DIPLOMA INDUSTRIAL SAFETY

GNFC TRAINING CENTER

SAFETY ENGINEERING-I

QUE-1 Need of planning?

ANS-1 Need of planning for safety & health & ‘Safety engineering approach in design, planning
& construction of new plant or new alteration/addition’ are basic & most essential, Because :-
1. General efficiency & safety in industrial activities can be greatly increased thereby,
2. Accident & Occupational disease can be prevented from the earliest planning stages,
3. Cost saving factors can be considered by effective use of floor area, providing ample
space for men, material & machines, reducing the cost of the material handling, reducing
the time of work or process making efficient use of resources, personnel & equipment
etc.,
4. Efficient flow of work is maintained &
5. Safety & comfort of people are achieved.
Therefore safety & lay-out engineer must take into account:-
 Products & products lay-out.
 Raw material, process & their lay-out.
 Size & type of site & building.
 Machinery, equipment & vessel required.
 Assessment of man-power required.
 Relationship between departments.
 Process flow chart.
 String & flow diagram.
 Templates & scale models.
 Drawing & pilot plants and
 Travel chart etc...
QUE-2 General principles of lay-out planning.
ANS-2 Some general principles/suggestions for good lay-out are:-
 Enough workspace should be provided for workers to work without restriction.
 Proper roads, pathways, tracks, cat-ways etc. should be provided for free passage of man
& material to avoid delay & obstruction.
 Sufficient doors, windows, ventilators must be providing for good ventilation & lighting.
  Installation of machinery, floors, stairs, lifting machines, electric wiring etc...Must be
done to ensure safety.
 Keep the handling of material to the minimum.
 Provide safe means of access to all work places.
 Provide safe transport facilities to for men & materials,
 Provide adequate emergency exits,
 Purchase machines & equipments with built in safety,
 Isolate high noise, vibration, fire and explosion & toxicity hazards.
 Provide for safety maintenance personnel.
 Allow space for future expansion.
 Provide repair & maintenance workshop, welfare facilities & education & training
facilities.
 Use appropriate colors, notices, signs, labels, posters for safety.
 Provide easy location for fire alarms, fire fighting equipment, personal protective
equipment ( PPE ), emergency kit, emergency assembly points, medical centre, safety
offices etc… &
 Arrange good house keeping (GHK).
QUE-3 List of items for good planning.
ANS-3 As follows:-
 Site,
 Transportation facilities,
 Handling & storage facilities,
 Personal & welfare facilities,
 Engineering, utility & safety facilities,
 Walkways, stairs, ramp, plat-forms etc…
 Good lighting & ventilation,
 Elevators & lifting machines,
 Boilers & pressure vessels,
 Fixed & portable machinery & equipments,
 Electrical installation,
 Fire protection &
 Other provision for health & safety, viz. effluent disposal, water, first-aid, emergency
power & equipment etc…
QUE-4 Travel chart-Short notes.
ANS-4 TRAVEL CHART
 Travel chart is simple & useful method to analyses deficiencies in the lay-out of a factory
& in planning a good lay-out
The deficiencies in poor lay-out are……
 Congested shop floor.
 Excessive waiting time of machines & material,
 Poor space utilization,
 Absence of easy access to machines, tools & materials,
 Excessive handling of materials,
 Irregular flow of process and materials,
 Back tracking & zigzag movements,
 Absence of necessary aisles (walk-way, path) & routes.
 Unbalanced activities resulting in poor utilization of man, machine & materials.
 Inflexibility of lay-out allowing no scope for future expansion or alteration needed with
time.
 The travel chart technique defects above deficiencies to improve the plant lay-out. It is a
mathematical approach which measures quantitatively the movements of materials & in-
process work. .the purposes of such measure are:-
 To access the quantities & the nature of material flowing from area to area & from
machine to machine.
 To reduce movements to minimum.
 To re-locate contributing & user areas on the base of percentage contribution &
 To re-arrange operations in each section for self-sufficiency.
 Unit movement is noted by multiplying distance & frequency, From the data of number
of components, their weights, distances traveled, frequency of trips etc… templates for
the machines & equipments & other details the travel charts are prepared.
The study of travel chart suggests improvement in material handling methods
&machines in operation, types of containers, aisles, travel routes etc…

QUE-5 Job safety analysis--- Short note.

ANS-5 JOB SAFETY ANALYSIS (JSA).
Job safety analysis is a procedure of analyzing jobs for the specific purpose of finding the
hazards in each step in the job and developing the safety precautions to be adopted. This is best
done at the stage of planning of production. The technique, however can be applied at any stage,
and in fact it is the one of the most important means of discovering hazards in the various jobs of
an existing process where the safety aspects might not have been fully taken care of in the lay-
out of the plant or the design of the equipment, machinery process, or the method of the working.
 Maintenance job are often those which are not analyses, though the accident risk is more in
them. It is essential that those jobs and other less repetitive jobs having accident potential are
analyses for safety and adequate safety measures laid down.
PROCEDURE
The procedure of the job safety analysis is simple and consists of four basic steps:-
Select the job,
Break the job into successive steps,
Identify the hazards and potential accident,
Develop ways to eliminate the hazards and prevent the potential accident.
1. SELECT THE JOB :-
It would be advantageous to select the job safety analysis based on their accident potential.
Jobs with potential for more frequent accidents, severity of injury and new jobs in which the
accident potential is unknown should be selected first.
2. BREAKING THE JOB :-
The job should be broken down to basic steps in the proper sequence. The step should not
be too general or too detailed. Description of each step should give the idea of what is being
done. A job safety break down sheet giving the following 3 heading is used for analyzing the
hazards in the jobs.
a. Operation
b. Hazards
c. Precautions

3. IDENTIFYING HAZARDS :-
The person who does the analysis should observed closely and examine all possibilities of
accident in each step. He should note down these hazard under the second column of the break
down sheet. For identifying the hazards he should watch the operation as many times as may be
required and also have discussion with the operators concerned any other who has knowledge of
the job. Thus he will be able to develop a complete and reliable list of hazard in the job.
4. DEVELOPING SOLUTION :-
The solution to the hazards in the job may be worked out by:-
a. Finding a new method or procedure of doing the job.
b. Reducing the necessity or frequency of doing a job that is hazardous and
c. Changing the physical conditions that create the hazard.
After the precaution to be taken in each step is developed, these safety precautions are to
be incorporated in the job or process sheets. Job safety instruction sheets containing
 safe-guards and safe procedures to be adopted in the different jobs, particularly the
hazardous one could also be made out and issued to the supervisions and operators.
The job sheets or the job safety instruction sheets should be explained to the
operators and necessary training imparted to them, do that they could follow correctly
the procedures of safe-guards laid down. It is important that the supervisors keep a
watch to ensure that the safety measures are strictly followed. If accidents are happening
in spite of complying with the procedures laid down based on job safety analysis, the
analysis obviously would need further review.
EXAMPLES :-
The procedures of job safety analysis are illustrated by examples.
PROBLEM :-
In a foundry, ferrous casting weighting about 20 Kgs is fettled by hand on a
pedestal grinder. The casting are sorted on one side of the grinder from they are picked
up, fitted on the grinder and replaced on the floor other side of the machine. Analyze the
job using the job safety analysis technique and determine the hazards and safety
precaution to be taken.

JOB BREAKDOWN SHEET

Opr Description Hazards Precaution

step

1 State the 1. Breakage of Wheel. 1 Check for the adjust

machine 2. Contact with Wheel. the guard.
3. Flying Particle. 2 Adjust tool rest.
3 Get wheel dressed if
Necessary.

2 Pick up the 1)Rough or sharp surface
job 2)fall of casting
3)strains and sprains
3 Grind 1)Flying particles
2)Wheel breakage due to
Jamming etc…
3)Dust: silicosis,
nuisance
4 Use goggles/shield.
1)Use hand gloves
2)Use safety shoes
3)Proper method of
Storing
4)Proper training in
lifting
1) Use goggles/shield.
2)Do not jam
3)LEV for machine or
Respirator.
4) Apron & Gloves.

4 Replace the 1)Rough or sharp surface 1)Use hand gloves

job 2)fall of casting
3)strains and sprains
2)Use safety shoes
3)Proper method of
Storing
4)Proper training in
lifting

QUE-6 House keeping definition.

ANS-6 House keeping means cleanliness & orderliness. A good house keeping means a place of
everything and everything in a place. Poor house keeping is a source of accident in industry.
POOR HOUSE KEEPING:-
A poor house keeping means existence of unsafe conditional work place which may cause
accident. Examples of poor house keeping are giving below.
 Floor with loose articles, nails, oil, grease, ditch/pit, uncovered manhole, broken etc..
 Work place, work bench, wall, ceiling, door window-fuel of dust, dirt or unwanted things
hanging or lying giving a shabby book.
 Non-disposal of sward, scrap, effluent and waste from the work place.
 Non-extraction of air pollutants like dust, fume, smoke, gases, vapor, mist, etc… from the
work environment.
 Inadequate ventilation causing discomfort in the work place in terms of temperature,
humidity, air movements, air changes, etc…
 Improper lighting causing low level of illumination or shadow, uneven distribution of
luminous flux, production of glare.
 Non-provision or blocking approaches to emergency equipment (fire bucket, portable fire
extinguisher, first aid box, emergency shower, stretcher room, etc…)
 Keeping or staking materials, equipments, tools etc. at such position as to hinder easy and
safe movement of men & materials or stack may collapse by sight disturbance.
QUE-7 House keeping & safety are the two side of same coin -- explain it.
ANS-7 House keeping means cleanliness & orderliness. A good house keeping means a place of
everything and everything in a place. Poor house keeping is a source of accident in industry.
A good house keeping takes care of all the shortcomings and make a work place
reasonably conductive, safe & comfortable. Worker finds it easy and less tiring job to complete
their assigned task successfully and safely. If the floor, wall, door, window, ceiling, ventilation
are properly maintained, it may be ascertained that house keeping will play a vital role in
achieving safety in industry.
For safety purpose, a good housekeeping may be maintained if we follow the DO’S &
DONT’S given bellow.
DO’S :-
1. Keep your surrounding clean to the extent possible.
2. Maintain floor free from cracks, pitholes, scrap object, oil, grease, chemicals, waste
materials, loose articles, unevenness etc…
3. Ensure your work bench / table free from unwanted things.
4. Keep tools, accessories, attachments and other essential devices / aids at the respective
place after use.
5. Dispose off swarf and waste at a clear interval of time.
6. Ensure extraction of dust, fume, gas, vapors, mist from your work area.
7. Maintain comfortable work atmosphere in respect of temp., humidity, air movement, air
changes, etc…
8. Store materials without blocking normal passage in the shop floor.
9. Keep oily waste in a separate bin with cover.
10. Maintain emergency equipment always in order.
11. Keep passage to emergency equipment free from obstacles.
12. Maintain proper floor marking for aisle ways, storage area inside and outside the plant.
13. Try to keep your work place with a decorative touch.
DON’TS:-
 1. Do not oily waste here and there.
2. Do not smoke or naked flame in restricted area marked “No smoking”.
3. Do not keep loose articles / object narrowing down common passage aisle way,
gangway, etc…
4. Do not misuse fire bucket.
5. Don’t allow unwanted things to accumulate at your work place.

QUE-8 Safety officer – Role for good housekeeping.

Ans-8 A general impression for everybody’s mind is there housekeeping is “sweeping and
cleaning” and good standard can be achieved by employing a gang of sweepers and cleaners.
This is not true: Housekeeping is not merely sweeping & not the “solely” responsibility of
cleaners or sweepers. More important aspect is keep things neat and clean while working.
Provide a place for everything and keep everything is at its place. Most of the things we do
“carelessly”. Which add upto a big need to clean at the end of work or day.

Role of Safety officer for good housekeeping plan.

1. Keep appearance of your area near and tidy.
2. Keep walkways, approaches clean and free from obstructions.
3. Ensure no leakages of products manufactured and processed in your area. NO WASTAGE.
4. Utilities are costly. Ensure no leakage of steam, water, air, fuel, etc…
5. Keep all drains clean and covered.
6. Store material orderly manner.
7. Keep all service houses, tools, drums equipment etc. in order.
8. Ensure cotton waste, papers etc. not scattered.
9. Keep all service houses, tools, drums equipment etc. in order.
10. Ensure best upkeep of fire and safety appliances.
11. Keep all caution and sign boards/notice boards in position and up-to-date.
12. Keep office furniture/fixtures in order with aesthetic sense.
13. Ensure good look of area, equipment and appliances by cleaning and painting.
14. Keep roof-fixtures and walls free from cobwebs.
15. Collect all garbage/refuge in proper container and ensure regular and safe disposal.
16. Avoid loose and hanging elect, wires. Keep all elect. Fittings in order.
17. Avoid accumulation of scrap-packing cases and other unwanted materials around your area.
18. Keep area in pleasing condition by lawns, gardening, displays, etc…
19. Ensure hygienic and clean condition of lavatory blocks, water cooler, wash rooms.
20. Ensure place for everything and everything in its place.

QUE-9 Japanese concept of 5-S.

ANS-9 CONCEPT FOR FIVE – S
It is Japanese technique of good housekeeping and work place organization. Although
the concept of 5S is deceptively simple, implementing and sustaining 5S is not easy,
Organization has to go along way to prevent and overcome the difficulties of 5S
implementation.
1S- SEIRI;Sorting concept: - Identify necessary items. Discard unnecessary/surplus items &
their disposal. Red tagging to VVIP/other materials, equipments, machines, floor,
shelves, areas, with enlisted required quantities.
2S- SEITON; Arranging concept:- Items/parts where and how to store. Local, clubbed, big,
heavy costly, odd, risky items, their placement with respect to motions/ economy/
frequency, demarcation with sign boards, painting, colour coding.
3S- SEISE; Cleaning /signing concept:-Schedule assignment for signing jobs through
standard procedure.
4S- SEIKETSU; Standardization concept:- For maintenance of cleanliness / discovery /
removal of dirt / leakages / spillage / fumes / process waste on prompt regular and
scientific basis with personal accountability.
5S- SHE TSUKE – Self discipline concept:-Through system’s pernancy, awareness
programmes, training, support, recognition and reward.
Good housekeeping involves every phase of industrial operation and should apply
throughout the entire premises, indoor and out. It is more than mere cleanliness; it
requires orderly condition, the avoidance of congestion, and attention to such details
as an orderly lay-out of the whole workplace, the marking 0f aisles, adequate storage
arrangements and suitable provision fir cleaning and maintenance.
QUE-10 Built in safety... Short note.
ANS-10 BUILT IN SAFETY:-
 1. Certain dangerous parts can be made safe during construction in that the part is
design in such a way that it no longer constitutes a hazard.
2. Built in safety is synonym for safety by construction. It describe an approach by
which machinery is designed and built on such a way that potentially dangerous
part are made safe by construction or so guarded or positioned as to prevent
access to them. However the transmission system inside a solid casing is an
example of built in safety, parts themselves still return then inherent danger.
3. To construct a safe machine with built in safety, designer should be trained to
regard safety as an integral part of machine design. At the design states of the
machine attention should be given to,
a) Transmission equipments.
b) Point of operation and cables.
c) Maintenance and cleaning.
d) Adjustments.
4. Advantages of built in safety,
a) No additional or make shift safe guard are require after purchase.
b) Built in safe guard are ergonomic.
c) They are economical.
d) Improve production
e) Prevent damage to equipment and material in process.
f) No access to danger zone.
g) No contact with overheated or cooled part/equipment.
QUE-11 what are the measure to be taken in safe guarding while designing the machine and
constructing the machine?
ANS-11 Safe guarding measures,
1. Following measures are to be taken while designing machine/safe system.
a) Where even practical dangerous part should eliminate or effectively enclosed during
initially designing of machine. If they cannot be eliminated, suitable safe guards
should be incorporated as a part of the design.
b) Where movable guard/cover is used as a safe guard, it should be interlock with drive.
c) The guard must be securely attached to the machine such a way that it can only be
removed by tool.
d) Lubrication and routine maintenance facilities should be incorporated remote from
the danger area.
e) Every mechanism and control of the guards should be of a fail safe design.
2. Following should be considered while constructing a guard.
 a) All guards should be of sound design and adequate strength.
b) Guards may be made of metal, timber, laminated, toughened glass or suitable plastic.
Shelter proof material should be preferred.
c) The size of opening in the wire mesh guards should be properly considered along with
the worker fingers and hand access.
d) Safe guard should not it self be a hazard, such as trapping or shear points, splinter, sharp
edges like to cause injury.
e) The guard must be securely attached to the machine and must require a tool to remove it.
QUE-12 Principle of design of guards.
ANS-12 Following principle must be considered when designing machine.
a) Dangerous part of machine should be eliminated or effectively enclosed in the initial
design. If they can not be eliminated then suitable safe guard should be incorporated as
a part of the design. If not possible then take care of it in later stage.
b) Provision should be made of facilitate the fitting of alternative type of safe guards on
machinery when system of work is varies.
c) Where a movable guard, cover etc. as used as a safe guard, it should be interlocked
with the drive to the parts being safe guarded.
d) The guard must be securely attached to the machine and must require a tool to remove it.
e) Lubrication and routine maintenance facilities should be incorporated remote from the
danger area.
f) Suitable supplementary light should be provided at operating points.
g) Every mechanism and control of the guards should be of a fail safe design.
QUE-13 Zero state energy (ZMS)
ANS-13 Discuss as below:
1. Primary source of power of all machinery is mostly electricity. In some cases
pneumatic, hydraulic or charged capacitors are used to execute the work. When the
equipment is first turned on after connecting to primary source of power, it is common
for pneumatic and hydraulic components of the equipment to get charged before the
machine can perform properly. This may be in the form of pumping the accumulators
and surge tanks, char gag actuating cylinders loading hoppers lifting counter weight. All
three actions result in energy of one from or another leading stored in parts of the
machines..
2. Shutting down the equipment should being with procedures for turning all operations
controls to “off” position. Next all energy sources to the equipment must the
disconnected or lock out. Accumulators must be lead down to atmospheric penury.
Pneumatic pressure should be brought to nil. Charged capacitors should be earthed and
 counter weight must be brought to ground level. If the stored kinetic and potential
energy a system is not brought to neutral condition and place the machine in zero
mechanical state (ZMS) any accident due to sudden release of stored energy.
3. Once all energy sources are neutralized, machine is called ZMS. This affords maximum
protection against unexpected mechanical movement.
QUE-14 Lock out & Tag out. Short note.
ANS-14 LOCK OUT & TAG OUT
1. All machinery and equipment have parts that wear out component that need
periodic adjustment or places that have to be serviced for one reason or another.
When such event occurs, the machinery is shut down for maintenance effort.
During maintenance the protective guard is removed to obtain access to
unserviceable parts, inter lock may be bypassed or safety devices may be
disconnected. During the shut down some members of the maintenance area
may have to put portion of their body into hazardous location which where
protected by the inoperative safety device. If the machinery is started up again
by some one who does not know that the worker is inside the machine serious
injury can result.
2. To prevent such an occurrence lock out or tag out procedures were developed.
The procedures require that worker secure the equipment in such a manner that
it cannot be started by any other person that himself the feature common to these
devices is a pair of mating tags which have machinery holes through which a
restraining device can be placed. The restraining device itself has several holes
through which individual workers can place their personal lock to which they
have the only key.
3. In practice each worker who is going to be working on the machine during the
shut down places his individual lick on the lock out device before entry into the
machine and work. The work can not be removed by any one else until that
worker has completed the assigned task and return to the lock out location. In
this way all worker must be out of the machinery and clear of the hazard before
the power can be turned load.
4. All classes of energy are subjected to the lock out provisions, while electric
power is the usual source for most machinery, all machines all hydraulic,
pneumatic, chemical and thermal sources must be connected. In addition, the
energy stored in springs, and the potential energy of elevated weights must be
taken into account.
 5. Tag out device is similar to log out, but they involve the applications of
substantial and durable tags rather than lock. These devices are attached by a
non-reversible link and sealed to prevent reuse. Such tags bear and legend such
as “DO NOT START” or “DO NOT OPERATE”. The link is cut of and tag is
removed by the worker when the task is completed. This system is not secure as
lock out. There is a little portion for more than one person in the repair area.
QUE-15 What safe practice is to be use to reduce tool injuries?
ANS-15 Five safe practices for reduce tool injuries.
1 Provide proper protective equipment and have employees wear it. Eye and face
protection prevents injuries from flying objects or liquids. Hand and arm
protection prevents injuries from flying or sharp objects. Respiratory protective
equipment can provide protection from particulates and fumes & use as per
described in 29 CFR 1910.134. Power tools can also create noise levels above
regulatory standards. When noise monitoring indicates that noise levels exceed
OSHAS standards, it will be necessary to induce noise-exposed employee in a
hearing conversation program with annual audiometric testing and use of
hearing protection. Companies also should consider use of less noisy models of
tools or other noise controls where noise levels exceed 90 dBA.
2 Select right tool for the job. Examples of unsafe practice include…..
a) Striking hardened striking faces of hand tools together, such as using a
hammer to strike another hammer or hatchet.
b) Using a claw hammer to strike a steel chisel.
c) Using a file or a screwdriver to pry.
d) Using a wrench instead of a hammer, and
e) Using pliers instead of the proper wrench.
3 Know if a tool is in good condition and keep it in good condition. Unsafe tools
include wrenches with cracked or worn jaws, screwdriver with broken tips, or
split or broken handles, mushroomed heads on chisels, dull saws, and
extension cords or electrical tools with broken plugs, improper or removed
grounding systems, or split insulation. Properly ground tools and use a ground
fault circuit’s interrupter (GFCI) protected circuits.
4 Use tool correctly. Some common causes of accidents are…
a) Screwdrivers applied to objects held in the hand.
b) Knives pooled towards the body.
c) Failure to ground electrical equipment.
d) Nail hammers striking hardened tools, and
 e) Using tools when work is not properly secured.
5 Keep tools in safe place. Many accidents caused by tools falling from
overhead. Another source of accident is leaving the cutting edge of knives,
chisels, and other sharp tools exposed when carrying them in pockets or
leaving them in tool boxes.
QUE-16 Necessary condition for good lighting or basic consideration for the good lighting.
Ans-16 Necessary condition for the good lighting is as follows;
1 Adequate illumination,
2 Avoidance of glare,
3 Uniform lighting,
4 Appropriate contrast,
5 Appropriate colour contrast,
6 Better colour rendering,
7 Avoidance of flicker and stroboscopic effect.
A) Adequate illumination:- Adequate, rational or good illumination needs sufficient
quality of illumination necessary for avoiding discomfort to the worker and
undue strain on eyes. The quantity of illuminations is given by luminous flux,
intensity, luminance, luminance and reflection factor. It varies from place to
place, person to person & with age of person also. Therefore by experiment
standard of illumination are recommended for a variety of places and jobs to
have sufficient quantity of light for better work performance. For example, far
very fine work like distinguishing black cloth intensity of 2000 lux is
recommended. The quality of illumination depends on three factors, a) Diffusion
b) Distribution and c) colour value. Diffusion is the process of reflection of light
by reflecting surface. This factor presents itself in the form of the problem of
glare. I.e. Brightness of such a character as to cause annoyance, discomfort,
interference with vision and eye fatigue.
B) Avoidance of GLARE;
1) Direct glare
2) 2) Reflected glare.

1) Direct Glare: - It comes directly from the light source to the eye. It depends for
it’s effects upon the position of the light source in the field of view and on the
contrast in brightness between the light source and it’s background. It can be
avoided by –
a) Reducing the brightness of the light source.
b) Reducing the area of high brightness.
c) Increasing the angle between the source of glare and the line of vision.
d) Increasing the source of glare so as to lessen the contrast.
2) Reflected Glare: - It comes to the eyes as glint or reflection of the light source
from some polished surface. It is caused by a mirror image of the bright light
sources reflected from shiny or wet workplaces such as glass or plated metal.
These reflections distract attention, make important detail difficulty to see and
cause acute discomfort. It can be avoided by –
a) Changing the finish by having mat finish.
b) Changing the task position or it’s surrounding.
c) Using the light source of low brightness.
d) Arranging the geometry of the installation so that there is no glint at the
particular direction.
C) Uniform light: - The human eye can clearly perceive difference in luminance of
over 50%. It takes time to adopt sudden variation in the intensity of light,
particularly from higher to lower intensity. So uniform distribution of lighting is
essential for most work rooms, control room, conference rooms, etc. Distribution
of light requires two problems to solve. 1) Uniformity of illumination 2)
Elimination of shadow.
1) Uniform Illumination – The distribution of light with a maximum and
minimum illumination at any point should not be more than one sixth
above or below the average level in the area. Indicate lighting is the best
method for producing Uniform illumination. The disadvantage of
indirect light is its cost. Since considerable light is lost through
absorption. However its benefit is more than work its extra cost.
2) Elimination of shadow: - Shadow should be avoided but some shadow
effect may be desirable from the general lighting system. There are a
few specific visual task where clearly defined. Shadows improve
visibility and such effect should be provided by supplementary lighting
equipment arranged for the particular task.
D) Appropriate Contrast: - The ability to see detail depends upon the contrast
between the detail and it’s background. The grater contrast difference in
luminance, the more readily the seeing task is performed. The eye function most
comfortably and efficiently when the luminance within the reminder of the
environment are relatively uniform. Therefore all luminance in the field of view
 should be carefully controlled. Reflectance should be maintained -- near as
practical.
1 For ceiling it should be 80-90%
2 For walls it should be 40-60%
3 For desk, bench, tops, machine & equipment it should be 25-45%
4 For floors not less than 20%
High reflectance surface are desirable to provide the recommended
luminance relationship and high utilization of light. They improve the
appearance of the work place. It is also desirable that the background is slightly
darker than seeing task.
E) Appropriate colour contrast: -Eye sees an object by the light in reflects and
distinguishes it’s detail mainly by colour contrast. Thus, in addition to luminance
contrast, colour contrasts may be influenced by the choice of the colour of light.
The choice of correct colour of light depends upon the task to be performed and
the requirements to be met by vision. It may be noted that there must not only be
adequate illumination to see an object clearly but also the object must be visible
in it’s surrounding. It must have moderate colour contrast.
F) Better colour Rendering: - It refers to the appearance of coloured objects when
illuminated by a particular light source. It is property of light which facilitates
the perception of surface colours. It depends on the spectral composition of light.
The maximum value of colour rendering Indies is 100 and at this value there is
no shift means the colour rendering is perfect. The light source selected should
have the desired colour rendering properties.
G) Flicker and Stroboscopic effect: - All lamps working on alternating current (A.C)
give light which pulsates at twice the supply frequency. This type of
discontinuous light of almost any frequency can produce stroboscopic effect.
During effect a rotating or reciprocating object can appear to be stationary or
moving slowly, or even appear to be rotating in the opposite direction etc. This
illusion can cause accident in industrial situation. It is a real hazard in the
presence of moving machinery. High intensity discharge lamps and fluorescent
tubular lamps have lamps have some flicker content in their light output.
QUE-17 Glare --- Short note
ANS-17 Discuss in above question…refer it…..
QUE-18 Flicker & Stroboscopic effects -- Short note.
ANS-18 Discuss in que-16… refer it….
QUE-19 Effects of good lighting.
ANS-19 without light the object has no colour, no shape. Light & colour affects on human
efficiency, moral & fatigue. Medical research had proved that sufficient amount
of light is needed for healthy physiological functioning of human organization.
Bad light adversely effects human health.
EFFECTS OF GOOD LIGHTING: -
1) It affects our sight as well as the object to be seen.
2) It helps in two ways-
a) Better seeing for work performance.
b) Better environment.
3) Better seeing condition causes better discrimination, &
concentration, alertness and less fatigue.
4) Better discrimination causes less spoilage and quick fault detection.
5) More alert concentration which increases better work output.
6) Better environment produces better moral, supervision and keen
interest.
7) Less fatigue allows grater output and more production.
8) All these factors causes better ability to perceive objects and
keep a clear view of all details, of better conservation of material reduced,
labor turnover, better house keeping, less waste of material, energy and labor
prevention of eye strain and accidents, increased accuracy, efficient
productivity, speed of seeing and reading and improvement in health and
safety of working people.
9) Higher productivity with safety leads to higher profits.
10 After all, good lighting ultimately improves profitability. The
spectral composition of light and colour layout should be appropriate to gain their
maximum advantages.
QUE-20 Light & Safety
ANS-20 There is close relation between accident frequency and lighting condition as per
numerous studies. One insurance company has estimated that around 24% accident occurred due
to imperfect lighting. So it is more important in our life. In one factory when illumination was
increased from 50 to 200 lux the reduction of accident was 32%. Another reduction of 16.5%
was noticed when the walls were treated with high reflectance paint which increase the
illumination level to 250 lux. Poor lighting requires more time to see or to distinguish object.
Glare & shadows causes eye strain resulting in more chances of accidents. Therefore to increase
safety prescribed standard of illumination is the basic working condition. This proves the direct
relationship between lighting & safety.
QUE-21 Purpose of ventilation & temperature control.
ANS-21 Why good ventilation is necessary? The need of purpose of ventilation and temperature
control are summarized here as follows: -
1) Air is a life and fresh air is the first need for survival of
human beings. Absence of air brings death within a few minutes. Life
without breathing is not possible & the fresh air is needed for the whole life
for breathing & functioning of human body. Therefore good ventilation
giving sufficient fresh air is the treatment requirement.
2) Human body can not tolerate excessive temperature.
Heat stress produced by high heat exposure adverse effects on health &
safety of work people. Therefore environment temperature control is also
permanently needed for well functioning of human body. Ventilation helps
in removing excessive temperature.
3) Carbon dioxide is continuously exhausted by all human
beings. Much more contaminants are added by manufacturing process or
pollute air. There fore cleaning of oxygen are also necessary. This is possible
by good ventilation & pollution control technique only.
4) Where due to weather or atmospheric condition or
process parameters, excessive temperature is unbearable or discomfortable
air conditioning or refrigeration system are also necessary. Conversely,
where air heating is necessary as in case of cold climate, it must be provided.
5) Basic function of ventilation are to: -
a) Maintain the oxygen content of the air and to prevent
CO2 concentration from rising.
b) Prevent body odors.
c) Prevents harmful concentration of aerosol & air borne
contaminants and
d) Maintain reasonable condition of thermal limit for
comfort & efficiency which result in decreased heat stress, increased
production, reduced accidents rates (hot conditions inducer unsafe act) and
adverse health effects (interaction with other hazards), higher level of job
satisfaction, reduced absenteeism, improve attitudes, reduced downtimes for
hot vessels and compliance of required standard.
6) While designing industrial buildings care must be taken
to provide good ventilation for dilution of inside air to prevent vitiation by
causes, such as body odorous, to remove process released contaminants and
 heat & heat exposure to maintain satisfactory thermal environment, to
maintain heat balance of body & to prevent acute discomfort & injury to the
health of the workers. If natural ventilation is not sufficient for this purpose,
mechanical ventilation, cooling system or other technique must be employed
to achieve satisfactory results.
7) The basic need for ventilation is to maintain the body
heat balance equation by controlling air & surrounding temperature,
humidity & air velocity. Therefore supply, well distribution & maintenance
of fresh air through out the factory are utmost necessary to maintain
comfortable working condition as expected by section 13 to 15 of our
Factory act 1948.
Factor affecting the ventilation system are:-
1) Temperature of air in room,
2) Air velocity,
3) Temperature different between inside & outside of the room,
4) Radiation,
5) Humidity,
6) Clothing of workers.

QUE-22 Classification of ventilation system.

ANS-22 See classification chart of ventilation.

QUE-23 Control of heat stress & Heat exposure.

ANS-23 In addition to the ventilation, natural or mechanical as explained above, it become
necessary in process situation to apply other means for control of heat exposure towards workers.
1) Control at source: - The first obvious step for mitigating the effects of heat is to eliminate the
heat sources wherever possible or to segregate them. Some of the hot process equipment could
be placed out of doors with only a protective roof.
The location of furnace in separate wings rather than in a large single building will simplify
the problem of supplying air for general ventilation. These wings may have high roof to provide
between chimney effects for the removal of hot air over the furnaces.
2) Local Exhaust Ventilation: - Another method of removing of heat from the source is by
providing ventilated enclosures such as Canopy or exhaust hoods by which natural convex
column of heated air rises from a hot process environment. This will minimize the temperature
rise in the space around the hot process.
3) Insulation: - The insulation of furnaces and other heat producing equipment will not only
reduce the amount of heat exposure but also result in the consequent saving in fuel consumption.
If all the heat produced by a process is reduced into a work room and the heat production is
constant, no amount of insulation around the process will bring about reduction in heat exposure.
The insulation will be of value only when heat produced has several avenues of escape, the
dissipation into the workroom being only one of these. In such asses, a combination of insulation
and exhaust or gravity ventilation will often be quite effective.
4). Control of radiation heat: - In some industries commonly referred to as “hot” industries, the
frequency of very hot objects and surface such as furnaces, ovens, furnace stacks, molten
material, hot ingots of metal, castings, and forging in such that the major environmental heat load
is in the form of radiant heat which may be several times greater than convective heat load. No
amount of ventilation with or without air cooling will reduce the heat exposure since air
temperature has no significant influence on the flow of radiant heat. The only effective control is
the direct one of decreasing the amount of radiant heat impinging on the exposed workers. This
can be accomplished by either lowering the surface temperature of the hot equipment (By
insulation or by water cooling). Or by radiation shielding. A shielding is simplified a sheet of
material, opaque to the infrared waves (or essentially so) places between a hot object such as
furnace and works surroundings. The shield should not contact the radiating surface and the
presence of a ventilated air space between the hot object and the shield to avoid heating of the
shield by conduction and to remove the heated air in between. Materials best suited for radiant
heat shields are those with surface that maintain the high and low emissivities under plant
conditions. Glazed aluminum sheet has these properties. It is the most common material used for
radiation shielding.
Roofs of corrugated iron sheets or of asbestos cement sheets that heated by sun in hot weather
and act as content source of heat, the major portion of which is radiant heat. Control of this type
of heat exposure may be achieved by lowering the surface temperature of the roof by one or
more of the following methods.
i. Insulation roof by providing a layer of material of low conductivity
ii. Shielding by the provision of a false roof or ceiling with sufficient
air space ventilated to outside atmosphere.
iii. White-washing or white-painting the exterior surface of the roof
iv. Spraying of water intermittently over the roof to cool it by evaporation.
Opening and glazing in the walls and roof through sun’s rays could directly penetrate in summer
should as far as practicable be screened.
 LOCAL RELIEF.
In certain situation when a general reduction of heat exposure throughout the plant is not
feasible and at the above methods such as exhaust ventilation and radiation shielding have not
brought down the thermal environment to a tolerable degree, relief may be provided locally i.e.
at the workplaces by surrounding the exposed positive ventilation. Following three methods
may be employed depending on the work situation.
a) Providing a complete enclosure around the workers with separate ventilation in order to
maintain cooler working conditions. This may be in the form of air conditioned control
room, small shelter booth, or ventilated crane cab.
b) Surrounding the worker with a relatively cool atmosphere by a direct supply of air
introduced at the working level or over a small area of the plant.
c) Directing a high velocity air stream at the worker when the air is capable of absorbing heat
i.e. either its dry bulb is reasonably lower than the body temperature or its humidity is low
enough to allow evaporation of sweat.

PERSONAL PROTECTIVE EQUIPMENTS

In certain operation, where workers have expose to higher temp. Protective clothing and
protective shielding of heat reflecting type can be used for controlling heat exposures. The
protective clothing is generally made of aluminized asbestos cloth with mitts, leggings, aprons,
jacket, helmets and speal arm sleeves according to specific operation.

QUE-24 Special precaution for flammable liquid & pressurize gases to avoid static electricity.
ANS-24
 Tanker and dispensing or receiving unit must be bonded together during filling and
emptying. Earth them where ever possible.
 All metal parts of non conductive tanker vessel used for transporting liquid prone to cause
static hazard must be bonded and earthed.
 Earthing conductor / clamps should be fixed as far as possible from where flammable
vapours can escape.
 It is necessary to bend or earth the tanker during gravity filling underground storage tanks
through single-length, closed-piping system.
 Experience indicates that bonding is not necessary when filling farm tanks with small
diameter pipes ar flow velocities less than 1 m/s.
  The inherent earthing of rail tank wagons and storage tanker is generally sufficient for
dissipating charges.
 There is no evidence for static hazards arising from fuelling motor vehicles.
 Ether and carbon disulphide should be transferred into containers by using a filling tube/
funnel extending up to the bottom of container and ensuring that all metallic parts are
properly earthed. Avoid use of non conductive containers, filling tubes or funnel.
 Since carbon dioxide, released as a liquid from nozzles at high pressure can result in
static accumulations on the nozzles and receiving container, these should be made wholly
from conductive material and be earthed.
 Hydrogen-air and acetylene – air mixtures containing entrained solid or liquid particles
very low ignition energized should be handled with special care.
 In spray painting operations where considerable static is generated, it is necessary to bond
and earth the spray gun and any conductive object being sprayed. Ensure that paint layers
do not impair the effectiveness of bonding / earthing.
QUE. 25 Various types of mech. -materials handling.
ANS. 25 Following are various types of mechanical material handling,
1. Overhead traveling crane. [ E O T ]
2. Jib crane [ Mobile crane / Gantry crane ]
3. Power trucks
4. Conveyors
5. Lifting tackles
6. Fork lift trucks
7. Pay loaders
8. Power shovels
9. Winch crabe
10. Hoist & Lifts
11. Bucket Elevators
12. Pullers etc…

QUE-25 Different types of traveling crane.

ANS-25 As follows:-
1) MOBILE CRANE:- Engine driven tyre mounted mobile crane with
load lifting system consisting of extendable single boom & hook
 using hydraulic technology, turning / swiveling angle of 360 degree,
hydraulic pressure developed with in-built electrical pump, used for
lifting and shifting of material. Cranes available in wide range of
capacities and cranes available for movement on rough terrains
specific tyres.
2) CRAWLER CRANE:- Engine driven, crawler motion through chain
and sprocket arrangement, single hoist or main & auxiliary hoist
configuration available, completely independent operation of main &
auxiliary hoist, fixed or fabricated extendable boom, conversion of
hook block to 3/2/1 sheave by using spacers, with or without jib, all
controls and brake and clutches operating pneumatically,
turning/swiveling angle of 360 degree, used for lifting of material
(not used for shifting).
3) HYDRA MOBILE CRANE:- Engine driven tyre mounted crane with
load lifting mechanism consisting of extendable single boom & hook
using hydraulic technology, limited turning/swiveling angle,
hydraulic pressure developed with in-built electrical pump, used for
lifting and shifting of material. Crane available in moderate range of
capacity.
4) SUPER SKY HORSE CRANE:- Engine driven, crawler motion
through chain and sprocket arrangement, single hoist or main &
auxiliary hoist configuration available, fixed or fabricated extendable
booms, conversion of hook block to 3/2/1 sheave by using spacers,
extendable, with or without jib, all controls and brake and clutches
operating pneumatically, turning/swiveling angle of 360 degree, used
for lifting of material (not for shifting of material). Crane available in
wide range of capacities.
5) ELECTRICALLY OPERATED TRAVELLING CRANE:- Electric
motor driven, traveling on rails installed at suitable height in the
building for lifting and shifting of material within the building only,
long travel and cross travel movement on rails for length and width of
building, single hoist or main & auxiliary hoist configuration
available, up and down hoisting using wire ropes and pulleys,
precision inching operation of hoist feasible for maintenance of
equipment such as large generators, turbine, motors, pumps, etc.,
electrical control and braking using either electrical motors, or
 thruster, or electro-magnetic. Cranes available in wide range of
capacities.
Major consideration for safe operation of different types of cranes is
ability for correct reading of load charts provided with respect to boom
length angle and radius requirements for particular load.
It is essential that highly trained operator is developed for operation of
crane so as to avoid mishaps due to unsafe operation. Period load testing and
checking is must for high rated cranes to ensure safety aspects.
QUE-26 Fire exit- short note.
ANS-26 FIRE EXIT:-
1. In this rule--
 “Horizontal exit” means an arrangement which allows alternative egress form
a floor area to another floor at or near the same level in an adjoining building
or an adjoining part of the same building; and
 “Travel distance” means the distance an occupant has to reach an exit.
2. An exit may be doorway, corridor, and passageway to an external stairway or to a
verandah or to an internal stairway segregated from the rest of building by the fire
resisting walls which shall provide continuous and protected means of egress to the
exterior of a building or to an exterior open space. An exit may also include a
horizontal exit leading to a adjoining building at the same level.
3. Lifts, escalators and revolving doors shall not be considered as exit for the purpose of
this sub-rule.
4. In every room of the factory exits sufficient to permit safe escape of the occupants in
case of fire or other emergency shall be provided which shall be free of any
obstruction.
5. This exit shall be clearly visible and suitably illuminated with suitable arrangement,
whatever artificial lighting is to be adopted for this purpose, to maintain the required
illumination in case of failure of the normal source of electrical supply.
6. This exit shall be marked in a language understood by majority of the workers.
7. Iron rung ladders or spiral stair cases shall not be used as stair cases.
8. Fire resisting doors or roller shutters shall be provided at appropriate places along the
escape routes to prevent spreads of fire and smoke, particularly at the entrance of lifts
or stairs where funnel or flue effects may be created inducing an upward of fire.
9. All exits shall provide continuous means of egress to the exterior of a building or to
an exterior open space leading to a street.
 10. Exits shall be so located that the travel distance to reach at least one of them on the
floor shall not exceed 30 meters.
11. In case of those factories where high hazard materials are stored or used, the travel
distance to the exits shall not exceed 22.5 meters and there shall be at least two ways
of escape from every room. However, small escape toilet rooms so located that the
point of access thereto are out of or suitably shielded from areas of high hazards.
12. Wherever more than one exit is required for any room space or floors, exits shall be
placed as remote from each other as possible and shall be arranged to provide direct
access in separate direction from any point in the area served.
13. No exit doorway shall be less than 100 cm in width; doorways shall be not less than
200 cm in height.
14. Occupants per unit width shall be 50 for stairs and 75 for doors.
15. Exit doorways shall open outwards, that is away from the room but shall not obstruct
along any exit. No door when opened, shall reduce the required width of stair way or
lending to less than 90 cm. over head or sliding doors shall not be installed for this
purpose.
16. An exit door shall not open immediately upon a flight of stairs. A lending at least 1.5
m * 1.5 m in size shall be provided in the stair way at each door way. The level of
lending shall be the same as that of the floor which it serves.

QUE-27 Classification of hazardous area for electrical installation.

ANS-27 the classification of areas for electrical installation In petroleum refinery are other
similar areas where hazards of explosion due to gases and vapors exists and in which flammable
gases and volatile liquids are processed, stored or loaded, unloaded and otherwise handled.
The classification of areas has been done according to the extent of risk involved so that it
provides a guideline to the choices of the equipment to be installed in different areas on the basis
of the extent of hazards.
To determine the type of electrical installation appropriate to a particular situation, the areas have
been divided in to three main division namely – division-0, division-1 and division-2, according
to the degree of probability of the presence of hazardous atmosphere.
DIVISION – 0 AREAS:-
An area in which a hazardous atmosphere is continuously present shall fall under this category.
Since a hazardous atmosphere exists continuously any failure of electrical apparatus installed in
division-0 any installed electrical apparatus must afford a degree of protection as near as
practicable to the absolute.
It is recommended that the use of electrical apparatus should, where practicable be completely
excluded from division-0 areas, but when this is practicable the recommendation laid down IS:
5571 (guide for selection electrical equipment for hazardous areas) should be followed.

DIVISION – 1 AREAS:-
An area in which a hazardous atmosphere is likely to occur under normal operating condition
shall fall under this category. This classification is applied to areas in which a hazardous
atmosphere is likely to occur any time and which therefore, required the fullest practicable
application of measures to prevent the occurrence of a hazardous electrical condition at any time
and in any circumstances. Recommended types of electrical apparatus and wiring for use in
division-1 areas are given in IS: 5571.

DIVISION – 2 AREAS:-
In area in which a hazardous atmosphere is likely to occur only under abnormal operating
conditions shall fall under this category. This classification is applicable only where a fire and
explosion hazards is unlikely and may be cause only by simultaneous and improbable occurrence
of an arc or spark resulting from an electrical failure and a hazardous atmosphere arising through
failure of the condition of control. It pre-supposes that any hazardous atmosphere resulting from
abnormal occurrences is rapidly dispersed, so that it is possible contact with the electrical
apparatus of minimum duration. Any situation which allows a hazardous atmosphere to collect
such as a pit or trench although it may be in open air shall in itself be caused as Division – 1 area,
even though the surrounding area is classified as Division – 2.

SAFE AREA:-
Although generally speaking safe areas may be ascertained without difficulty. The following are
given of 0 cases where this classification may not immediately be apparent.