17ME662 - INDUSTRIAL SAFETY 41

MODULE-3
MECHANICAL SAFETY

PERSONAL PROTECTIVE EQUIPMENT (PPE):

 The first step in accident prevention programme is elimination of various hazards while designing
the process.
 If this is not possible, next step is to control the physical, mechanical and chemical hazards in the
work environment by suitable engineering design.
 When this is also not possible and also even with ideal conditions are achieved hazardous conditions
are likely to arise due to sudden equipment failure, malfunctioning of systems, inefficient operation
and maintenance of equipment, non-availability of experienced personnel etc.
 Under such conditions the last and third layer of defence is the usage of Personal protective
equipment.
 Even though PPE cannot stop an accident from taking place it will help in preventing and minimising
the injury.
 Personal protective equipment (PPE) refers to protective clothing, helmets, goggles, or other
garments or equipment designed to protect the wearer's body from injury or infection. 

Factors affecting selection and usage of PPE:

 Type of hazard
 Degree of protection required
 Managements philosophy and commitment towards safety
 Employees behaviour towards safety
 Ease and comfort with which they can be used
 Freedom of movement with the equipment worn
 Availability and accepted standards for material of construction and their performance
 The type of training required
 Maintenance of these equipment
 Kind of PPE – Respiratory or Non Respiratory

Non respiratory PPEs are further divided into following groups

 Eye Protection
 Face Protection (at times Eye and face protections are combined)
 Ear Protection
 Head protection
 Torso and body protection
 Hand (Palm, fingers etc) and arms protection
 Foot and leg protection
 General protection

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PPEs – Selection based on hazardous conditions

Function
Protection against injuries by
physical contact ( outer surface of
the body
Protection against injury with
chemicals electrical, burning or
freezing
Protection against injury with
absorption/non mechanical
penetration (outer surface of the
body
Protection against inhalation and
ingestion of injurious substances
Protection against injurious
forces and circumstances
Hazardous agencies/condition Type of PPE to be selected
Heavy, rough, sharp, abrasive Helmets, safety shoe, goggles,
and moving objects and materials leather gloves, aprons and skin
guards
Corrosive, irritating, hot or cold Rubber/Asbestos gloves, suit,
substances like acid, alkalies, hot apron, leggings, shoes,
metals and charged equipment conductive and on conductive
shoes, cup type of goggles, face
shields
Nuclear or other radiant energy, Special protective coverings,
high frequency light and heat welders goggles and masks, sun
radiations, radio frequency glasses, ear plugs, ear muffs,
energy and temperature extremes protective clothing
Toxic, irritant, harmful gases, Masks and Respirators of all
vapours, dust, fumes, irradiated kinds
particles
Air or water under pressure/ Divers suit, trousers, bandages,
vacuum elastic stockings

PPEs - Selection based on parts of the body to be protected

Part of the body PPE to be used Protection against

Fibre helmet Fall of objects, hitting against falling objects

Head Electrical resistance Helmet Shock when working on electrical lines

Welders leather cap
Plastic face shield
Face Asbestos hood
Welding helmet and shield
Panorama goggles with plastic
visor
Leather mask goggles
Spectacles type goggles with plain
Eye
shatter proof lens
Panorama goggles with green
plastic visor
Gas welding goggles
Falling of molten slag during overhead welding
and splashing of liquid
Liquid chemical splashing, striking of dust
particles
Radiation of heat in furnace work
Welding fumes, sparks, ultra violet rays
(during arc welding)
Oil and paint splashes, dust and chip entries
Foreign bodies entering the eyes and against
smoke
Foreign bodies entering the eye while working
on machines
Reflected arc during arc welding
Gas welding and gas cutting

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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Acid and alkali proof rubber Splashes of corrosive substances like acid and
goggles alkalies, chemical substances
Ear plugs High noise level above 95 dbs

Ear Ear Muffs High noise levels

Both plug and muffs Very high noise levels above 110 dbs
Against dust and powder particles (entering
Dust proof respirator
lungs through nose.)
Nose Heavy fumes mask Against acid fumes, vapours and gases (0.1 %)

Canister Mask Against acid fumes, vapours and gases (0.2 %)

Leather apron Falling of hot chips, slags etc

Asbestos apron Heat radiation

Body PVC apron Splashing of chemicals

Lead apron X-rays and gamma rays

Safety belts Falling of person from a height

Leather gloves Cuts due to handling

Asbestos gloves Heat radiation

Rubber gloves Burns due to acid and alkalies

Electrical resistance gloves Electrical shock

Hand
Canvas gloves Contact with oil, grease and other dirt

Lead gloves X rays and gamma rays

Protective barrier creams Skin diseases, sun burns

Hand sleeves Falling of hot slags during overhead welding

Leg guard Welding sparks

Striking against objects, struck by moving
Leather safety shoes objects, fall of objects, stepping on sharp
Legs objects, slip, hot surfaces
Heat radiation, stepping on hot and sharp
Asbestos safety shoes
objects, fall of objects moving objects
Gum boots Mud, dirty floor, chemical liquids

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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MACHINE SHOP SAFETY RULES:

1. State of Mind. Do not operate power tools when you are ill, taking strong medications, fatigued or
consuming alcoholic drinks. Do not smoke while working with tools.
2. Wear proper clothing for the type of work being done. Do not wear loose-fitting clothes that can
get caught in moving parts. Do not roll up long sleeves. Do not wear highly flammable clothes. Do
not wear sandals, open-toed or canvas shoes. Wearing safety shoes is preferable for protection of
feet and toes.
3. Remove all jewellery, including rings, necklaces, bracelets and watches that could get caught in
tooling before starting work.
4. Protect your eyes, face, head, and scalp. Safety Glasses must be worn at all times in the shop. As a
minimum, wear industrial-quality safety glasses with side shields. Some operations may require
additional eye protection or other personal protective equipment. Add a face shield or wear impact
resistant goggles if flying particles are expected during the machining process. For welding wear eye
and face protection appropriate for the kind of work being conducted.
5. Hair. Pull back long hair in a band and tuck it under your shirt collar or a cap to keep it from getting
caught in tools. Long beards must also be contained.
6. Avoid distractions. Keep your mind on your work. Talking or listening to the radio/ mobiles/ loud
music while running machinery can lead to accidents. Stop working and turn off the power tool you
are working with if distracted by something or someone. Never look away from your work when
operating a power tool.
7. Keep the work area clean. Keep the floor free of scraps and oil. Cluttered work areas invite
accidents. Keeping workshop and storage spaces clean and dry can help prevent many accidents.
Sparks can ignite scraps, sawdust and solvents. Water can conduct electricity. Do not stand in
water, on damp floors or in the rain when working with electrical tools. Keep hands and tools dry.
8. Keep all passages free. Exits and access to emergency equipment must be kept clear at all times.
9. Use the correct tools for the job. Do not use a tool or attachment for something it was not designed
to do. Select the correct bit, cutter or grinding wheel for the material with which you are working.
This saves time and improves the quality of work and reduces the risk of mishap.
10. Metal work. When working with metal, secure the metal materials with clamps or in a machinist's
vise to keep it from moving.
11. Work only at operating speed. Do not use a power tool before it has reached operating speed or
while it is coming to a stop. Never force a tool by applying too much pressure. Let each tool work
at its own speed without forcing it. Once a power tool has been turned off, allow it to coast to a stop.
Never force an object into moving parts to stop a machine.
12. Keep tools clean and in good condition. Always clean up power tools before putting them away.
Avoid using tools that are faulty. Use power tools only for their intended functions.
13. Repairing and Cleaning Power Tools. Always turn off and unplug a power tool before (1)
adjusting, oiling, cleaning or repairing it; (2) attaching an accessory; or (3) changing bits, blades or
grinding wheels. Unplug or lockout tools when not in use. Do not leave tools, hardware and other
materials out when not in use.
14. Compressed air: Employees shall not use compressed air for cleaning themselves or their clothing.
The operator shall not direct compressed air at nearby employees. Compressed air used for cleaning
work areas, such as work benches, table saws, and drill presses, shall not exceed 30 psi at the outlet,
and shall be permitted only with effective chip guarding or personal protective equipment to protect
the operator and other employees from flying debris.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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15. Keep guards in place. Safety guards cannot protect you if they are not in place and in proper
working order.
16. Do not leave a machine running unattended. Make sure all moving parts have come to a complete
stop before you leave the work area or before you make minor adjustments. In many cases
adjustments and repairs require locking and blocking of energy, including stored energy, before
proceeding.
17. Know the machine. Before using any machine and tool, read the operator's manual to learn the
applications, limitations, and potential of each power tool. Never use a tool unless trained to do so.
Inspect it before each use and replace or repair if parts are worn or damaged or power cord tangled.
The cord should be flexible, but not easy to knot. Clean the cord regularly and inspect the grounding
connections
18. Know the switch location(s). Remember where the switch is located so you can turn off the
machine quickly.
19. Use safe blades. Never use cracked or kinked saw blades. Keep saw blades sharp and properly set.
20. Ventilation. Welding, cutting or brazing should not be carried out in the shop. Move equipment to
the welding area where it is properly ventilated table located under the awning in the courtyard.
Avoid operating power tools in locations where sparks could ignite flammable vapours. Keep the
shop well ventilated and flammable materials properly stored.
21. Combustible materials like Rags. Used rags, especially oily and greasy ones, should be kept in a
covered, marked container. Rags should be a safe distance from the welder and other sources of
ignition.
22. Hazardous materials. Take extra care when working with hazardous materials. Due to the extreme
fire hazard, machining or grinding of magnesium is prohibited in any Machine Shop. Handle
fibreglass with care. Its particles can irritate the skin, eyes and respiratory system. When soldering,
remember that lead solder is toxic. The work area should be ventilated or you should wear the
appropriate respirator if you have been properly trained to do so.
23. Storage. Develop a system of racks, bins and tool panels to make it easy to find the right tool or
materials quickly. Don't store tools, supplies or spare parts in the aisle or on the floor where they
become tripping hazards. Keep other flammable materials away from heaters and welding areas to
prevent fire. Grease, oil, paint and solvents should be stored in a closed metal container, preferably
in metal cabinets. Gasoline or other fuels should never be stored inside the shop. Supplies and
equipment should be stored in an area designed specifically for them.

CAUSES OF ACCIDENTS WHILE WORKING WITH MACHINERY:

 Loose clothing, hair, jewellery being caught in moving parts.
 Materials ejected from the machine when it is operational.
 Inadvertent starting of the machine.
 Slipping and falling into an unguarded nip.
 Contact with sharp edges, e.g., cutting blade.
 Making adjustments while the machine is operational.
 Unauthorized operation of machines.
 Lack of preventive maintenance.

HAZARDS:

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 Rotating machine parts give rise to nip points. Examples are

o Rotating gears
o Belt and its pulley
o Chain and sprocket
o Between grinding wheel and tool rest
o Between rotating and fixed parts
 Rotating parts operating alone • Shafts • Couplings
 Reciprocating and sliding motions
 Any machine part which can cause injury, must be guarded.
 Machine guards help to eliminate personnel hazards created by points of operation, ingoing nip
points, rotating parts and flying chip.

COMMONLY USED MACHINE GUARDS ARE:

1. Fixed guard- is kept in place permanently by fasteners that can only be released by the use of a tool.
2. Interlocked guard- shuts off or disengages power to the machine and prevents it from starting when
the guard is removed/opened.
3. Adjustable guard- provides a barrier which can be adjusted to suit the varying sizes of the input
stock.
4. Self-adjusting guard- provides a barrier which moves according to the size of the stock entering the
danger area
5. Two hand control- concurrent use of both hands is required to operate the machine, preventing the
operator from reaching the danger area.
6. Pull back- the device is attached to the wrist of the operator which pulls the operator’s hands away
from the point of operation or other hazardous areas when the machine operates

SAFETY RULES FOR LATHE:

 Safety glasses or goggles must be worn. A face shield and/or dust mask is also required if the
operation is dusty.
 A person using the lathe must have prior instruction. Inexperienced must be supervised.
 Operators should carefully inspect all parts of a lathe for defects before starting a job.
 Clamp your work firmly. Use the correct type and size of chuck for the job.
 Persons using the lathe must check that the stock does not have any splits, cracks or knots. The stock
must be constantly checked to ensure that it will not break during lathing.
 After adjusting the chuck, remove the chuck wrench immediately. Be sure all guards are in place
around the rotating heads of the lathe before attempting to operate the machine.
 Use sharp tools, properly adjusted for height and position.
 Turn the faceplate or chuck by hand to make sure there is no binding and the work will not strike any
part of the lathe.
 Stop the machine and unplug before making any adjustments or measurements.
 If metal or plastic shavings build up on the tool, stop the lathe and remove them with pliers, never
with bare hands.
 Be careful not to run the cutting tool into the chuck. Make sure there will be ample clearance on the
work before starting to cut.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 Files must not be used on the lathe unless they are fitted with handles. The use of hand-held strips of
abrasive cloth to polish the work is prohibited.
 Always feed the stock into the rotation of the cutter.

SAFETY RULES FOR DRILLING MACHINE:

Drilling machines are one of the most dangerous hand operated pieces of equipment in the shop area.

 Safety goggles or glasses with side shields must be worn to prevent the eyes from being struck by
flying chips. It may also be necessary to wear a face shield. Eye protection must be worn under the
face shield.
 To guard the operator from contacting the spindle, a plastic or mesh shield can be used. When
necessary, a telescoping guard that covers the end of the tool can be used.
 Using dull drills is a frequent cause of bit breakage. A thin drill may also break and cause injury.
Ensure that the drill bit used is the proper on for the job. The drill's head and arm, as well as the work
must be securely clamped.
 Catching, hair, skin, clothing or gloves in the revolving parts is a common hazard when working
with a drill press. Remove all jewellery; do not wear gloves or loose clothing when operating this
piece of equipment.
 Remove all chuck keys and wrenches before operating
 Sweeping chips or trying to remove long spiral chips by hand must be avoided. Use a stick for this
purpose.
 Ensure that the key or the drift is not left in the chuck. If the drill press is turned on, the key or chuck
will become like a missile with great velocity.
 Failing to replace the guard over the speed change pulley or gears can cause entanglement in the
gears. Be sure that prior to starting the equipment that all guards are in place.
 The table must be secure and set to desired height and angle prior to commencing work. A loose
table can cause the bit to jam, sending the work piece into high-speed rotation.
 The drill bit must not be allowed to cut into the table. A spacer board can be used if necessary for
this purpose.
 The work area must be kept orderly. Tripping over debris into the rotating parts from on untidy work
area could happen. The drill press will grab any loose materials and tighten them around the
revolving parts.
 The work should be firmly held. If the work is too small to hold safely by hand, it should be held by
a vice or held between tow pieces of wood or metal (depending on the material being drilled)
 When deep holes are drilled, frequently remove the drill and clean out the chips. If the chips are
allowed to collect, they may jam up the bit, freeze in the hole and then break. Furthermore, a frozen
tool may cause unclamped or insecurely clamped work to spin and injure the operator. The bit does
not need to be raised clear of the hole in order to do this. It is actually better that you don't as you run
the risk of having the work move while the bit is out.
 Power must be disconnected and locked out prior to making any changes or adjustment son the drill
press.
 When turning off the power to leave the equipment, always ensure that the drill has come to a
complete stop before leaving. The chuck should never be stopped by hand, but allowed to stop on its
own.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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SAFETY RULES FOR TABLE SAW:

The circular blade of a table saw moves at very high speed. Employ the following precautions when using
this tool:

 Use the saw guard at all times. No operation shall be done with the guards removed.
 Never reach over the saw blade to remove scraps, or to provide support to the work piece. If you are
off- balance, you could fall into the saw
 Always stand to the side of the saw, and never directly in line with the blade. If the saw catches the
material you are working on, the saw will throw it in line with the blade.
 To prevent kickback never use a dull blade and never cut without the guide and splitter guard in
place. In addition, don't drop wood on top of the saw blade.
 When cutting, NEVER PULL the work piece through the saw. Start and finish the cut from the front
of the saw.
 Never feed the work piece from the back of the saw.
 Use a push stick according to the manufacturer's guidelines

SAFETY RULES FOR BAND SAW:

 Do not wear any clothing or jewellery that can catch on parts of the saw blade. It is good practice to
remove all jewellery prior to using the saw. Safety glasses or goggles must be worn. If a face shield
is required, safety glasses or goggles should be worn under it.
 When hand feeding, the operator's hands will be close to the blade, therefore a push stick must be
used.
 The band saw wheel and all working parts of the blade must be enclosed to prevent contact points.
 Ensure that the blade is in properly installed. The teeth of the blade should point downwards as it
goes through the table.
 The saw will have a tension guide, which must correspond with the width of the blade.
 While the blade cannot be completely covered, the adjustable blade guard should be installed as
close as possible to the work piece. This will prevent contact with the front and sides of the blade..
 Check the blade to ensure that it tracks properly.
 The blade must reach full speed before cutting. Feed the stock at a moderate speed. Do not force the
cut.
 Make several relief cuts before attempting a sharp curve cut. This prevents the saw blade from
binding and possibly breaking the blade or causing it to jump of the wheel guides.
 Plan cuts to avoid having to back out of long, curving cuts.
 Before backing out of a cut, shut off the saw and allow it to come to a complete stop. A band saw
may coast for a long time.
 The operator or another person should never stand on the right hand side of the table. If a blade
breaks it will fly off to the right. Broken blades should be changed only when the power has been
shut off and the saw has come to a complete stop. The equipment should be locked out when a blade
is being changed or other maintenance work is performed.
 Do not twist or apply pressure to the blade.
 Clear material away from the table only with a stick. Never remove material from the table with your
hands.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 A clicking sound indicates that the blade could be cracked. Shut off the power and lock out the
equipment prior to changing.

SAFETY RULES FOR GRINDING MACHINE:

 Stand to one side of the wheel when turning on the power.
 Before commencing grinding, allow the grinding wheel to run at operating speed for at least one
minute.
 When commencing a grinding operation, bring the object into contact with the grinding wheel slowly
and smoothly avoiding impact or bumping motions.
 Dress the wheel on the face only. Dressing the sides may cause it to become too thin for safe use.
 Use the face of the wheel when grinding. Do not press too hard on the wheel.
 Vibrating wheels should not be used. They must be dressed or replaced or the bearings of the shaft
replaced if they are worn.
 Do not touch the ground portion of the work piece until you are sure that it is cool.
 Shut off the power and do not leave until the wheel has come to a complete stop.
 Clean the work area when finished using the grinder.
 Disconnect angle grinders from the power source when making repairs or changing discs.
 Pedestal grinders-turn off the power switch and lockout the electrical switch before doing any
repairs.
Other safety precaution includes:

 Always wear eye protection. (Safety glasses under a face shield).

 Remove ties, rings, watches and other jewellery. Long hair should be tied back and loose sleeves
should not be worn. Do not wear gloves when operating a buffing, grinding or polishing wheel.
 Make sure the wheel guards are in place and properly adjusted and tightened.
 Don't adjust a grinder when it is running.
 Blotter and wheel flanges used to mount the grinding wheels onto the shaft of the grinder must be in
place.
 Wheels should be inspected prior to turning on the power. Wheels with cracks or chips or that are
badly rutted should not be used. They may require dressing or permanent removal from service.
 Check that the speed rating of the grinding wheel is equal to or exceeds the speed rating of the
grinder. The maximum approved speed stamped on the wheel blotter should be checked against the
arbour speed of the machine to ensure that the safe peripheral speed is not exceeded.

SAFETY RULES FOR WELDING:

In case of welding, Injury can result from fire, explosions, electric shock, or harmful agents. Both the
general and specific safety precautions listed below must be strictly observed by workers who weld or cut
metals.
 Ideally, welding should be performed in a separate, well-ventilated room with a fire-resistant
flooring material. If welding is to be conducted in other areas, the area must be free of flammable
materials. Do not weld in a building with wooden floors, unless the floors are protected from hot
metal by means of fire resistant fabric, sand, or other fireproof material. Remove all flammable
material, such as cotton, oil, gasoline, etc., from the vicinity of welding

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 Non-flammable clothing, eye, and hand protection must be worn to protect from molten metal and
hot sparks.
 Do not leave hot rejected electrode stubs, steel scrap, or tools on the floor or around the welding
equipment. Accidents and/or fires may occur.
 Keep a suitable fire extinguisher nearby at all times. Ensure the fire extinguisher is in operable
condition.
 Mark all hot metal after welding operations are completed.
The following Hazards can occur during Arc Welding.

 Radiation from the arc, in the form of Ultraviolet and Infrared rays
 Flying sparks and globules of molten metal
 Electric shock
 Metal fumes
 Burns

Safety precaution to be taken during welding:

Radiation:

 Cover the face, hands, arms and other skin surfaces to prevent exposure to the radiation
 Arc welding helmet or face shield with approved lens should be used to protect eyes
 Long exposure of arc is known to cause permanent damage to the retina of the eye

Electric shock

 Use of insulated electrode holders and wearing leathers and gloves

 Welding should not be performed in wet or damp areas
 Proper grounding of equipment’s should be ensured to avoid electric shocks

Flying sparks and molten metal

 Wear suitable clothing and cuff less trousers

 Wear proper foot protection like high top boots with steel toes
 Remove any flammable materials near the vicinity of the welding

Metal fumes

 Welding fumes produce harmful vapours which causes irritation to eyes, nose, throat and lungs
 Wear proper masks which will cover entire face and filter the welding fumes
 Proper ventilation should be provided such that the fumes escape though proper channel

Burns

 Never handle welded metals with bare hands, use tongs instead to avoid burning of hands
 Wear flame resistant or flame retardant clothing and hair protected all the time

SAFETY RULES FOR FORGING:

 Always avoid the use of damaged hammers. The handle of the hammer should always be tightly
fitted in the head of the hammer
 Never try to strike a hardened surface with a hardened tool.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 No person should stand in line with the flying objects.

 Always use the proper tongs tool to grip and lift objects according to the type of work.
 The anvil should always be clean and free from moisture and grease while in use.
 Always wear proper clothes such as apron, foot-wears and goggles.
 Always put out the fire in the forge before leaving the forging shop.
 Always keep the working space clean and tidy.
 Proper safety guards should be provided on all revolving parts.
 Head of the chisel should be free from burrs and should never be allowed to spread.

SAFETY RULES FOR PRESSING:

Mechanical presses have always been considered a high-risk machine. The hazards involved are
1. Being Caught in Between Objects. Power presses are used to punch, bend, or shear a metal work
piece using a tooling or die attached to the slide and the bed. During a point-of-operation, severe
crushing, amputation and even death may occur should “a caught in between” hazard occur.
2. Press brakes are used to bend metal sheets. While the actual operation of the press brake does not
require the operator’s hands to be placed at the point-of-operation, the close proximity to the closing
dies still poses a significant risk. “Caught in between” hazards happen when the stock “whips”’ or
bends up, creating a pinch-point hazard between it and the front face of the slide.
3. Cut by Sharp Edges. Attention should be paid to the loading and unloading of materials and work
pieces as the sharp edges of a sheet metal can cause cuts.
4. Struck by Falling Objects. Lifting of the die is needed during power press setup. During this time,
due care must be taken to prevent the die from dropping.
5. Struck by Flying Objects. During punching operations, metal chips from either material or die may
break and fly out, especially if the power press is not aligned with the die. These flying metal chips
can potentially hit the operator and other workers in the area and cause serious injury.
6. Dragged Towards Danger Zone. This is particularly hazardous for automatic feeding set-ups.
Operators should take special care when using the machine.
7. Noise-induced Deafness. Power presses are inherently noisy and noise levels can be as high as
95~115dB(A). The sources of noise are likely to be pneumatic and mechanical vibrations. Proper ear
protection PPE to be used under such conditions.
8. Energy Source Failure. Electrical, mechanical and pneumatic machine components might fail. For
example, the failure of a single-stroke linkage (mechanical), the failure of control relay (electrical)
and the loss of air pressure (pneumatic) might pose hazards that are likely to cause accidents.

SAFE HANDLING OF MATERIALS - COMPRESSED GAS

CYLINDERS:
 Compressed gases like acetylene, oxygen, Carbon dioxide, LPG, testing gases etc are used in
factories. It is quite safe to store and use if proper precautions are taken and all safety requirements
are followed.
 It is advisable to store minimum quantity to minimise hazard.
 If the no. of flammable gas cylinders equals or exceeds 15 or non-flammable gas cylinders equals or
exceeds 50, permission for storage needs to be obtained from Controller of Explosives, Nagpur.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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Safety precautions for storing compressed gas cylinders:

 Cylinders to be stored in a well ventilated area/room
 Gas cylinders kept on open area to be protected from Sun, rain and corrosive atmosphere
 Storage area to be declared a non-smoking area
 If it is stored in a closed room, the switches should be located outside the room and electrical fittings
used shall be flame proof.
 Oxygen and acetylene should be stored at least one metre apart
 Acetylene should be stored upright position as it is in dissolved form
 Cylinders to be kept away from heat sources.
 Cylinders, their valves, fittings, regulators, hoses to be periodically checked for its functioning and
should be kept free from oil and greasy substances.
 Cylinders should not be dropped
 It is illegal to tamper with numbers and markings on the cylinders
 Valves of the empty cylinders should be kept closed and protected using caps
 Gas cylinders should never be used as rollers or support whether full or empty
 While transporting use hand carts properly secured with chain to avoid fall
 If a cylinder has to be transported over a short distance it has to be rolled over its bottom edge and
should not be dragged.
 A fibre rope sling may be used for lifting a cylinder. Metallic slings should not be used for lifting.
 Full and empty cylinders should be marked properly and stored separately.
 When the cylinder is placed upright position, use chain to secure from falling.
 Valves are the weakest part of the cylinder and hence proper care to be taken to protect them.
 Visually inspect stored cylinders on a routine basis, or at least weekly, for any indication of leakage
or problems.

SAFE HANDLING OF MATERIALS- CORROSIVE MATERIALS:

 Acids and alkalis are corrosive substances and their contact with human body causes severe burn and
irritation.

Storage:
 Corrosive materials may be stored in plastic carboys in small quantities.
 Metallic containers or rubber lined tanks may be used for larger quantities
 The storage area to be with acid resistant tiles with proper drainage arrangement with suitable slope.
 Provide water tap and eye wash fountain near the handling and storage area.
 Store minimum quantity required.
 A hazard warning board should be prominently displayed in the storage area.
 Containers should have label containing information about the content.

Safety precautions – corrosive materials:

 Only trained personnel who is aware of hazards and hazard mitigation should only use and handle it.
They should be given specific safety instruction and strict personal supervision.

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 All PPEs such as goggles, suits, gloves, gum boots aprons as the case may be must be used.
 To dilute the acid, acid to be slowly added to water while stirring. Never add water to acid and alkali.
 In case of accidental contact with corrosive substance, the affected area to be thoroughly washed
with water for 10 to 15 minutes.
 In case of accidental splash of corrosive substance to the eyes, they should be thoroughly washed
with water for 10-15 minutes with eyes kept wide open. Washing is very important with plenty of
water before rushing the injured to the medical help.
 In case of corrosive material splashing on the floor, it should be washed with water.
 Compressed air should not be used in loading, unloading and cleaning/splashing the corrosive
substance.

SAFE HANDLING AND STORAGE – HYDROCARBONS:

 Hydrocarbons (Petroleum products) can be classified into three catagories
o Class A - Flash point less than 23 Deg C
o Class B - Flash point more than 23 Deg C but less than 65 Deg C
o Class C - Flash point more than 65 Deg C but less than 95 Deg C
 Flash point is the temperature at which the liquid gives off sufficient vapour to form a flammable
mixture which would ignite if ignition source is introduced.
 Safety aspects with regard to storage/handling of hydrocarbons depends upon the Class of
Hydrocarbon

Safe handling and Storage – Hydrocarbons (Class A):

Examples for Class A – Several Thinners, petrol, xylene etc.
Safety Precautions:

 More than 30 litres of Class A hydrocarbon should not be stored in the shop floor
 Carboys/barrels in which they are stored should have air tight lids and should not be filled full.
About 10 % of container volume should be left unfilled.
 Storages exceeding 300 litres in carboys or bulk needs permission and licence as per Petroleum
Rules.
 The storage area to be non-smoking area, well ventilated, segregated and all electrical fittings to be
flameproof.
 Wherever these materials are handled and stored care should be taken to ensure no ignition source.
 DCP or CO2 extinguishers should be available in the area of use/storage/handling
 Accumulation of combustible material such as cotton waste, rags, wood etc in the vicinity of storage
should not be allowed.
 If stored in bulk in tanks, tank should be segregated by fencing, earthed at two places, should have
vent and inlet pipe going right down the bottom of the tank. The vent should have a bend so that rain
water does not enter the tank. Dip stick should be non-sparking metal.

Safe handling and Storage – Hydrocarbons ( Class B & C):

Examples of Class B & C – Diesel, Kerosene, LDO etc

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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Safety Precautions:

 Storage of more than 2500 litres of Class B and 45,000 litres of Class C petroleum product requires a
licence under Petroleum Act.
 The storage are to be segregated from the main work are and should be non-smoking zone.
 Maximum of one day consumption may be stored in the shop floor area or main work area.
 DCP, CO2 or foam fire extinguishers should be available in the area of usage/storage/handling.
 If stored in bulk in tanks, the tanks to be segregated by fencing, earthing at minimum two places,
combustible material like wood, cotton waste, rags, to be removed, dyke wall around the tank to
contain spillages are mandated. The tank must have proper vent and level indicator (Dip stick, gauge
glass or electronic level indicator). It is advisable not to fill the tank up to maximum but leave about
5% of its volume unfilled. The bulk storage to be monitored regularly for safety.
 Barrels/carboys containing class B and C hydrocarbons should be stored in specified area only.

Disposal of Empty containers containing hydrocarbons:

 The user should keep the empty containers at the specified area in the work place where any kind of
ignition source is not present and inform the disposal committee about the number of containers to be
disposed off.
 The disposal dept. should collect the same from different users, wash with water, ensure no
hydrocarbon vapour is present in the container and shift it to the specified area in the scrap yard.
 The specified storage area for the empty containers to be segregated from the rest of the scrap
material and free from combustible material such as wood, rags, cotton waste etc. The area to be
declared as non-smoking area.
 The buyer should ensure that no hydro carbons are present in the containers and if required he can
request for additional wash before collection.
 The seller in his agreement for sale should incorporate in the sale order that the company is not liable
for any mishap involving empty containers once it is taken out of factory premises.

SAFE HANDLING AND STORAGE – WASTE DRUMS &

CONTAINERS:
Safe operating Procedure (SOP) for storage, handling and disposal of waste containers of hazardous
substances have been standardised.

1. Storage:
 A provision for a well ventilated shed should be made for storage of containers used for hazardous
chemicals such as flammable, explosives and toxics. Containers should be piled so as to avoid
spillages.
 The material of the containers should be selected to suit hazardous property and quantity.
 Electrical fittings inside and outside the shed should be flameproof.
 Proper fire hydrant system and/or sufficient fire extinguishers of required type and size to be
provided.
 A trained and knowledgeable person should be made in charge of this activity.

2. Decontamination:

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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The process of removing or neutralising the hazardous chemical from containers, personnel and equipment
is called decontamination. This is critical to safety and health at hazardous waste sites.

 Decontamination protects workers form hazardous substances that may contaminate and permeate to
their protective clothing, equipment, tools etc. used at such site.
 It prevents mixing of chemicals.
 It protects community by preventing uncontrolled transportation of contaminant from the site.

3. Decontamination Plan:
There should be a decontamination plan before any personnel or equipment enters the area where hazardous
substances exist.
Plan should contain:

 The number and layout of decontamination stations.

 Decontamination procedure and equipment required.
 Procedure to prevent contamination of clean area.
 Establish procedure to minimise worker contact with contaminants.
 Establish methods for disposing clothing and equipment that are not completely decontaminated.
 The plan should be changed whenever new type of PPEs are introduced, new equipment or condition
change or new or additional information is made available.

4. Prevention of contamination:
 First step in minimisation of contamination is to establish standard operating procedure and reduce
potential contamination. The SOP should include proper procedure for dressing, PPEs, methods,
sequence of events etc.
 Evolve a work practices that minimises hazard substances
 Use remote sampling, handling and container opening techniques
 Protect monitoring and sampling instruments by bagging them. Make openings in the bags for
sample ports and sensors thus reducing contamination of instruments.
 Wear disposable outer garments and use disposable equipment wherever possible
 Cover equipment and tools with strippable coating which can be removed during decontamination
 Encase the source of contamination eg. with plastic sheet or overpacks.

5. Types of Contaminants:
Contaminants can on the surface of PPE or sub surface by permeating through the PPE. Surface
contaminants is easy to detect and remove but sub surface contaminants are difficult to detect and remove
and may continue to permeate.
Five major factors affecting extent of permeation

 Contact time
 Concentration
 Temperature

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 Size of contamination molecule and pore size

 Physical state of waste

6. Decontamination methods:
 All personnel, clothing, equipment and samples leaving the contaminated area must be
decontaminated to remove harmful chemicals or infectious organisms. It can done by physically
removing, chemical detoxification or disinfections or combination of both physical and chemical
means.
 Physical removal: physical means involving dislodging, displacement, rinsing, wiping off and
evaporation. High pressure or heat should be used cautiously since they can spread contamination
and cause burns. Coating of clothing with antistatic solutions can be removed by wash additives and
antistatic sprays which are commercially available. Some contaminants require force which include
scraping, brushing and wiping. Removal of adhesive contaminants can be enhanced by solidifying,
freezing, adsorption and absorption. Volatile contaminants can be removed by evaporation followed
by rinsing with water.
Other decontamination methods:

 Chemical leaching, extraction, evaporation, Pressurised air jets, scrubbing, steam jets, Chemical
detoxification (Inactivation) by halogen stripping, neutralisation, oxidation/reduction, thermal
degradation
 Disinfecting/sterilisation by chemical disinfectants, dry heat sterilisation, Gas/vapour sterilisation,
Irradiation, steam sterilisation

MECHANICAL HAZARDS IN INDUSTRY:

Mechanical hazards are a type of physical hazard. Mechanical hazards are those associated with power-
driven machines, whether automated or manually operated.

 A strain results when muscles are overstretched or torn, a sprain results from torn ligaments in a
joint. – Strains and sprains can cause swelling and intense pain.
 A cut occurs when a body part comes in contact with a sharp edge. – Seriousness of cutting or
tearing depends on damage done to skin, veins, arteries, muscles, and even bones.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

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 Power-driven shears for severing paper, metal, plastic, elastomers & composites are widely used. –
Such machines often amputate fingers & hands when operators reached under the shearing blade,
and activated the blade before fully removing their hand.
 Crushing injuries occur when a part of the body is caught between hard surfaces that progressively
move together-crushing anything between them.

NSC requirements for safeguards:

 Prevent contact - Safeguards should prevent human contact with any potentially harmful machine
part.
 Be secure and durable - Workers cannot render them ineffective by tampering with or disabling
them. Durable enough to withstand the rigors of the workplace.
 Protect against falling objects - Shield moving parts from falling objects, which can hurled out,
creating a projectile.
 Create no new hazard - Safeguards should overcome the hazards in question without creating new
ones. • Sharp edges, unfinished surfaces, or protruding bolts.
 Create no interference - Safeguards that interfere with progress of work are likely to be disregarded
or disabled by workers feeling the pressure of production deadlines.
 Allow safe maintenance - More frequently performed maintenance tasks (lubrication, etc.)
accomplished without the removal of guards.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 58

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 59

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.