in a well-ventilated area. Use fans and keep doors and windows open.
• Wear personal protective equipment, including respiratory protection, gloves, goggles and
faceshields.
• Know that not all gloves can protect workers in every situation.
• Wear clothing, such as long-sleeved shirts, that covers your skin in case the bleach spills
or splashes.
• Keep bleach stored in a cool, dry place away from direct sunlight and heat. Close the lid
tightly after use.
• Keep away from metals.
• Refrain from eating, drinking or smoking while using bleach, and thoroughly wash your
hands with soap and water after use. (6 Marks)
(b) Treatment process sequence involved in ETP for Textile industry:
(ii) The untreated textile wastewater from different sections consists of high levels of TSS, dyes,
chemicals & auxiliaries, metal toxicants and BOD which must be treated before they are
discharged to environment. When wastewater passes through the ETP, pollutants are removed
and the quality of the water is improved to an acceptance/standard level, allowing for final
discharge to the environment without any risk.
It is the by-product of the effluent treatment process, produced in form of solid waste. In fact the

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 production of sludge is a good indicator as to out whether the ETP is running continuously or
not. Sludge can be generated at different stages of treatment, including screening, primary
settling, chemical precipitation, and the activated sludge or tricking filter stage, but most will
come from the physic-chemical stage of treatment. The sludge collected from different stages has
different characteristics and compositions. It may contain breakdown products of the original
factory waste or compounds created from the waste products and chemicals added to aid the
treatment process. For example, nitrogen or phosphorous compounds from chemicals that are
added to the activated sludge process or sulphur compounds resulting from the large quantities of
sodium sulphate used in dyeing. Despite the differences in the nature of the sludge from each
process stage, all the sludge is usually combined and handled together. (3 Marks)
1. Primary Treatment:
• Screening
• Sedimentation
• Equalization
• Neutralisation
• Chemical coagulation and Mechanical flocculation
2. Secondary Treatment:
• Aerated lagoons
• Trickling filters
• Activated sludge process
• Oxidation ditch and pond
• Anaerobic digestion
3. Tertiary Treatment:
• Electrolytic precipitation & Foam fractionation
• Electro chemical processes
• Ion exchange method
• Photo catalytic degradation
• Adsorption
• Thermal evaporation
• Membrane filtration (5 Marks)

14. (a) The textile industry of different units involved with dyeing, weaving, printing, spinning, finishing
and a number of other processes that are required to change over fiber into a completed texture or
garment.
The major health and safety problems in textile industries are,
• Exposure to chemical,
• Exposure to cotton dust,

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 • Exposure to noise,
• Exposure to UV rays,
• Biological hazard,
• Psychosocial hazard and Ergonomic issues. (8 Marks)
Cotton dust inhalation (byssinosis):
The workers engaged in the processing and spinning of cotton are exposed to significant amounts
of cotton dust. They are also exposed to particles of pesticides and soil. Exposure to cotton dust
and other particles leads to respiratory disorders among the textile workers. The fatal disease of
byssinosis, commonly known as brown lung, is caused among people working in the textile
industry on account of excessive exposure to cotton dust. The symptoms of this disease include
tightening of the chest, coughing, wheezing and shortness of breath. (8 Marks)
(b) High noise level causes psychological effects and physical damage, including irritability, loss of
concentration, anxiety and increased pulse rate. A one minute exposure to a sound level over
100dBA can cause permanent hearing loss. The studies show that a large number of textile
workers, especially weavers, suffer from occupational hearing loss. The machinery
manufacturers made considerable efforts in keeping the noise emission as low as possible while
improving the speed of their machines, but the measures are not adequate to protect the textile
workers from occupational hearing loss. (4 Marks)
First think about how to remove the source of noise altogether – for example, housing a noisy
machine where it cannot be heard by workers. If that is not possible, investigate:
• using quieter equipment or a different, quieter process
• engineering/technical controls to reduce, at source, the noise produced by a machine or
process
• using screens, barriers, enclosures and absorbent materials to reduce the noise on its path
to the people exposed
• designing and laying out the workplace to create quiet workstations
• improved working techniques to reduce noise levels
• limiting the time people spend in noisy areas.
Measures that give ongoing or medium- and long-term benefits, and would be expected to be part
of your noise-control programme, are:
• a low-noise purchasing policy for machinery and equipment
• proper and regular maintenance of machinery and equipment that takes account of noise.
(12 Marks)

15. (a) Section 21 and section 17 in Factories Act 1948.

Section 17: Lighting
• In every part of a factory where workers are working of passing there shall be provided

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 and maintained sufficient and suitable lighting, natural or artificial, or both.
• In every factory all glazed windows and skylights used for the lighting of the workrooms
shall be kept clean on both the inner and outer surfaces and, so far as compliance with the
provisions of any rules made under sub-section (3) of section 13 will allow, free from
obstruction.
• In every factory effective provision shall, so far as is practicable, be made for the
prevention of—
(a) glare, either directly from a source of light or by reflection from a smooth or polished surface:
(b) the formation of shadows to such an extent as to cause eye-strain or the risk of accident to any
worker.
• The State Government may prescribe standards of sufficient and suitable lighting for
factories or for any class or description of factories or for any manufacturing process.
(8 Marks)
Section 21: Fencing of machinery
• every moving part of a prime mover and every flywheel connected to a prime mover,
whether the prime mover or flywheel is in the engine house or not;
• the headrace and tailrace of every water-wheel and water turbine:
• any part of a stock-bar which projects beyond the head stock of a lathe; and
• unless they are in such position or of such construction as to be safe to every person
employed in the factory as they would be if they were securely fenced, the following,
namely:—
• every part of an electric generator, a motor or rotary converter;
• every part of transmission machinery; and
• every dangerous part of any other machinery;
shall be securely fenced by safeguards of substantial construction which shall be constantly
maintained and kept in position] while the parts of machinery the y are fencing are in motion or
in use:
Provided that for the purpose of determining whether any part of machinery is in such position or
is of such construction as to be safe as aforesaid, account shall not be taken of any occasion
when—
• it is necessary to make an examination of any part of the machinery aforesaid while it is in
motion or, a s a result of such examination, to carry out lubrication or other adjusting
operation while the machinery is in motion, being an examination or operation which it is
necessary to be carried out
while that part of the machinery is in motion, or
• in the case of any part of a transmission machinery used in such process as may be
prescribed (being a process of a continuous nature the carrying on of which shall be, or is

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 likely to be, substantially interfered with by the stoppage of that part of the machinery), it
is necessary to make an examination of such part of the machinery while it is in motion or,
as a result of such examination, to carry out any mounting or shipping of belts or
lubrication or other adjusting operation while the machinery is in motion, and such
examination or operation is made or carried out in accordance with the provisions of sub-
section (1) of section 22.]
• The State Government may by rules prescribe such further precautions as it may consider
necessary in respect of any particular machinery or part thereof, or exempt, subject to such
condition as may be prescribed, for securing the safety of the workers, any particular
machinery or part thereof from the provisions of this section.
(8 Marks)
(b) The issues that should be considered by Industry when developing a system for the safe collection
and disposal of its waste:
• Protecting human health and the environment: The purpose of the Guide is to promote
sound waste management that protects human health and the environment. It takes a multi-
media approach that emphasizes surface-water, ground-water, and air protection, and
presents a comprehensive framework of technologies and practices that make up an
effective waste management system. (4 Marks)
• Tailoring management practices to risks: There is enormous diversity in the type and
nature of industrial waste and the environmental settings in which it is managed. The
Guide provides conservative management recommendations and simple-to-use modeling
tools to tailor management practices to waste- and location-specific risks. It also identifies
in-depth analytic tools to conduct more comprehensive site-specific analyses. (4 Marks)
• Affirming state and tribal leadership: States, tribes, and some local governments have
primary responsibility for adopting and implementing programs to ensure proper
management of industrial waste. This Guide can help states, tribes, and local governments
in carrying out those programs. Individual states or tribes might have more stringent or
extensive regulatory requirements based on local or regional conditions or policy
considerations. The Guide complements, but does not supersede, those regulatory
programs; it can help you make decisions on meeting applicable regulatory requirements
and filling potential gaps. Facility managers and the public should consult with the
appropriate regulatory agency throughout the process to understand regulatory
requirements and how to use this Guide. (4 Marks)
• Fostering partnerships: The public, facility managers, state and local governments, and
tribes share a common interest in preserving quality neighborhoods, protecting the
environment and public health, and enhancing the economic well-being of the community.
The Guide can provide a common technical framework to facilitate discussion and help
stakeholders work together to achieve meaningful environmental results. (4 Marks)

Prepared by Verified by Approved by

Module Coordinator H.O.D

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