UNI

T1
I
NTRODUCTI
ON
Hazar di sat er m associ atedwi thasubst ancet hati sl i
kel i
hoodt ocauseani njur yi nagi v en
env ironmentorsi tuat i
on.
Indust rialhazar dmaybedef inedasanycondi tionpr oducedbyi ndust riest hatmaycause
i
nj uryordeat ht oper sonnelorl ossofpr oductorpr oper ty.Saf et yi nsi mpl et er msmeans
freedom f rom t heoccur renceofr iskori njur yorl oss.
Indust rialsaf et yorempl oy eesaf et yItref erst ot hepr otect i
onofwor ker sf rom t hedangerof
i
ndust ri
al acci dent s.
Saf et yhazar ds Toxi c and cor rosi ve chemi cal s,fi
re,expl osi ons and per sonnelf alli
ng i nt o
acci dent sar et hemaj orheal thandsaf etyhazar dsencount er edi nt heoper ationsofchemi cal
andphar maceut ical r
el atedi ndust r i
es.
Acci dentpr ev ent ionneedssy stemi candt echni calst udyofev eryaspectoft hepl antdesi gn
andoper at i
on.Today ’
si ndust ryempl oysuserf riendl ymachi ner y,whi chcanwi t
hst andhuman
errorandequi pmentf ailur e.
Def inef ireandcombust i
on?
Combust ionmaybedef inedasachemi calr eact ionaccompani edbyt heemi ssi onofl ightand
heat Thr ee f act or s ar e essent ialf or combust i
on namel y Temper at ur e,Oxy gen and
Combust iblemat er ials.
Firei sanexot her mi cchemi cal react ionbet weenoxy genandf uel
Whati s" lockout /tagout "?
"Lockout /tagout "r ef erst ospeci ficpr act i
cesandpr ocedur est osaf eguar dempl oyeesf r
om
the unexpect ed ener gi zat i
on orst artup ofmachi ner yand equi pment ,ort he r elease of
hazar dousener gydur i
ngser viceormai nt enanceact i
vities.1Thi sr equi res,i npar t
,t hata
desi gnat edi npi dualt urnsof fanddi sconnect st hemachi ner yorequi pmentf rom i tsener gy
sour ce( s)bef or eper for mi ngser viceormai nt enanceandt hatt heaut hor izedempl oyee( s)
eitherl ockort agt heener gy -i
sol atingdev i
ce( s)t opr ev entt her eleaseofhazar dousener gy
andt akest epst ov erifyt hatt heener gyhasbeeni solat edef fect i
v ely .Ift hepot ent ialexi stsf or
ther eleaseofhazar dousst or edener gyorf ort her eaccumul ationofst or edener gyt oa
hazar dousl ev el ,theempl oy ermustensur et hatt heempl oyee( s)t akest epst opr eventi njury
thatmayr esul tf rom t her eleaseoft hest or edener gy.
Lockoutdev ices hol d ener gy -isol ation dev ices i n a saf e or "of f"posi ti
on.Theypr ov i
de
prot ect i
onbypr ev ent i
ngmachi nesorequi pmentf rom becomi ngener gizedbecauset heyar e
posi tiver est raint st hatnoonecanr emov ewi thoutakeyorot herunl ocki ngmechani sm,or
throughext raor di nar ymeans, suchasbol tcut ters.Tagoutdev ices, bycont rast ,arepr omi nent
war ni ngdev i
cest hatanaut hor izedempl oy eef astenst oener gy -i
sol atingdev icest owar n
empl oy eesnott or eener gizet hemachi newhi leheorsheser vicesormai nt ainsi t.Tagout
dev icesar eeasi ert or emov eand, byt hemsel ves, prov ideempl oy eeswi thl esspr otect iont han
dol ockoutdev ices.
WHATI STHEDI FFERENCEBETWEENLOCKOUTANDTAGOUT?
Lockouti st hepl acementofanener gyi sol ati
ondev i
ceonapi eceofequi pmentt or enderi t
i
noper abl e.Al ockoutusesal ockt ohol danener gyi sol ati
ondev icei nasaf eposi t
ionand
prev ent st heener gizat ionoft hemachi neorequi pment .Tagouti swhenat agi spl acedona
pieceofequi pmentt oi ndi cat et hatt heequi pmentbei ngcont rolledmaynotbeoper at edunt i
l
thet agoutdev icei sr emov ed.
Hav ey oucheckedal lmechani calhazar dsi ny ourwor kpl ace?
Cont actusi fy ouneedmor ei nf or mat i
onorhel poncont rollingmechani calhaz ardsi ny our
workplaceand/ orony ourf ar
m.
Machinescansi gni fi
cant lyimpr ovepr oduct i
onandef fi
ciency .Butt heydonotcomewi thout
ri
sks.Themov i
ng par ts,shar p edges,and hotsur facesar ehazar dst o wor ker s.Many
machine- relatedi njuriescanbepr ev ent edwi tht heproperuseofsaf eguar ds.Itisimpor t
antt o
understandwhatdanger smachi nespr esentandwhatel ement sar eneededt oi mpl ement
eff
ectivesaf eguar dingpr acti
ces.
WHEREMECHANI CALHAZARDSOCCUR
Hazardsof tenoccuratt hepoi ntofoper at
ion,ort hepoi ntwher ewor kisper formedont he
material.Thi scoul dbecut ti
ng,shapi ng,bor ing,orfor mingofst ock.Regar dl
esst het ypeof
work,thepoi ntofoper ationoft hewor kmustbesaf eguar ded.
Additi
onal ly,al lpar tsoft hemachi net hatmov eposet hreatofi njury.Exampl esi nclude:
fl
ywheel s,pul leys,bel ts,coupl ings,chai ns,cr anks,gear s,et c.Thef eedmechani smsand
auxil
i
ar ypar tsoft hemachi neshoul dal sobeconsi dered.
Anotherar eapr onet ohazar dar ei n-runningni ppoi nts.Thesear ecr eatedi nt hreeway s:
between2r otatingpar ts, bet
weenr otatingandt angent i
alpar ts,orbetweenr otati
ngandf ixed
part
swhi chshear , crush, orabr ade.
WHOI SRESPONSI BLEFORMACHI NESAFETY?
Management ,super visorsandempl oyeesal l holdresponsi bili
tiesrel
atedt omachi nesaf ety.
 Managementshoul d:ensur eal lmachi ner yisproper lyguar ded
 Super vi
sor sshoul d:trainempl oy eesonspeci ficguar dr ul
esi nt heirar eas,ensur e
machi neguar dsr emai ni npl aceandar efuncti
onal ,andi mmedi atelycor r
ectmachi ne
guar ddef i
ci encies
 Empl oyeesshoul d:notr emov eguar dsunl essmachi nei slockedandt agged,r epor t
machi neguar d pr obl
emst o super visorsi mmedi ately,and notoper ateequi pment
unlessguar dsar ei nplace
1.1Ev olutionofModer nHeal th&Saf et yConcept sTr acingt hehistoricaldev elopmentof
heath&saf et yconcer nsandpr ogr ams

Ear
li
estCi
vi
li
zat
ion•Fami
l
ygr
oupsexpandedt
otr
ibes•Repr
esent
edcommoni
nter
est
s,
kinshi p•A pr act icalpr i
nci pl edev eloped:– t hegr eat estul timat egoodsf ort hegr eat est
number–t hus, aper sonwasnotasi mpor tantast het ribe, unlessofcour se, itwast hechi ef
AsTr ibesEv ol v ed•Successesofonet ribemeantt hedownf allofanot her•Saf et yconcer ns
cent eredar oundt het ri
be,andf orsel ecti ndi vi
dual s•Onl ywhenapr olifer ati
onofi njuriesor
i
llnessesaf f
lict edl ar geornot iceabl enumber sofi ndi vidual sdi dt het ri
beact
As Tr ibes Ev ol ved •The f irstact ionswer e pr obabl yagai nstdi sease ( gr eatpl agues)•
Acci dent swer e, fort hemostpar t,consi der edper sonal mat t
ers
FirstCont rolof“ Acci dent s”•Puni shi ngcount ermeasur es,notdi rectpr ev ent i
on•Hammur abi
(2100BC)or der edacompi lationofabodyofl awsf orBaby lon•Knownast heCodeof
Hammur abi ,t her ul eswer ecar vedi ncunei f orm, nowl ocat edi nPar is
CodeofHammur abiExampl es•I fshi ppi ngbyseaandf reightl ost , mustr ei mbur seowner•I f
shi psankbutwasr e- fl
oat ed,hal fpr i
cer eimbur sement•I fcausedbyacol l
ision,deci sionof
blamewasbasedonwhowasanchor edf irst
CodeofHammur abiExampl es•I fasl av ewer ei njured( byot hert hant hemast er )mustpay
mast er•I fanoxgor esaman,t heacti sonl ycompensi blei ft heoxwasknownt obemean
Primar yMot ivat ionofBaby loni ans•Redr essf ordamages•I fpr ev ent i
onwasi ntended, itwas
onl yanout comeoft hepuni shi ngi ndemni ficat i
onschedul es
focusi ng on Occupat ionalHazar ds •I n anci entt imes,mostoft he manuall aborwas
per formedbysl av es•Sl aveswer econsi der edt obev aluabl ecapi talasset s•Pl i
neyt heEl der
(AD23- 79)wr ot eoft hedi seasesofsl av es
Focusi ng on Occupat ionalHazar ds •Ber nardo Ramazzi ni( 1600’ s)descr ibed di seases
associ atedwi t hv ar iousoccupat ions•Engl ishLaborRegul ations–excessesofappr ent ice
syst em ( chi l
dr enandsubsequent l
ywomen)– l imi t
sf ormi ni ng oper at ions( no chi l
dr en,
women)–f act or yr egul at i
onsf ormachi neguar di ng
TheI ndemni ficat ion/ Enf orcementAppr oach•Adv entofWor ker ’
sCompensat i
on•Mast er
-
ser vantr el ationshi pwashi st orical lycl ose•Mast erconcepthassi ncegr owni nto,per haps,a
cor por ation•I nj ur edwor kessoughtpr otect ion, i
ndemni fication, redr ess
Wor ker ’
sCompensat ion•Thr eei roncl addef enses: –cont ri
but or ynegl igence–assumpt ionof
ri
sk–f ellowser vantr ule
Wor ker ’
sCompensat ion•Nof aulti nsur ancesy st em dev eloped•Theonl ypr oofneededwas
thatt hei njur yoccur r edont hej ob•I ngener al,medi calbi ll
scov ered,andapor ti
onofsal ary
prov ided•Ev ent scat egor i
zedast empor aryorper manent ,partial ort otal.
Wor ker ’
sCompensat ion •Casual tyi nsur ancecar r i
er smot ivat ed t o keep acci dent st oa
mi nimum •I nsur ancecompani esi ni tat edsaf etyi nspect i
onser vices•whataboutt hisshi ftof
attent i
onandper hapsl iabili
ty )f rom empl oy ert oi nsur ancecompany ?
Exper i
enceRat ingSy st em •Pr obl em ov er comebyuseofexper i
encer at i
ngsy stem,whi ch
affect edr ates•( whataboutdi sincent iv et or epor t? )•Needf oruni for mi tyi nr epor ti
ngar ose•
In1937, theANSIZ16. 1met hodf orcompi li
ngwor ki njurydat a, wasdev el oped
Ot herNot abl eEv ent s•Publ icsaf etyconcer nsandpr oductl i
abi l
i
tyl aws•Adv entofOSHA,
1970•Env ir
onment alconcer ns•Ev olut ionofspeci alties–i ndust ri
alhy giene,heal thphy sics,
biosaf et y•Ot herr egul at i
ons, gui del ines, st andar dsofcar e
AgeofSel ect edSaf et y-
Rel at edOr gani zat ions( andpar allelcer tifi
cat ions) (CBSP)Rev i
ew•The
conceptofsaf etyev olvedf rom apopul at ion-based,ort r
ibal ,appr oach•Thef irstsaf ety
cont rolswer epuni shi ngcount er measur es•I ndemni ficat ionappr oachev olvedi ntowor ker ’
s
compensat i
onsy st em •Themast er -ser v antr elationshi phaschangeddr amat i
cal l
y
1.2Fi r
eHazar d
FIREORCOMBUSTI ON
Combust ionmaybedef inedasachemi calr eact i
onaccompani edbyt heemi ssi onofl i
ghtand
heat Thr ee f act ors ar e essent i
alf or combust i
on namel y Temper atur e,Oxy gen and
Combust iblemat erials
Spont aneouscombust ion and non expl osi on pr oofelect ricalequi pmenti sthepot ential
i
gnitionsour ce.Fi r
eoccuri nindust r
yismor ef r
equent l
yt hanexpl osionsandt oxicrelease,
alt
hought heconsequencesi nt er msofl ossofl ifearegener all
yl ess.Ther eforef i
remi ghtbe
l
esshazar dous.Fi r
ecant akesev eraldiff
er entf ormsi ncludi ngBoi l
ingl i
quidexpandi ngv apor
explosion, Pool firesandJetf ires.
Fir
esar ecommoni nt hehome,i nt heshop,bar n,orsi lo,andar oundf ar m machi ner yand
automot i
vev ehicles.Gr easecancat chf ir
ei ntheki t
chenorshop.Fl ammabl emat er i
alscan
beigni tedwhenwel dingormet alcut ti
ngi sdonenear by.Dustandcr opdebr iscanbei gnited
i
noronmachi nery .
Spont aneouscombust ioncanoccuri nst oreddamphay ,wi thi mpr operlyst oredsilage,ori n
pil
esofoi lyrags.El ect ri
cci rcuitscanov erheatandcausef ires.
 Aut o-
ignition:Thesi tuationwher ef l
ammabl emat erialsst orednearanopenf l
ameor
wher eheatcanbui ldupr esul tsinaf ir eri
sk.
 Combust ible: Thecapaci tyt obebur nedmakesamat er i
al combust ible.
 Fl ammabl e/ Nonf lammabl e:These t erms ar e used i nter changeabl y wi tht he term
“combust ible.”
 Fl ashPoi nt :A poi ntatr oom t emper aturewher easol ventwi llpr oducev aporsi n
enoughconcent rationt oi gnitewhenbr oughtnearasour ceofheat .
 Spont aneousCombust i
on:Thephenomenoni nwhi chamat erialunexpect edlybur sts
i
nt oflameswi thoutappar entcause.
 Vapor s:Vapor sar ethegasf orm ofsubst ancest hatar enor mal lyint hesol i
dorl i
quid
form.
 Vol atil
ity:Thet endencyofal iquidt ov apor i
zeorev apor atei ntot heai r
.Gasol i
nei s
volati
le.

TheFi reTr iangle:Threet hingsar enecessar yf oraf ir

et ostartandtocont inuet oburn.They
are:fuel ,heat ,andair.Fuel scanbeav arietyofmat eri
als.Heatsour cescanbeel ectr
ical
,
openf lame,spar ks,andchemi calr eacti
ons.Oxy geni spar tofthechemi str
yt hatsupportsa
fi
re.Wi thoutanyoneoft hesef actors,afirecannotexi st .
TypesofFi re:Firesarecl assi f
iedaccor dingt othef uelt hatburns.Alett
erdesi gnati
onsy stem
i
sused.Cat egori
esoff ir
ecommont oagr icult
ureandr uralresi
dencesar eCl assA,B,andC.
ClassAf i
res–or i
ginatedf rom or dinarycombust iblemat eri
als(eg:Paper,wood,t exti
lesand
rubbish), ClassBf ir
es-ori
gi natedf rom li
quid( eg:oil
s, gr eases,fl
ammabl el i
quidsetc).ClassC
fi
res–or i
ginatedfrom elect ri
cal equipment s
FIRESAFETY:
Fi resaf etyisasubj ectconnect ednotonl ywi thhumanandpr oper t
ysaf etybuti s
rel
atedwi thdesi gnofbui l
dingsandt heirser vi
ces.Fi real t
houghagoodf riendofhumani ty
,
wheni tspr eadsun-cont rolled,inbui l
dingscanbev iciousenemyr esult
ingi nheav ylossof
proper t
yandl ives.
Indust r
ialFi reSaf etyi st hesetofpr acticesi ntendedt or educet hedest r
uct i
oncaused
byf i
re.•I ndust rialFi r eSaf et ymeasur esi ncludet hoset hatar ei ntendedt oprev entignitionof
anuncont rol l
edf ire,andt hoset hatar eusedt ol imitt hedev elopmentandef fectsofaf i
re
afteritstar ts.
CommonCausesForFi reHazar dsI nI ndust ries
•Elect ri
calsy stemst hatar eov erloaded, resul t
ingi nhotwi ri
ngorconnect ions,orf ailed
component s
•Combust i
bl est or agear easwi thi nsufficientpr otect i
on
•Combust i
bl esnearequi pmentt hatgener atesheat ,flame, orspar ks
•Candl esandot heropenf lames
•Smoki ng( Ci gar et tes, cigar s, pipes, li
ght ers, etc.)
•Equi pmentt hatgener atesheatandut i
lizescombust iblemat eri
als
FIREPREVENTI ON
Amaj orit
yoff irescanbepr event ed.Remembert hesci enceoft hef i
retriangle?Fuel ,air,and
heatmustr eactt oget herf oraf i
ret oexi st.Wi thoutanyoneoft hesef actors,af irei snot
possible.Af irepr ev ent ionpr ogr am canbebui l
tar oundknowl edgeoft hef i
retriangle.Sev er al
steps wi l
ll ead t o a sound f ire pr event i
on pr ogr am.Wor k-sit
e anal ysis,mai ntenance,
housekeepi ng,andf irepr ev entionandcont rolt rainingar epr ov enmet hodsofr educingt he
ri
skoff ir
e.Eachoft hesei temsi sdi scussed.
 Wor k-site Anal y sis:Fi re hazar ds shoul d be sur v eyed ateach f arm.Combust i
ble
mat er ialsshoul dbei dent ifi
edandst or edpr oper ly.Fi r
eext inguishersmustbeeasi ly
l
ocat edandr eadi lyav ailabl e.Fi reext ingui sher sshoul dbepr of essionallyinspect ed
and/ orr echar gedonanannual basi s.
 Mai nt enanceandHousekeepi ng:Equi pmentandf aci li
ti
esmustbemai ntainedandi n
wor ki ngor der .Regul armai nt enanceschedul esshoul dbef oll
owed.Forexampl e,wor n
bear ingsonamot orshaf tcanov erheatandi gnit enear byf l
ammabl emat erials.A
regul arl ubr icat ionschedul ecanr educet hatcauseoff ire.Goodhousekeepi nghel ps
prev entf i
res.Cl eanupoi l-soakedr agst or educet her iskofspar ksi gniti
ngt hecl oths.
 Fi rePr ev ent ionandCont rolTr aining:Ev er yonewor kingont hef arm mustbeapar tner
i
nt hepr ev ent ionandcont roloff i
res.Al lempl oy eesshoul dhav eaj obdescr iption
whi chi ncl udes:
• Regul arf irehazar di nspect i
on
• Tr ainingi nf ir
eext ingui sheruse
• Goodhousekeepi ngpr ocedur es

WaterType Dr yPowderType CO2Ty pe

Eachpersonisresponsi
blet
obeknowl edgeabl
einfi
reprev
enti
onandcontr
olpr
ocedur
es.To
corr
ect
lyselectt
heproperfi
reext
ingui
shertouseinaspeci
fi
cfir
esi
tuat
ion
Fi
reExt inguisher s
Fi
reext i
ngui sher sar ei dent ifi
edbyapi ctorialattachedt ot heext ingui sherbodyshowi ngthe
ty
peoff i
ref orwhi cht heyshoul dbeused.
 Wat ert ypeext inguisher scont ainwat erunderpr essur e.Uset hem f orClassAf i
resonl y.
Wat erspr eadsgr easef i
resandconduct sel ect ricit
y .Wat erputonanel ect ri
calf i
rewi l
l
conductt heel ectr
icalchar gebackt ot heuser .Elect rocut i
onwi l
lresul t.Thewat er
cool st hef iret oext inguishi t.Wat ert ypeext i
ngui sher sar emadeofst ainlessst eel,
hav eapr essur egauge, andl onghose.
 Chemi cal extinguisher scont ainadr ychemi calpowder .Theycanbeusedoncl assA, B,
andCf ires.Thedr ychemi calsuf focat est hef ir
ebyel imi nat i
ngt heai r
.Asmal lamount
ofmat er ialcanext inguishanequi pmentormot orf irequi ckl y
.Thedr ychemi caldoes
l
eav ear esiduet ocl eanup.The10- pound,dr ychemi calext ingui sherisr ecommended
foruse.
 Thedr ychemi calpowderext inguisheri si dent if
iedbyi t sshor t,thick,r ed-colored
cont ainerwi thabr ightmet alnozzl enextt ot hepr essur egauge.Anot herchemi cal
ext i
ngui sheri st he Hal on ext inguisher .These ext i
ngui sher s cont ain a gas t hat
i
nt errupt st hechemi calreact i
ont hatt akespl acewhenf uel sbur n.Theset ypesof
ext i
ngui sher sar eoftenusedt opr otectv aluabl eel ect ricalequi pmentsi ncet heyl eav e
nor esiduet ocl eanup.
 Car bondi oxi deext ingui sher scont ai nCO2( car bondi oxide)gas.Thi sext inguishercan
beusedonsmal lclassBandCf i
res.I tleav esnor esi due.Thepr essur izedCO2gas
cont actst heai randf ormsdr yi ce.Thef i
rei scool edbyt hedr yice.Ther ear elimitst o
theCO2ext ingui sher ’
suse.Lar gerf ir
eswi llr equi reagr eat ercapaci tyforcont rolthan
whatt hisext inguishercanpr ovide.Al so,t hedr yi cei ssocol dt hati tcanbur nt heski n
i
faper sont ouchest hedr yice.CO2ext ingui sher sar ei dent i
f i
edbyar edcont ainerwi th
al argerbl ackf unnel -shapednozzl ewhi chcanpi v otneart hepr essur egaugear ea.
UsingaFi reExt ingui sherTouseapor tablef i
reext ingui sher ,f ollow t hest epscal l
edPASS.
Thestepsi nclude:
•Pullt
hepi n
•Aim att hebaseoft hef i
re
•Squeezet het rigger
•Sweepf rom si det osi de

.
Remembert heacronym-PASS!I mport
antnot e:Alwaysai m att hebaseoft hefir
e.Thisi s
i
mpor t
antfort woreasons.Fir
st,asmal lfireextinguisherhasl i
mi t
edmat erial
.Itwillbe
wastedaimingabovet hefl
ame.Secondl y,thefir
eext inguishermaterialwil
lform abar r
ier
abovethefi
re.Thefl
amescanr ollupunderthebarriertowardy ou
FirePrepar
ednessBeingpreparedtocontrolafir
eisdif f
erentthanpreventi
onoff i
rehazards.
Ther ear eanumberofst epst otaket obepr eparedf oraf ireemer gency .Consi derst arti
ng
thesepr act icesiny ourhomeorpl aceofempl oyment .
•All f
ami lymember s/employeesshoul dbet r
ainedi nf i
repr eventi
onandcont rolmeasur es.
•Localf ir
ecompanyphonenumber sshoul dbeaccessi blet oallper sonsi nvolvedwi t
ht he
farm.Cel l phonesmaybet hebestf orm ofcommuni cat ionifphonel i
nesar ebur nedbyf i
re.
•Wr it
tendi recti
onst othehomeorf arm shoul dbest oredneareachphone.I napani c, people
commonl yf orgett hesimplestofdi rect i
onsorcannotst atet hem clearl
y .
•Prov idet hel ocalf i
recompanywi thadet ail
edmapoft hef armi ncludi ngpest i
cidest orage
areas,f erti
lizerst orageareas,manur epi t
sandl agoons,andcl eanwat erpondsour ces.The
fi
recompanycoul dhav etheseonf i
le, ortheycoul dbeav ail
ableinaweat her proofboxatt he
farml ane.
•Inst allsmokeal armsandcar bon-monoxi dedet ect ors.Testt hebat teriesr egularlyand
replacet hem asneeded.
•Schedul er egularf i
retrai
ningandf iredril
lswi ththef ami l
yandwi ththeempl oyees.
•Suppl yt hecor rectf i
reext inguisher sonal ltractor s.Bei ngpr epar edf oraf ir
ei sgood
i
nsur ancet hatal lpersonsinv olvedwi llreactinaf ocusedandsaf e.Bei ngpr eparedtocont rol
afireismanner
1.
3Mechani
calhazar
ds
Mechani calhazar dsarethoseassoci atedwi t
hpowerdr i
v enmachi nes,whet heraut omat edor
manual lyoper ated.Concer nsaboutsuchhazar dsdat ebackt otheI ndustri
alRev olut
ionand
theear l
iestday sofmechani zation.
•Fail
ur etopr ovidepropermachi neguar dsandenf or cetheirusecanbecost lyforcompani es
–Mechani calhazar dst hatar enotpr operlyguardedar ei mplicat
edi nthousandsofwor kplace
i
njuri
esev eryy ear .
– Smal lgai nsi n product i
vityobt ained bywi l
lfull
yby passing mechani calsaf eguar dson
machi nescancostcompani eshugef ines&medi cal bi
ll
s.
COMMONMECHANI CALI NJURI ES
Inindust ri
alset tings,peopl ei nteractwi thmachi nesdesi gnedt odr i
ll
,cut,shear ,punch,chi p,
staple,stitch,abr ade,shape, stamp, andsl i
t.I
fwor kersfailtofoll
owsaf etypr ecautions, t
hese
procedur escanhappent ohumans, i
nsteadofwor kpieces.
Mechani calhazar dsarecr eatedasar esultofeitherpower edormanual( human)useoft ools,
equipmentormachi neryandpl ant.Anexampl eofamechani calhazardi s:cont actand/ or
entanglementwi thunguar dedmov i
ngpar t sonamachi ne.Someoft heinjuriesthatcanoccur
asar esul tofmechani calhazar dsar easf oll
ows:

St
rai
ns/Sprai
ns,
Cuts,
Shear
ingI
njur
ies
Astr
ainresul
tswhenmuscl
esareov er
str
etchedort
orn,
aspr
ainr
esul
tsf
rom t
ornl
i
gament
s
i
naj oint.Strainsandspr ainscancauseswel li
ngandi ntensepain.Acutoccur swhenabody
partcomesi ncont actwi thashar pedge.Ser iousnessofcut tingort earingdependson
damagedonet oskin,v eins,ar teri
es,muscl es,andev enbones.Power -dri
venshear sfor
sev eri
ngpaper ,metal,pl ast i
c,el astomer s& composi tesar ewidelyused.Suchmachi nes
oftenamput atedf i
nger s&handswhenoper at
or sr eachedundert heshear i
ngbl ade,and
activatedt hebl adebef oref ull
yr emov i
ngtheirhand.
CrushingI njuries
Crushi ng injuriesoccurwhenapar toft hebodyi scaughtbet weenhar dsur f
acest hat
progressi vel
ymov et oget her —cr ushingany thingbet weent hem.•Twocat egori
es:squeeze-
pointty pes&r un-i
npoi nts.
–Squeeze- pointhazar dsexi stwhent wohar dsur faces,atl eastoneoft hem mov ing,push
cl
oseenought ogethert ocr ushobj ectsbetweent hem.
– Run- inpoi nthazar dsexi stwher et woobj ects,atl eastoneofwhi chi srotat
ing,come
progressi vel
ycl osertoget her .
•Bodypar tscanal sobecr ushedi not herway s.
–Aheav yobj ectfall
ingonaf oot; Ahammerhi tt
ingaf inger.CrushingInjuriesMeshi nggears
andbel tpull
ey sareexampl esofr un-i
npointhazar ds.

Br eaking
Machi nes used t o def orm engi neeri
ng mat eri
als in a v ariety of way s can al so
fracture—br eak—bones.A si mpl ef r
acturei s a br eak thatdoes notpi erce the ski n.A
compoundf ract
urei sabr eakt hathasbr okent hrought hesur roundi ngtissueandski n.A
compl et
ef racturedi v
idest heaf fectedbonei ntotwoormor esepar atepieces.Ani ncompl ete
fracturel eav est heaf fectedbonei nonepi ecebutcr acked.At ransv ersefractur
ei sabr eak
straightacr ossthebone.Anobl iquef r
acturei sdiagonal.Acommi nutedf r
actureexi stswhen
thebonei sbr okeni ntoanumberofsmal lpiecesatt hepoi ntoffract ur
e.
Punct uring
Punct uringr esultswhenanobj ectpenet ratesst rai
ghti ntothebodyandpul lsstraightout.
Cr eati
ngawoundi ntheshapeoft hepenet ratingobject.
•Thegr eat esthazar di spot enti
al f
ordamaget ointernalorgans.
SAFEGUARDI NGDEFI NED
TheNat ionalSaf etyCounci l(NSC)def inessaf eguarding as Machi nesaf eguarding ist o
mi nimizet her i
skofacci dentsofmachi ne- operatorcont act
.Saf eguardscanbebr oadly
cat egori
zedas
TYPESOFSAFEGUARDI NG
Pointofoper ati
onguar ds
Feeding/ej ectionmet hod
POINT- OF-OPERATI ONGUARDS
Poi ntofoper at
ioni sthear eaonamachi newher ewor kisact uall
yper formedupont he
materialbei ngpr ocessed. Thepoi ntofoper ationofmachi neswhoseoper at i
onexposesan
employ eet oi njury ,shal lbeguar ded.Theguar dingdev i
ceshal lbeinconf ormitywi thany
appropriatest andar dsther ef or
,or ,intheabsenceofappl icabl especi f
icst andar ds,shal lbe
sodesi gnedandconst ructedast opr eventt heoper atorf r
om hav i
nganypar tofhi sbodyi n
thedangerzonedur i
ngt heoper ati
ngcy cle.Speci alhandt ool sforpl acingandr emov i
ng
materialshal lbesuchast oper mi teasyhandl i
ngofmat erialwi t
houttheoper atorpl acinga
handint hedangerzone.Sucht oolsshal lnotbei nl ieuofot herguar dingr equiredbyt hi
s
sect
ion, butcanonl ybeusedt osuppl ementpr otectionpr ov i
ded.
Theyguar dagai nstmor et hanonehazar d.
 Fi xedguar dsar esui t
ablef ormanyspeci fi
cappl i
cations,canbeconst ructedi n-plant,
requirel i
ttlemai nt enance&sui tablef orhi gh-product ion, repetit
iveoper ati
ons.
 Di sadv ant agescani ncl
udel imitedv isibil
ity,li
mi tati
ont ospeci fi
coper ations&i nhibiti
ng
nor mal cleani ngandmai ntenance
 I nterl
ockedguar dsshutdownt hemachi nei fnotsecur el
yi npl ace,ori ft heyar e
disengaged.–Al lowssaf eaccesst or emov ej amsort oconductr outinemai ntenance
wi t
hout t aking of ft he guar d. These guar ds r equi re caref uladj ustment and
mai ntenanceand, insomecases, canbeeasi lydi sengaged
 Adj ustabl eguar dspr ov i
deabar ri
eragai nstav ari
etyofhazar dst hatar eassoci ated
wi t
hdi fferentpr oduct ionoper ations.–Adv antagei sf l
exi bil
i
ty.Theydonotpr ovideas
dependabl eabar rierasot herguar dsdo,andr equiref requentmai ntenance&car eful
adjustment .

FEEDI NGANDEJECTI ONMETHODS

Manyf eedingandej ectionmet hodsdonotr equir
et heoper atort opl acehisorherhandsi n
thedangerar ea.Insomecases, nooper at
orinv ol
vementi snecessar yaf t
erthemachi neisset
up.Inot hersituat i
ons, oper atorscanmanual l
yf eedt hest ockwi t
ht heassi st
anceofaf eeding
mechani sm.Pr oper l
ydesi gnedej ecti
onmet hodsdonotr equireanyoper atorinvolv
ement
afterthemachi nest artst of unct i
on.
Usingt hesef eedingandej ectionmet hodsdoesnotel i
mi natet heneedf orguardsanddev ices.
Guar dsanddev icesmustbeusedwher evertheyar enecessar yandpossi bleinorderto
prov i
depr otecti
onf rom exposur et ohazar ds.
Typesoff eedingandej ecti
onmet hods:
 Au tomat icFeed
 s tocki sf edf rom r oll
s, i
ndexedbymachi nemechani sm, etc.
 e liminat est heneedf oroper atorinvolvementi nt hedangerar ea
 o therguar dsar erequi r
edf oroperatorpr otection, usuall
yf i
xedbar r
ierguards
 r equiresf requentmai ntenance
 ma ynotbeadapt ablet ostockv ari
ati
on
  Semiaut
omat i
cFeed
 s tockisfedbychut es,movabledi
es,dial
f eed,pl
unger
s,orsli
dingbol
ster
 Aut
omat i
cEjecti
on
 wo r
kpiecesar eejectedbyai
rormechani calmeans
 ma ycreateahazar dofblowi
ngchipsordebr is
 s i
zeofst ocklimit
st heuseofthi
smet hod
 a i
rejecti
onmaypr esentanoisehazard
 Semiaut
omat i
cEj ect
ion
 wo r
kpiecesar eejectedbymechanicalmeanswhi chareini
ti
atedbythe
oper ator
 o per atordoesnothav et oenterdangerar eat or emov efini
shedwor k
 o therguar dsarerequiredf oroperatorprotecti
on
 ma ynotbeadapt abl
et ost ockvariati
on
CONTROLOFHAZARDOUSENERGY•OSHA i sof t
enr efer redtoast he“ l
ockout/tagout”
st
andard.•Topr ot ectpeopl efrom hazar dousener gywhi leper f
ormingser v
ice/maintenance
onmachines,tools, andequi pment.Lockout /TagoutLanguage
 Lockout-Pl acingal ockoutdev i
ceonanener gy -
isolatingdev i
cetopr eventaccidental
orinadvertent( carel
ess)energizingofamachi nedur i
ngser vi
cing.
 Lockoutdev ice-Anydev i
cet hatusesaposi ti
vemeanst okeepanener gy-i
solati
on
deviceinthesaf epositi
ont opr eventaccidental/
inadv ertentenergi
zing

 Tagout-Pl aci ngat agonanener gy-i

sol ationdev icet owar npeopl esot hattheydonot
accidentall
yori nadv ertent l
yener gizeapi eceofequi pment .
 Tagoutdev ice-Anypr omi nentwar ni ngdev icet hatcanbeaf fixedt o anener gy-
i
sol ati
ondev icetopr eventt heacci dent al ener gizingofamachi ne
Remov alofl ocksort ags-Bef oreremov al:•I nspectwor kar eatoensur enonessent ialitems
arer emov ed&t hemachi nei scapabl eofoper atingpr oper ly.•Not i
fyaf f
ect edempl oy ees
i
mmedi atelyaft
err emov ingt heener gycont roldev i
cesandbef oreener gi zingt hemachi ne.•
Ensur et hatenergycont rol dev i
cesar er emov edbyt hei ndiv i
dual whoaf f
ixedt hem.
GENERAL PRECAUTI ONS – Al loper at ors shoul d be t rained int he saf e oper ati
on and
mai ntenanceoft hei rmachi nes.– Al lmachi neoper atorsshoul dbet rainedi nemer gency
procedur estot akewhenacci dentsoccur .– Al lempl oy eesshoul dknow how t oact ivate
emer gencyshut downcont rols.•Knowi ngwher et hecont rolsar eandhowt oact i
vatet hem.–
Inspect i
on, maintenance, adj ust ment, r
epai r&cal i
brat i
onofsaf eguar dsshoul dbecar riedout
regularly.–Super v i
sor sshoul densur et hatsaf eguar dsar epr operlyinpl acewhenmachi nes
arei n use.– Empl oy ees who di sabl e orr emov e saf eguards shoul d be di sciplined
appr opriatel
y.Oper atort eams oft he same sy stem shoul d be t r
ained i n coor dinat i
on
techniques, andpr operuseofdev icest hatpr ev entpr emat ureact ivationbyat eam member .–
Oper atorsshoul dbet rained/ super v
isedt odr esspr oper l
y.•Nol onghai r,loosecl othi ng,
neckt i
es,r i
ngs,wat ches,et c.–Shor tcutst hatv iolatesaf et ypr i
nciples&pr acticesshoul dbe
avoi
ded.–Pr essur
esofdeadlinesshoul
dnev erbethecauseofunsaf eworkpracti
ces.–
Employeeswhowor karoundmachines—butdonotoper atethem—shoul
dbemadeawar eof
emergencypr ocedurestotakewhenanacci dentoccurs.•Whatshouldbedonewhena
mechanicalhazardisobserv
ed?–Theonl yacceptabl
eansweri si
mmediatecor
rect
iveacti
on,
andspecifi
cact i
ondependsontheprobl
em.

1.
4BOI
LERSANDPRESSUREVESSELS
CommonHazar dsandCausesExpl osion:Humaner ror,suchasl ackoft raining,f ailuret o
follow saf eoper ating pr ocedur es,et c.Fai lureofpr otectivesaf etyorcont roldev icesor
Insuf ficientori nf requenti nspect ionof fersboi lerandpr essur ev esselhazar dsi ni ndust ry.It
canbemoni tor edbyusi ngst andar dcodesi .eASMEandNBI C[ CodesAmer i
canSoci etyof
Mechani calEngi neer s( ASME) Code –Pr ov ide gui delines f or desi gn,f abricat ion,and
i
nst al l
ation and Nat i
onalBoar d ofBoi l
erand Pr essure VesselI nspect ors( NBI C)Code
–Pr ov ider ulesandgui dancef ori nspect ion]
Def ini t
ionsBoi ler :Acl osedv esselinwhi chwat eri sheat edbycombust ionoff uelsorheat
from ot hersour ces. Theheatf orms–St eam –Hotwat er,or–Hi gh- temper aturewat er( HTW) .
High- temper atur ewat er:Wat erkepti ncl osedsy stemsunderahi ghpr essur esot hati t
remai nsal i
qui dr athert hant ur ni
ngi ntost eam.
Pressur epar ts:Anycomponentofav essel ,boi l
er ,orwat erheat ert hatr et ainsst eam,hot
wat er ,orot herf luidsunderpr essur e.
Ty pesofBoi lers:
Elect ricBoi ler s:Apowerboi l
er ,heat i
ngboi ler,highorl owt emper at ur
ewat erboi leri nwhi ch
thesour ceofheati sel ect ricity .
HighTemper atur eWat erBoi l
er :Awat erboi leri ntendedf oroper ati
onsatpr essur esi nexcess
of160psi gort emper aturesi nexcessof250degr eesF.
HotWat erHeat ingBoi l
er:Aboi lerinwhi chnost eam i sgener ated,f rom whi chhotwat eri s
circul atedf orheat ingpur posesandt henr etur nedt ot heboi ler,andwhi choper at esata
pressur enotexceedi ng160psi gorat emper atur eof250degr eesFatt heboi l
erout l
et .
ProcessSt eam Gener ator:Av esselorsy stem ofv essel scompr isedofoneormor edr ums
andoneormor eheatexchangesur facesasusedi nwast eheatorheatr ecov eryt ypest eam
boi l
er s.
Unf iredSt eam Boi ler :Av esselorsy stem ofv essel si ntendedf oroper ationatapr essur ei n
excessof15psi gf ort hepur poseofpr oduci ngandcont rolli
nganout putoft hermal ener gy.
Wat erHeat erSuppl yBoi ler:Acl osedv esseli nwhi chwat erisheat edbycombust i
onoff uels,
elect rici
tyoranyot hersour ceandwi t
hdr awnf oruseext ernalt othesy stem atpr essur enot
exceedi ng160psi gandshoul dincludeal lcont r
ol sanddev i
cesnecessar yt opr ev entwat er
temper atur esf rom exceedi ng210degr eesF.
Safet yHazar dsBLEVE:boi li
ngl iqui dexpandi ngv aporexpl osi onThi si sat y peofexpl osi on
thatcanoccurwhenav esselcont ai ningapr essur i
zedl i
qui di sr upt ur ed.Suchexpl osi onscan
beext remel yhazar dous.ABLEVEr esul tsf r
om t her upt ur eofav esselcont ainingal i
qui d
subst ant i
al lyabov ei tsat mospher i
cboi lingpoi nt .Thesubst ancei sst or edpar tl
yi nliqui df or m,
withagaseousv aporabov et hel iqui df ill
ingt her emai nderoft hecont ainer.Pr ev ent ion
Measur esf orBoi lerFi resFul l
yencl osedboi l
err oomsLar gedooropeni ngsonboi lerr ooms
Noncombust i
bl ecei lingandaut omat icspr inkl ersPr opercl ear ancear oundext er i
orwal ls.
How t oMi nimi zeFi resandExpl osi onsEst ablisht est ingandser v icingpr ogr am.Al way st est
safet yandr eliefv alv esunderpr essur e.Hav er epai rsmadei mmedi at el
y.Checkandser vice
theboi leri nandoutofheat ingseason.Keepaboi lerlog
Desi gnandConst ruct i
onCont rol sandi nst rument ation—moni torandcont r ol combust ionand
steam pr oduct ionEconomi zer s—t ransf erheatf rom f luegast oi ncomi ngf eedwat erSuper
heat ers—i ncr ease t emper at ure ofst eam Ai rr epeat ers—t ransf erheatf rom f lue gas t o
i
ncomi ng ai r Chi mney s—di schar ge pr oduct s of combust i
ons Ash- di sposal
equipment —r emov eashpr oduced.Wat ert reat ment —r emov edi ssol vedO2andCO2, cont r ol
pHBl owdownpi pesandv al ves—r emov esl udgeandi mpur iti
esi nboi lerwat erSaf etyv alv es
and f usi blepl ugs—saf eoper at ion,r el i
ev eexcesspr essur eorv acuum condi ti
onsSt eam
pressur eandwat er-leveli ndi cat or s/ cont rols—moni torsaf eandpr operoper at i
onGoodpi pi ng
pract i
ce—mi nimi ze mai nt enance wor kand easyt or each Pl aci ng boi ler si n and outof
service—manuf act ur er’
sr ecommendat i
ons.AnnualI nspect ion,Cl eani ng and Mai nt enance
Cleanboi ler spr ompt ly.Fol l
ow cor rectgui del ines.Schedul emai nt enancegui del i
nes.Fol low
gener al pr ecaut ionsf orent rance.Wearpr operat tirewhenent er ing.
 Ext er nalI nspect i
on: Ascompl et eanexami nationascanber easonabl ymadeoft he
ext er nal sur facesandsaf et ydev iceswhi l
et heboi lerorpr essur ev essel isinoper ation.
 I nt ernalI nspect ion:Ascompl et eanexami nat ionascanber easonabl ymadeoft he
inter nalandext er nalsur facesofaboi lerorpr essur ev esselwhi l
ei ti sshutdownand
whi le manhol e pl ates,handhol e pl at es orot heri nspect ion openi ng cl osur es ar e
remov edasr equi redbyt hei nspect or.
 CommonBoi l
erHazar dsEx pl osi onhazar ds: Firehazar ds—l eakageoff uel orgas.
Safet yAppl i
ancesI nclude,butnotbel i
mi tedt o:Rupt uredi skdev i
ceSaf etyr eliefv alve
Temper atur el imi tcont rolPr essur el imi tcont rolMaj orgast raincont rolsLow wat ercut off s
Flamesuper v i
sor yuni t( i
gni ter )Hi ghandl owgaspr essur eswi tchesTr i
alf ori gnit
ionl imi ting
timer( 15seconds)
 Rel iefVal ve:Anaut omat icpr essur e-reliev ingdev i
ceact uat edbyast aticpr essur e
upst ream oft hev alvewhi chopensf urt herwi tht hei ncr easei npr essur eov ert he
openi ngpr essur e. Itisusedpr imar i
lyf orl i
qui dser vice.
 Rupt ureDi skDev ice:A nonr ecl osi ngpr essur e- r
eliefdev iceact uat edbyi nl etst at ic
pr essur eanddesi gnedt of unct ionbyt hebur stingofapr essur e-cont aini ngdi sk.
 Saf et yRel iefVal v e:Anaut omat i
c,pr essur e-act uat edr el i
ev ingdev icesui t
abl ef oruse
asasaf et yorr eliefv al ve, dependi ngonappl icat ion.
 Temper atur e/ pressur eRel iefVal ve:Av al
v esett or eliev eatadesi gnat edt emper at ure
andpr essur e.
 CommonFai luresOfPr essur eVessel s:Er rori ndesi gnandconst ructionI mpr oper
oper at ionCor r osionFai luret oi nspectpr oper lyandLackofpr ev entat ivemai nt enance
Fir
ePr ot ect ionKeepaboi lerl og:Pr ov idecl ear ancear oundboi lersLosscont rolst r ategi es
Boilerexpl osi onsandf iresTest ingpr ogr am Saf et yr eliefdev icesRepai rprogr am Pr ev ent ative
mai ntenancepr ogr am Keepaboi lerl og.Mostoft heboi l
erf ailuresar eduet oi nadequat e
maintenance
Boil
erMai ntenanceMostoft heboi l
erf ail
ur esar eduet oi nadequat emai nt enance.LowWat er
TestShoul dbet est edwi tht heboi leroper ati
ng,t hebur nershoul dshutof f
,i fi tdoesnoti t
shouldbei nv est igat ed.
 Hy dr ost at i
cTestAppl iedt oExi st i
ngVessel s:Todet ermi netight ness,t hehy drost atic
testpr essur eneedbenogr eat ert hant hesetpr essureoft hesaf et yv alvehav i
ngt he
l
owestset ting.Forsaf et yt est s, thepr essur eshoul dbeequalt o2t imest hemaxi mum
all
owabl ewor ki
ngpr essur e,l esscor rosionf act or,asappl icable.Al lmaj orr epairsand
alt
er at ionsshoul dr equi reasaf et ytest .
 Bl owof fEqui pment :Al lmat erial susedi nt hef abricati
onofobj ectbl owof fequi pment
shoul dcompl ywi t
hcode.Al lbl owof fequi pmentshoul dbeequi ppedwi thopeni ngst o
facilitat ecl eani ngandi nspect i
on.Openv alvesoneachl ow- waterf uelcut of fv alve, low
wat eral ar m,t estst heswi tchesandcl ear soutdebr isandobst ruct ions.Cl ear anceAl l
object sshoul dbesol ocat edt hatadequat espacei spr ovidedf ort hepr operoper ation,
i
nspect ion, andnecessar ymai nt enanceandr epai roftheboi l
erandi tscont r ols.
 Ai randVent ilati
on:Aper manentsour ceofout sideai rshoul dbepr ov i
dedf oreach
room t oper mi tsat i
sf act orycombust ionoff uelandv entil
ationi fnecessar yunder
nor maloper at i
ons.Themi nimum v ent i
lationf orcoal ,gas,oroi lbur ner si nr ooms
cont ai ningobj ectsisbasedont heBt u’sperhour ,
requiredai r,
andl ouv er edar ea.
 Boi ler Rooms Saf ety pr ecaut ions:f loor s—sl i
pper y and di rtyl i
ght i
ng—sour ce of
emer gencyl i
ght ing;cont rolsandgaugeswel ll i
t;sparef l
ashlight s;exi tswel llitand
i
dent ifiedexi ts—t woormor eexi ts( r
emot elyl ocat edf r
om eachot her );pr operexi tsf or
eachst or yt oaf ir
eescapeordi rect l
yout sideemer gencyshut downbut t onsatexi ts
stairs,l adder s and r unway s—pr operaccess t o oper ate and ser v i
ce boi lersaf ely.
Oper atorTr ai ning,Pr ocedur esandBoi l
erRoom Emer genci esOper at orer rori samaj or
cont ribut ingf act ori nboi l
eracci dent s.Oper atorsmustunder st andt hepr ocessand
hazar dswi t
ht hesy st em, includi ngt hepur poseandpr i
nciplesoft hecont r
olandsaf ety
dev icesi nstal l
ed.Pr ocedur esf orst ar t
-up,shut downandbasi ct roubl eshoot i
ngmust
bedev el opedwi thassi stancef rom t hemanuf actureroraqual ifiedper son.Emer gency
procedur e mustbe dev eloped f oroper ation.Tr ai
n mul ti
ple oper at or s as wel las
secur i
t yper sonnel pat rolli
ngpr emi sesandf acili
t y
.

PRESSUREVESSELS
Unfiredpr essur ev essels:ai rt anks,st eam- jacket edket tl
es,di gesters,v ul
cani zers,andot her
suchv essel s.
• Apr essur ev esselisav esselinwhi chpr essur eisobt ainedf rom anext er nalsour ce,or
byt heappl icat i
onofheatf r
om ani ndi rectordi rectsour ce.Vessel smaygases, vapor s,
andl iquidsatv ariouspr essuresandt emper atures.
• Fi r
edPr essur eVessel s
• Ext ernal heatsour ce
• Unf iredpr essur ev essel
• Noext ernal heatsour ce
Desi gnAndConst ructionOfPr essur eVessel s
ASME – Amer ican Soci et y ofMechani calEngi neersASME Boi l
erand Pr essur e Vessel
Coder ulesf ort hedesi gn, fabr i
cat i
on,andi nspect ionofboi l
er sandpr essurev essel s
NationalBoar dofBoi l
erandPr essureVesselI nspect or s
Composedofchi efboi l
erandpr essur ev esseli nspect orsr epresentingst at es,ci t
ies,and
prov i
ncesenf orci ng pr essur eequi pmentl awsand r egulations.NBI C CodeNat ionalBoar d
Inspect ion Code ( NBI C)i s a consensus documentSet s st andar ds fort he i nstal
lati
on,
i
nspect i
on, andr epai rand/ oral terati
onofboi lers,pressur ev essels, andpr essur er eli
efdev i
ce
Wor ker sTr ainingTr ai
noper atingper sonnel :tooper ateequi pmentpr oper l
yt omaker outine
safetycheckst ocal lqual ifi
edmai ntenanceper sonneli fnecessar yorappr opr iateNat i
onal
Boar dCer ti
ficat esofaut hor i
zat i
ont oper form speci fi
ct asksNBst amps.
CommonCausesofExpl osi onsi nPr essur eVessel s:Er rorsi ndesi gn,const ructi
on,and
i
nst all
at i
on I mpr operi nst al
lat i
on,human f ail
ure,and i nadequat et raini
ng ofoper ators
Corrosi on/ erosi onofconst r
uct ionmat eri
al sFai lureori ntent i
onaldef eatofsaf et ydev i
ces;
fail
ureorov errideofaut omat iccont roldev icesFai l
uret oinspectandt estthor oughl y,properly,
andf requent l
yI mpr operappl i
cationofequi pment ;ov erf i
ringLackofpl annedpr eventive
mai ntenance.

Unfi
redPr essur eVessel s:Theycanwi thst andi nternalpressur eorv acuum butdonothav e
thedi r
ectf ireofbur ningf uelorel ect ri
cheat ersimpi ngingagai nstthewal l
s.Heatmaybe
generat edbychemi calr eact ionswi thint hev esselorbyappl yingel ectr
icheat ,steam,hotoi l
,
orot herheat i
ngmedi um howev er.Unf iredPr essureVessel s( UPV)Vessel sdesi gnedto
containf luids underi nter nalpr essur e orv acuum and notheat ed directlyt hr
ough the
combust i
onoff uelsorot herext er nalheatsour ces.Foundi ncommer ci
alandi ndustri
al
faci
li
ties.Heatcanbegener at
edf rom chemi calreact i
onswi thinv esselorbyappl yinga
heati
ngmedi um wi t
hint hev esselorci r
cul ati
ngi tar oundt hev essel( j
acket )
.Exampl es:
compr essed ai rt anks,pr opanet anks,deaer atorsand condensat et anks,st eam-jacket
ed
kett
les, pulpmi l
ldigest ers,rubberv ulcani zers.
Hazar dsFl ammabl eandcombust ibl eliqui dsOv erpressurepr otect i
onf ai
lureCor rosi
on
 Cont rolProperdesi gn–Fol lowt heASMEcodeI nternalinspect i
on–Regul arinspecti
on
byqual if
iedper sons–Conf inedspaceent r
y:v esselent ryper mi t–Pr opercl eani
ng
Hydrostaticorpneumat ict est–Nor mal lyno mor et han 1. 5t i
mest he maxi mum
all
owabl ewor kingpr essureoft hev essel
 Cont rol Det ecting cr acks and measur i
ng t hickness –Radi ography –Ul t r
asoni
c
 exami nat ion –Li qui d dy e penet rantt est i
ng –Magnet i
c par ticlet esting –Lacquer
met hod–Hammert est
 Cont rolTr ainingandsuper vi
sion–Car eful l
ysel ectoper at ors–Thor ought rai ningof
saf eoper at ionandemer gencypr ocedur e–Empl oyacheckl istt oi nspectandmai nt ain
equi pment–Pr ovidecl osesuper visiononal loper ations
 Cont rolSaf etydev ices–Saf etyv alv es:shoul dbeASMEr atedandst amped–Rupt ure
disks: checkt hecondi tionatl eastonceay ear–Vacuum br eaker s: prot ectt hepr essur e
vesselagai nstbur stingf rom ov er pressur e–Wat erseal :adj ustt hedegr eeofpr essur e
–Vent s: reliev epr essur e
 High- Pr essur eSy st emsCommonhazar ds–Leak–Pul sat ion–Vi br ation–Ov er pr essur e
Cont rol –Makesur eal l element scl ean–Wor kf unct ional lywel l –Fr equenti nspect ion
 UPV—I nter nalI nspect ionI nternali nspect i
onPer i
odi ci nter nali nspect i
onst oev al uat e
i
nt egr ityofequi pment .I nspect i
onsshoul dbecar riedoutbyNBl icensedi nspect or st o
ensur ecompl iancewi thj urisdict i
onalori nsur ancer equi rement sUFP—VesselHi st ory
Document sI nspect i
onormai ntenancedepar tmentshoul dkeepf il
eorl ogofor i
gi nal
desi gndocument s,r ecor dsofi nspect ions,andv esselhi stor ydocument s.bl uepr ints
manuf act ur er ’
s dat ar epor t
s and i nst r
uct ions desi gn dat a,i ncl uding l ocat ion of
dimensi onalcheckpoi nt si nstallationi nformat i
onr ecor dsofpr ocesschangesv essel ’
s
histor icalpr of i
le,i ncl udi ng r ecor ds ofal lr epai rs and condi ti
ons f ound dur ing
i
nspect i
ons.
 UPV—Ent ryDev el
opsaf epol i
cyandpr ocedur ef orent eringt anksConf inedspacewi th
per mi tandl ockout /t agoutsaf etypr ocedur esr equi redbyOSHAPot entialhazar dsof
conf inedspaces:t oxi cmat eri
alsi ncl udi ngi ner tgasesf lammabl ev apor swhi chmaybe
i
gni tedi nsuf fici entoxy genheatorsmokef rom f ireinsi dev esseli nt r
oduct ionofhot
gasesorf luidsf r
om ext ernalsour cesst artupofagi t
at orsorput tingconf inedspacei n
mot ion.
 Priort oent ryint opr essur ev essel :Ensur ei tispr oper l
ydr ained, v ent i
lated, andcl eaned
Testat mospher ef oroxy gencont ent ,expl osiv eness,andt oxicl ev elsDi sconnectand
blankal lconnect ingpi pel ines,orcl ose,l ockout ,andt agv al vesont hel i
neAl lpower -
drivendev ices—di sconnect ed,l ockedout ,andt aggedConf ined- spaceper mi ti ssued
Prov i
deaccessf orsaf eent ryandexi tf r
om v esselUsesaf etyhar nessesandl ifelines
Putonpr operPPE
 UPV—Cl eani ngandPur gingCl eanandpur get hev essel ’
si nter nalsur facespr iort o
ent ry.Usespeci ficmet hodsbasedont hesubst ancecont ainedi nsidet hev essel .
For cedv ent i
lationi sr equi r
edt oensur eallpot ent iallyhar mf ulordanger ousgasesand
vapor s hav e been r emov ed.Testat mospher e pr iort o ent ryas wel las r out inely
throughoutwor kpr ocessesi nsideav essel .
 UPV—Test i
ngHy dr ost at ict estsCanbeusedf orv essel sconst r uct edwi thoutaccess
forani nt er nali nspect iont oensur et hev esseli sf i
tf orcont inuedser v i
ce.Tar get edf or
themaxi mum al lowabl ewor kingpr essur e,t hesetpr essur eoft hel owesti nst alled
saf etyv alv e,ort henor maloper at i
ngpr essur eoft heboi lerorpr essur ev esselat
discr et ionoft heaut hor i
zedi nspect or.Test ingshoul df ollow ASMECodeandNBI C
Codes.Mi ni mi zehazar dst oper sonneldur ingt est ing, i
sol at et estar eaf rom oper at i
ons,
andpr ov idesui tabl ebar ri
cades.
 UPV—Oper at orTr aini ng and Super visionThor oughl yt r
ai nempl oy eeswor king wi th
pressur ev essel si nr out inedut i
esandemer gencypr ocedur es.Super visor sshoul dbe
qual ifiedandknowl edgeabl e.Rev iew pot ent ialhazar dsofpr ocessesandsy st ems.
Wr ittendet ailedpr ocedur esshoul dber ev iewedper iodi cal lyandmadeav ailabl et o
 personnel .Useacheckl isti nt het rainingpr ocessf orst art-up,shut down,orr out ine
processi ngcy cl e.Communi cat i
onbet weenal lst af fandper sonneli scr itical .Pr oper
l
abel i
ngofv alv es,pi pingsy stems,andcont rolequi pmentpr ev ent sacci dent scaused
byoper atorer ror .
 UFP—Saf etyDev i
ces UFP v essel s used i n pr ocesses wi thv ar i
ous mat erials and
chemi cal s,equi peachv esselwi thappr opr i
at esaf et ydev i
cesf ort het ypeofv esseland
wor k per formed.Saf ety dev ices ar ei nst alled f or a pur pose:pr ot ect agai nst
over pressur echemi cal r
eact ionsabnor mal condi ti
ons
 Safet yDev icesUPV Ty pesofsaf etydev ices:saf etyv alv esr upt uredi sksv acuum
breaker swat erseal vent sr egulatingorr educi ngv alv es
 Aut ocl avesandOt herVessel swi thQui ck- Openi ngDoor sPr essur ei nterlocksshoul dbe
i
nst al l
edonaut ocl av esandot herpr essur ev essel scont aini ngl ar gev ol umesofst eam
equi ppedwi thqui ck- opendoor sorr eclosi ngdev ices.Pr essur ei nterlockwi llpr ev ent
theopeni ngoft hedoorunt i
lallpr essur ei sr eliev edandpr ev enti ntroduct ionofst eam
untilt hedoori scl osed.Openi ngt hedoorwi thchamberunderpr essur ewi llr elease
extremef or ceandmaycauseacci dent s.I nter iori t
emsmayber eleasedl ikepr oject il
es.
Mostcr i
ticalsy stem oft hesev essel si st hecl osur esy stem andi tscomponent s.
Oper atorsr out inelyi nspectaswel l asl icensedi nspect or s.
 UPV- Aut ocl avesSaf etyPr ocedur esSpeci ficpr essur ev esselsaf etypr ocedur es:Donot
wel dt oanypar toft hev essel.Donotcut ,dr ill
,orf ast ent oanypar toft hev essel .
Assumev esseli spr essur izedanyt imet hedoori scl osed.Checkf orsuf ficientoxy gen.
Leav e no f lammabl e mat er i
als, debr i
s, or pl ast ics i n aut ocl av e. Cl osur e
ali
gnment /inspectv essel Schedul eper iodicmai ntenance.
 UPVSt eam- Jacket edVessel sUsedt oheatl iqui dmi xtur est omoder at et emper ature
Steam ci rculat edbet weent heout erandi nnershel lsofv esselandheatt ransf erred
through t he i nnershel lt ot he cont ent s ofv esselUse saf etyv al ves Oper ating
procedur esf orsaf ety :Thor oughl ydr aint hest eam spacepr i
ort oaddi ngst eam t o
j
acket .Admi tst eam t ocol dv essel ssl owl yt oal low f orpar tst oheatandexpand
unifor ml y.Unl essaut omat icprot ect ion, openv ent sonl ywhenst eam i sshutof f.Wher e
agitat orsar eused, paddl esmustnotst r
iket hei nt er i
orsur facesoft hev essel .Vessel s
withl ar geopeni ngsmusthav eadequat esaf et ymeasur est opr eventf allsbyper sonnel
i
ntot hev essel .Fi l
lonl yt ot hepoi ntwher especi fi
edanddonotcr eat eunduespl ashi ng.
 Pressur eGaugesOper ationr equi rement s–Rest rictar easwher ehi ghgas- pressur e
syst emsoper at et oal lbutnecessar yper sonnel–Bar ricader eact or s,pr essur ev essel s,
andheatexchanger s–I nstallremot econt rol sy stemsandot hermoni t
or ingdev i
ce
1.
5El
ect
ri
calExposur
e
Elect
ricalHazar ds:Usingel ectr
icalcur r
entandel ect r
icalequi pmentcanl eadt osev eral
hazards includi
ng el ectr
ic shock,heat ,and fire.El ectric Shock Hazar d When a per son
becomespar tofanel ectri
cci r
cuit,theyar eaconduct oroft heel ectri
calcur r
ent.Since
elect
ri
citycannotbeseen, thehazar disoftenover lookedunt iltoolate.Bodi l
yinjur
yanddeat h
canoccur .Currentflowingt hrought hebodywi llaf fectt hebodyi nsomemanner .Asl i
ght
ti
ngli
ngsensat i
onmaybef elt.Ashockmaybef eltwhi chcanr esul
tinmuscul arcontract
ions
thatcan“ knock”t hevict
im awayf rom t
heci r
cuit
.
Electri
cshockmay“ lock”t hemuscl estowher er eleasef rom theci r
cuitisimpossible.
Inseverecases, heartmuscl er hyt
hmsar edisr
upt edanddeat hresults.El ectr
icalcurr
entalso
producesheatwhi chcanbur nbodyt i
ssuesbot hext ernall
yandi nt ernall
y.HeatandFi re
Elect
rici
tycan be t he sour ce ofheatt oignitef lammabl e mat erials.Cur rentflow ina
conduct orpr oducesheatbecauseoft heconduct or’
sr esi
stancet ot hef l
ow ofel ect
ri
city
.
Increasedheati nelectr
icalconductorscanbeexpect edwhen:
•Thewi r
esizei st oosmal ltocarrythecur r
ent(tryi
ngt or unanel ect
ri
cmot oronal ampcor d)
•Theel ectri
call oadi stoogr eat(operati
ngahai rdr yer,curl
ingi r
on,andt oasteront hesame
circuit
)
•Theel ectr
icall oadi stoof arawayf rom t heel ectri
calsour ce(a1/ 2electri
cdr i
llmotor
oper at
edatt heendofa100-f ootextensioncord)
•Theel ectr
icalconnect i
onsar eloose,andi ncreasedr esi
stancedev elopsCont actwithan
electri
calcur rentcanki llaper son.Thehear tmuscl eswi l
llockupi ft heel ectr
icalcur
rent
passest hrought heheartwhenal lthehear tvalv
esar eclosed( r
estphase) .

Inr ecogni zing, avoi di

ngandpr otectingagai nstel ectricalhazar dskeepi nmi nd–saf ety.
B=BURNS
Abur ni st hemostcommonshock- relatedi nj
ury .Bur nsf rom el ectri
ci tyareoneoft hreet ypes:
Elect ricalAr c/Flash Ther mal Cont act
E=ELECTROCUTI ON
Elect rocut i
onr esul tswhenahumani sexposedt oal ethal amountofel ectricalenergy .
S=SHOCK
•Shockr esul tswhent hebodybecomespar toft heel ectri
cal circui t
;
•Elect ricalshocki sdef i
nedasar eflexr esponset ot hepassageofel ect ri
ccur r
entthrought he
body .A=A=ARCFLASH/ BLAST
Anar cf l
ashi st hesuddenr eleaseofel ect r
icalener gyt hrought heai rwhenahi gh- voltage
gapexi stsandt herei sabr eakdownbet weenconduct ors.
F=FI RE
Mostel ect ricalf i
resr esul tfrom pr oblemswi thf aultyelect ri
calout lets,oldwi ri
ng,pr oblems
wit hcor ds( suchasext ensi onandappl iancecor ds),pl ugs, r
ecept acles, andswi t
ches
E=EXPLOSI ON
Anexpl osi oncanoccurwhenel ect ri
cityignitesanexpl osivemi xtureofmat er i
alintheai r.
Aqual if
iedel ectricianwi l
lbenecessar ytowor kwi tht heel ect ricalsyst em bey ondwhat
i
sdescr i
bedher e.
Dist ri
but ionPanel –Theci rcuitbr eakerorf useboxcont ainsmanyci r cuits.Thi sisthel ocat i
on
ofci rcui tbr eakerdev i
cest ost opcur rentf l
owt oanel ectri
calci rcuit.Youmaybeassi gnedt o
got ot hedi stri
but ionpanel( somet i
mescal l
edci r
cui tbr eakerpanelorf usebox)t ot urna
circui tonorof f.
Circui tBr eaker sandFuses–Thesedev i
cesf oundi nt hedi stri
but i
onpanelpr otectthewi r
esof
theci rcui tfrom ov erheat i
ng.Ov er l
oadscausef usest o“ blow”andci rcuitbreaker st o“ tr
ip”to
elect rical fl
ow.Thr eecommonpr ot ectivedev i
cesar e:
•Fuses
•Ci rcui tbr eaker s
•Gr oundf aul tcircuitinterrupt ers( GFCI s)
Fuses ar e ei thera scr ew- i
n orcar t
r i
dge t ype.A met alst rip mel t
s when t he ci rcuitis
ov erloadedandi nterrupt st heci rcui t
.Thef usemustber eplaced.Shutof ft he“mai n”power
swi tchbef or echangi ngf uses.Ci rcuitbr eaker slookl i
keswi tches.Whenabi -metalst ri
p( two
differ entmet als)i sheat edf r
om el ectri
cal ov erload, themet al becomesdi stortedi nshapeand
causest heci r
cui tbr eakert ocutout .Theov erloadpr obl em mustbecor rect edandt heswi t
ch
retur nedt ot heonposi tion.Gr oundFaul tCi r
cui tI nterr upter scanl ookl i
keanel ect r
icalout let
oraci rcui tbr eaker .TheseGFCIdev icesbr eakt heci r cuiti nmi crosecondswhenadi ffer ence
i
ncur r enti ssensed.Thesedev icesar eusedwher emoi sturei sf ound.Mi l
kingpar l
or sand
mi l
kr ooms,swi mmi ngpool s,ki tchens,l aundr ies,andout doorr ecept aclesshoul dhav eGFCI
prot ect ion.Ar edr esetbut t
onandt estlightar eamakeGFCIdev i
cesdi ffer entt hanar egul ar
out l
et .I ffuses, circui tbreaker s, andGFCIdev icesar econst ant l
y“ blowi ng, ”asky ourempl oy er
tocheckt hesi tuationbef orey oucont i
nue.
Swi tchesandRecept acles–Swi tchesener gizeci rcuits.Recept aclesconnectt heappl iancet o
theci rcui t.Car elessusecandamaget her ecept acleandappl i
ance.I fy ouar eassi gnedt oa
j
obwher et heel ect ri
calswi tchand/orr ecept acl eisdamaged,askt heempl oyert omaket he
repai rs.
PREVENTI ONOFELECTRI CALHAZARDS
Allwor kplacehasanel ect ri
calsaf etypol icycr eat edbyaut hor i
ty.El ect ri
calSaf et yPol icy :The
foll
owi ngi temsshoul dbei ncludedi nt heel ect ricalsaf etypol i
cy:Powerequi pmentshoul dbe
pluggedi ntowal lr ecept acleswi thpowerswi tchesi nt heof fposi ti
on.El ectricalequi pment
shoul dbeunpl uggedbygr aspi ngt hepl ugandpul l
ing.Nev erpul lorj er kt hecor dt ounpl ugt he
equi pment .Fr ay ed,cr ackedorexposedwi ri
ngonequi pmentcor dsmustbecor rected.Al so
checkf ordef ectivecor dcl ampsatl ocationswher et hepowercor dent er st heequi pmentor
theat tachmentpl ug.Tempor aryorper manentst orageofmat erialsmustnotbeal lowed
withi n3f eetofanel ectricalequi pment .Anyel ect ri
calequi pmentcausi ngshocksorwhi ch
hashi ghl eakagepot ent i
al mustbet aggedwi thaDANGER—DONOTUSEl abel orequi val ent .
Responsi biliti
esofi ndiv i
dualempl oyeeTr ainingandEducat i
on:Manyacci dent sar ecaused
duet ol ackknowl edgeoft heequi pmentori tsoper at ion.Soempl oy eesshoul dbet r
ai nedi n
elect rical saf etywor kpr act i
cesandequi pmentoper ation.
Hazar dous Condi tion Repor ting :Empl oy ees shoul d al way sr epor tunsaf e equi pment ,
condi tionsorpr ocedur es.Undernocondi t
ionshoul ddef ect i
v eel ect ricalequi pmentcausi ng
elect rical shockbeusedi mmedi ately.
Wor kPr act i
ces: Empl oyeesar er esponsi blef orf ollowi ngt heirempl oy er ’
ssaf ewor kpr act ices,
procedur esandpol i
cy .
Housekeepi ng:Goodhousekeepi ngr equi resal lempl oy eest oobser v eact i
vitiest hatcoul d
causeel ectricalshockhazar ds.Forexampl eusi ngel ectricalequi pmentt hati snotpr oper ly
groundedi nar east hathav ewat eront hef loorcancr eat eshockhazar ds.
Cl eani ngt ool sandel ectricalequi pmentwi t
hsol v ent scancr eateheal t
handphy sicalsaf ety
probl ems.