Safety in Industry

BHARATH NIKETAN ENGINEERING
COLLEGE
AUNDIPATTY, THENI – 625536
DEPARTMENT OF MECHANICALENGINEERING
M.E - Industrial Safety Engineering
IS5010 – SAFETY IN ENGINEERING INDUSTRY
III Semester - R 2017
Prepared by
L.Anand,
AP/Mech
IS5010 SAFETY IN ENGINEERING INDUSTRY LTPC
3 00 3
OBJECTIVES
To know the safety rules and regulations, standards and codes
To study various mechanical machines and their safety importance
To understand the principles of machine guarding and operation of protective devices.
To know the working principle of mechanical engineering processes such as metal forming and joining
process and their safety risks.
Developing the knowledge related to health and welfare measures in engineering industry
UNIT I SAFETY IN METAL WORKING MACHINERY AND WOOD WORKING MACHINES 9
General safety rules, principles, maintenance, Inspections of turning machines, boring machines, milling
machine, planning machine and grinding machines, CNC machines,
Wood working machinery, types, safety principles, electrical guards, work area, material handling, inspection,
standards and codes- saws, types, hazards.
UNIT II PRINCIPLES OF MACHINE GUARDING 9
Guarding during maintenance, Zero Mechanical State (ZMS), Definition, Policy for ZMS – guarding of
hazards - point of operation protective devices, machine guarding, types, fixed guard, interlock guard,
automatic guard, trip guard, electron eye, positional control guard, fixed guard fencing- guard construction-
guard opening.
Selection and suitability: lathe-drilling-boring-milling-grinding-shaping-sawing-shearing-presses-forge
hammer-flywheels-shafts-couplings-gears-sprockets wheels and chains-pulleys and belts-authorized entry to
hazardous installations-benefits of good guarding systems.
UNIT III SAFETY IN WELDING AND GAS CUTTING 9
Gas welding and oxygen cutting, resistances welding, arc welding and cutting, common hazards, personal
protective equipment, training, safety precautions in brazing, soldering and metalizing – explosive welding,
selection, care and maintenance of the associated equipment and instruments – safety in generation,
distribution and handling of industrial gases-colour coding – flashback arrestor – leak detection-pipe line
safety-storage and handling of gas cylinders.
UNIT IV SAFETY IN COLD FARMING AND HOT WORKING OF METALS 9
Cold working, power presses, point of operation safe guarding, auxiliary mechanisms, feeding and cutting
mechanism, hand or foot-operated presses, power press electric controls, power press set up and die removal,
inspection and maintenance-metal sheers-press brakes.
Hot working safety in forging, hot rolling mill operation, safe guards in hot rolling mills – hot bending of
pipes, hazards and control measures.
Safety in gas furnace operation, cupola, crucibles, ovens, foundry health hazards, work environment, material
handling in foundries, foundry production cleaning and finishing foundry processes.
UNIT V SAFETY IN FINISHING, INSPECTION AND TESTING 9
Heat treatment operations, electro plating, paint shops, sand and shot blasting, safety in inspection and testing,
dynamic balancing, hydro testing, valves, boiler drums and headers, pressure vessels, air leak test, steam
testing, safety in radiography, personal monitoring devices, radiation hazards, engineering and administrative
controls, Indian Boilers Regulation.
Health and welfare measures in engineering industry-pollution control in engineering industry-industrial waste
disposal.
TOTAL: 45 PERIODS
OUTCOMES:
Students can have the knowledge in safety rules, standards and codes in various mechanical
engineering processes
They can design machine guarding systems for various machines such as lathe, drilling, boring, milling
etc.,
They can implement the safety concepts in welding, gas cutting, storage and handling of gas
cylinders, metal forming processes etc.,
Students will have knowledge in testing and inspection as per rules in boilers, heat treatment
operations etc.,
They can take preventive measures in health and welfare of workers’ aspects in engineering
industry.
REFERENCES
1. “Accident Prevention Manual” – NSC, Chicago, 1982.
2. “Occupational safety Manual” BHEL, Trichy, 1988.
3. “Safety Management by John V. Grimaldi and Rollin H. Simonds, All India Travelers Book seller,
New Delhi 1989.
4. “Safety in Industry” N.V. Krishnan Jaico Publishery House, 1996.
5. Indian Boiler acts and Regulations, Government of India.
6. Safety in the use of wood working machines, HMSO, UK 1992.
7. Health and Safety in welding and Allied processes, welding Institute, UK, High Tech. Publishing Ltd.,
London, 1989.
The Hazards of CNC Machines:
Mechanical components that present crushing or amputation hazards:
• Point of operation
• Power-transmission apparatuses
• Other moving parts
Basic mechanical motions and actions that can potentially be hazardous:

• Rotating, reciprocating and transverse motions
• Cutting, punching, shearing and bending actions
• In-running nip points
Routine but hazardous activities that pose increased risk of severe injury to employees during:
• Machine setup
• Clearing jams
• Machine adjustments
• Cleaning of machine
• Lubricating of machine parts
• Scheduled and unscheduled maintenance
Focus Your Efforts to Reduce Losses:

No manufacturing process should be without an effective safety and health program that includes proper
machine safeguarding, lockout/tagout procedures and operator training and supervision.
• Ensure that existing and newly purchased machinery include appropriate guarding and safety controls,
including safety interlocks on machinery with movable gates or doors providing access to the point of
operation.
• Develop, implement and enforce a comprehensive hazardous energy control program, including
machine-specific lockout/tagout procedures and training.
• Provide employee training on machinery used, worksite hazards and controls for these hazards. Training
should be in the employee’s primary language and at appropriate literacy levels to ensure comprehension.
• Provide frequent supervision of newly-hired and inexperienced employees.

• Conduct periodic equipment hazard analysis/inspections to ensure equipment is safe to operate.
• Whenever a new procedure (e.g., using non-routine tools) or equipment is introduced, conduct a job
safety analysis (JSA). When conducting the JSA, determine the tasks, what could go wrong, what the
consequences could be, how hazards could arise, what the contributing factors are and the likelihood that
a hazard could occur.
SAFETY PRINCIPLES FOR CNC MACHINE TOOLS:

Toni Retsch, Guido Schmitter, Albert Marty
Whenever simple and conventional production equipment, such as machine tools, is automated, the result
is complex technical systems as well as new hazards. This automation is achieved through the use of
computer numeric control (CNC) systems on machine tools, called CNC machine tools (e.g., milling
machines, machining centres, drills and grinders). In order to be able to identify the potential hazards
inherent in automatic tools, the various operating modes of each system should be analysed. Previously
conducted analyses indicate that a differentiation should be made between two types of operation: normal
operation and special operation.
It is often impossible to prescribe the safety requirements for CNC machine tools in the shape of specific
measures. This may be because there are too few regulations and standards specific to the equipment
which provide concrete solutions. Safety requirements can be determined only if the possible hazards are
identified systematically by conducting a hazard analysis, particularly if these complex technical systems
are fitted with freely programmable control systems (as with CNC machine tools).
In the case of newly developed CNC machine tools, the manufacturer is obliged to carry out a hazard
analysis on the equipment in order to identify whatever dangers may be present and to show by means of
constructive solutions that all dangers to persons, in all of the different operating modes, are eliminated.
All the hazards identified must be subjected to a risk assessment wherein each risk of an event is
dependent on the scope of damage and the frequency with which it may occur. The hazard to be assessed
is also given a risk category (minimized, normal, increased). Wherever the risk cannot be accepted on the
basis of the risk assessment, solutions (safety measures) must be found. The purpose of these solutions is
to reduce the frequency of occurrence and the scope of damage of an unplanned and potentially
hazardous incident (an “event”).
The approaches to solutions for normal and increased risks are to be found in indirect and direct safety
technology; for minimized risks, they are to be found in referral safety technology:
· Direct safety technology. Care is taken at the design stage to eliminate any hazards (e.g., the elimination
of shearing and trapping points).
· Indirect safety technology. The hazard remains. However, the addition of technical arrangements
prevents the hazard from turning into an event (e.g., such arrangements may include the prevention of
access to dangerous moving parts by means of physical safety hoods, the provision of safety devices
which turn power off, shielding from flying parts using safety guards, etc.).
· Referral safety technology. This applies only to residual hazards and minimized risks-that is, hazards
which can lead to an event as a result of human factors. The occurrence of such an event can be prevented
by appropriate behaviour on the part of the person concerned (e.g., instructions on behaviour in the
operating and maintenance manuals, personnel training, etc.).
International Safety Requirements

The EC Machinery Directive (89/392/EEC; see box) of 1989 lays down the principal safety and health
requirements for machines. (According to the Machinery Directive, a machine is considered to be the
sum total of interlinked parts or devices, of which at least one can move and correspondingly has a
function.) In addition, individual standards are created by international standardization bodies to illustrate
possible solutions (e.g., by attending to fundamental safety aspects, or by examining electrical equipment
fitted to industrial machinery). The aim of these standards is to specify protection goals. These
international safety requirements give manufacturers the necessary legal basis to specify these
requirements in the above-mentioned hazard analyses and risk assessments.
Operating Modes
When using machine tools, a differentiation is made between normal operation and special operation.
Statistics and investigations indicate that the majority of incidents and accidents do not take place in
normal operation (i.e., during the automatic fulfilment of the assignment concerned). With these types of
machines and installations, there is an emphasis on special modes of operations such as commissioning,
setting up, programming, test runs, checks, troubleshooting or maintenance. In these operating modes,
persons are usually in a danger zone. The safety concept must protect personnel from harmful events in
these types of situations.
Normal operation
The following applies to automatic machines when carrying out normal operation: (1) the machine fulfils
the assignment for which it was designed and constructed without any further intervention by the
operator, and (2) applied to a simple turning machine, this means that a workpiece is turned to the correct
shape and chips are produced. If the workpiece is changed manually, changing the workpiece is a special
mode of operation.
Special modes of operation
Special modes of operation are working processes which allow normal operation. Under this heading, for
example, one would include workpiece or tool changes, rectifying a fault in a production process,
rectifying a machine fault, setting up, programming, test runs, cleaning and maintenance. In normal
operation, automatic systems fulfil their assignments independently. From the viewpoint of working
safety, however, automatic normal operation becomes critical when the operator has to intervene working
processes. Under no circumstances may the persons intervening in such processes be exposed to hazards.
Personnel
Consideration must be given to the persons working in the various modes of operation as well as to third
parties when safeguarding machine tools. Third parties also include those indirectly concerned with the
machine, such as supervisors, inspectors, assistants for transporting material and dismantling work,
visitors and others.
Demands and Safety Measures for Machine Accessories

Interventions for jobs in special operation modes mean that special accessories have to be used to assure
work can be conducted safely. The first type of accessories include equipment and items used to intervene
in the automatic process without the operator’s having to access a hazardous zone. This type of accessory
includes (1) chip hooks and tongs which have been so designed that chips in the machining area can be
removed or pulled away through the apertures provided in the safety guards, and (2) workpiece clamping
devices with which the production material can be manually inserted into or removed from an automatic
cycle
Various special modes of operation-for example, remedial work or maintenance work-make it necessary
for personnel to intervene in a system. In these cases, too, there is a whole range of machine accessories
designed to increase working safety-for example, devices to handle heavy grinding wheels when the latter
are changed on grinders, as well as special crane slings for dismantling or erecting heavy components
when machines are overhauled. These devices are the second type of machine accessory for increasing
safety during work in special operations. Special operation control systems can also be considered to
represent a second type of machine accessory. Particular activities can be carried out safely with such
accessories-for example, a device can be set up in the machine axes when feed movements are necessary
with the safety guards open.
These special operation control systems must satisfy particular safety requirements. For example, they
must ensure that only the movement requested is carried out in the way requested and only for as long as
requested. The special operation control system must therefore be designed in such a way as to prevent
any faulty action from turning into hazardous movements or states.
Equipment which increases the degree of automation of an installation can be considered to be a third
type of machine accessory for increasing working safety. Actions which were previously carried out
manually are done automatically by the machine in normal operation, such as equipment including portal
loaders, which change the workpieces on machine tools automatically. The safeguarding of automatic
normal operation causes few problems because the intervention of an operator in the course of events is
unnecessary and because possible interventions can be prevented by safety devices.
Requirements and Safety Measures for the Automation of Machine Tools

Unfortunately, automation has not led to the elimination of accidents in production plants. Investigations
simply show a shift in the occurrence of accidents from normal to special operation, primarily due to the
automation of normal operation so that interventions in the course of production are no longer necessary
and personnel are thus no longer exposed to danger. On the other hand, highly automatic machines are
complex systems which are difficult to assess when faults occur. Even the specialists employed to rectify
faults are not always able to do so without incurring accidents. The amount of software needed to operate
increasingly complex machines is growing in volume and complexity, with the result that an increasing
number of electrical and commissioning engineers suffer accidents. There is no such thing as flawless
software, and changes in software often lead to changes elsewhere which were neither expected nor
wanted. In order to prevent safety from being affected, hazardous faulty behaviour caused by external
influence and component failures must not be possible. This condition can be fulfilled only if the safety
circuit is designed as simply as possible and is separate from the rest of the controls. The elements or sub-
assemblies used in the safety circuit must also be fail-safe.
It is the task of the designer to develop designs that satisfy safety requirements. The designer cannot
avoid having to consider the necessary working procedures, including the special modes of operation,
with great care. Analyses must be made to determine which safe work procedures are necessary, and the
operating personnel must become familiar with them. In the majority of cases, a control system for
special operation will be necessary. The control system usually observes or regulates a movement, while
at the same time, no other movement must be initiated (as no other movement is needed for this work,
and thus none is expected by the operator). The control system does not necessarily have to carry out the
same assignments in the various modes of special operation.
Requirements and Safety Measures in Normal and Special Modes of Operation
Normal operation
The specification of safety goals should not impede technical progress because adapted solutions can be
selected. The use of CNC machine tools makes maximum demands on hazard analysis, risk assessment
and safety concepts. The following describes several safety goals and possible solutions in greater detail.
Safety goal
· Manual or physical access to hazardous areas during automatic movements must be prevented.
Possible solutions
· Prevent manual or physical access into danger zones by means of mechanical barriers.
· Provide safety devices that respond when approached (light barriers, safety mats) and switch off
machinery safely during interventions or entry.
· Allow manual or physical access to machinery (or its vicinity) only when the entire system is in a safe
state (e.g., by using interlocking devices with closure mechanisms on the access doors).
Safety goal
· The possibility of any persons being injured as a result of the release of energy (flying parts or beams of
energy) should be eliminated.
Possible solution
· Prevent the release of energy from the danger zone-for example, by a correspondingly dimensioned
safety hood.
Special operation
The interfaces between normal operation and special operation (e.g., door interlocking devices, light
barriers, safety mats) are necessary to enable the safety control system to recognize automatically the
presence of personnel. The following describes certain special operation modes (e.g., setting up,
programming) on CNC machine tools which require movements that must be assessed directly at the site
of operation.
Safety goals
· Movements must take place only in such a way that they cannot be a hazard for the persons concerned.
Such movements must be executed only in the scheduled style and speed and continued only as long as
instructed.
· They are to be attempted only if it can be guaranteed that no parts of the human body are in the danger
zone.
Possible solution
· Install special operating control systems which permit only controllable and manageable movements
using finger-tip control via “acknowledge-type” push buttons. The speed of movements is thus safely
reduced (provided that energy has been reduced by means of an isolation transformer or similar
monitoring equipment).
Demands on Safety Control Systems

One of the features of a safety control system must be that the safety function is guaranteed to work
whenever any faults arise so as to direct processes from a hazardous state to a safe state.
Safety goals
· A fault in the safety control system must not trigger off a dangerous state.
· A fault in the safety control system must be identified (immediately or at intervals).
Possible solutions
· Put in place a redundant and diverse layout of electro-mechanical control systems, including test
circuits.
· Put in place a redundant and diverse set-up of microprocessor control systems developed by different
teams. This approach is considered to be state of the art, for example, in the case of safety light barriers.
Conclusion
It is apparent that the increasing trend in accidents in normal and special modes of operation cannot be
halted without a clear and unmistakable safety concept. This fact must be taken into account in the
preparation of safety regulations and guidelines. New guidelines in the shape of safety goals are
necessary in order to allow advanced solutions. This objective enables designers to choose the optimum
solution for a specific case while at the same time demonstrating the safety features of their machines in a
fairly simple way by describing a solution to each safety goal. This solution can then be compared with
other existing and accepted solutions, and if it is better or at least of equal value, a new solution can then
be chosen. In this way, progress is not hampered by narrowly formulated regulations.
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Main Features of the EEC Machinery Directive
The Council Directive of 14 June 1989 on the approximation of the laws of the Member States relating
machinery (89/392/EEC) applies to each individual state.
· Each individual state must integrate the directive in its legislation.

· Valid from 1 January 1993.
· Requires that all manufacturers adhere to the state of the art.
· The manufacturer must produce a technical construction file which contains full information on all
fundamental aspects of safety and health care.
· The manufacturer must issue the declaration of conformity and the CE marking of the machines.
· Failure to place a complete technical documentation at the disposal of a state supervisory centre is
considered to represent the non-fulfilment of the machine guidelines. A pan-EEC sales prohibition may
be the consequence.
Safety Goals for the Construction and Use of CNC Machine Tools
1. Lathes
1.1 Normal mode of operation

1.1.1 The work area is to be safeguarded so that it is impossible to reach or step into the danger zones
of automatic movements, either intentionally or unintentionally.
1.1.2 The tool magazine is to be safeguarded so that it is impossible to reach or step into the danger
zones of automatic movements, either intentionally or unintentionally.
1.1.3 The workpiece magazine is to be safeguarded so that it is impossible to reach or step into the
danger zones of automatic movements, either intentionally or unintentionally.
1.1.4 Chip removal must not result in personal injury due to the chips or moving parts of the machine.
1.1.5 Personal injuries resulting from reaching into drive systems must be prevented.
1.1.6 The possibility of reaching into the danger zones of moving chip conveyors must be prevented.
1.1.7 No personal injury to operators or third persons must result from flying workpieces or parts
thereof.
For example, this can occur
· due to insufficient clamping

· due to inadmissible cutting force
· due to inadmissible rotation speed
· due to collision with the tool or machine parts
· due to workpiece breakage
· due to defective clamping fixtures
· due to power failure
1.1.8 No personal injury must result from flying workpiece clamping fixtures.
1.1.9 No personal injury must result from flying chips.
1.1.10 No personal injury must result from flying tools or parts thereof.
· due to material defects

· due to a collision with the workpiece or a machine part
· due to inadequate clamping or tightening
1.2 Special modes of operation

1.2.1 Workpiece changing.
1.2.1.1 Workpiece clamping must be done in such a way that no parts of the body can become trapped
between closing clamping fixtures and workpiece or between the advancing sleeve tip and workpiece.
1.2.1.2 The starting of a drive (spindles, axes, sleeves, turret heads or chip conveyors) as a consequence
of a defective command or invalid command must be prevented.
1.2.1.3 It must be possible to manipulate the workpiece manually or with tools without danger.
1.2.2 Tool changing in tool holder or tool turret head.
1.2.2.1 Danger resulting from the defective behaviour of the system or due to entering an invalid
command must be prevented.
1.2.3 Tool changing in the tool magazine.
1.2.3.1 Movements in the tool magazine resulting from a defective or invalid command must be
prevented during tool changing.
1.2.3.2 It must not be possible to reach into other moving machine parts from the tool loading station.
1.2.3.3 It must not be possible to reach into danger zones on the further movement of the tool magazine
or during the search. If taking place with the guards for normal operation mode removed, these
movements may only be of the designated kind and only be carried out during the period of time ordered
and only when it can be ensured that no parts of the body are in these danger zones.
1.2.4 Measurement check.
1.2.4.1 Reaching into the work area must only be possible after all movements have been brought to a
standstill.
1.2.4.2 The starting of a drive resulting from a defective command or invalid command input must be
prevented.
1.2.5 Set-up.
1.2.5.1 If movements are executed during set-up with the guards for normal mode of operation
removed, then the operator must be safeguarded by another means.
1.2.5.2 No dangerous movements or changes of movements must be initiated as a result of a defective
command or invalid command input.
1.2.6 Programming.
1.2.6.1 No movements may be initiated during programming which endanger a person in the work area.
1.2.7 Production fault.
1.2.7.1 The starting of a drive resulting from a defective command on invalid command input setpoint
must be prevented.
1.2.7.2 No dangerous movements or situations are to be initiated by the movement or removal of the
workpiece or waste.
1.2.7.3 Where movements have to take place with the guards for the normal mode of operation
removed, these movements may only be of the kind designated and only executed for the period of time
ordered and only when it can be ensured that no parts of the body are in these danger zones.
1.2.8 Troubleshooting.
1.2.8.1 Reaching into the danger zones of automatic movements must be prevented.
1.2.8.2 The starting of a drive as a result of a defective command or invalid command input must be
prevented.
1.2.8.3 A movement of the machine on manipulation of the defective part must be prevented.
1.2.8.4 Personal injury resulting from a machine part splintering off or dropping must be prevented.
1.2.8.5 If, during troubleshooting, movements have to take place with the guards for the normal mode
of operation removed, these movements may only be of the kind designated and only executed for the
period of time ordered and only when it can be ensured that no parts of the body are in these danger
zones.
1.2.9 Machine malfunction and repair.
1.2.9.1 The machine must be prevented from starting.
1.2.9.2 Manipulation of the different parts of the machine must be possible either manually or with
tools without any danger.
1.2.9.3 It must not be possible to touch live parts of the machine.
1.2.9.4 Personal injury must not result from the issue of fluid or gaseous media.
2. Milling machines

No personal injury to operators or third persons must result from flying workpieces or parts
thereof.


· due to inadmissible speed of rotation
· due to collision with workpiece or machine part

2.2.1.1 Where power-operated clamping fixtures are used, it must not be possible for parts of the body
to become trapped between the closing parts of the clamping fixture and the workpiece.
2.2.1.2 The starting of a drive (spindle, axis) resulting from a defective command or invalid command
input must be prevented.
2.2.1.3 The manipulation of the workpiece must be possible manually or with tools without any danger.
2.2.2 Tool changing.
prevented.
2.2.2.2 It must not be possible for fingers to become trapped when putting in tools.
standstill.
prevented.
2.2.4 Set-up.
2.2.4.1 If movements are executed during set-up with guards for normal mode of operation removed,
the operator must be safeguarded by another means.
2.2.4.2 No dangerous movements or changes of movements must be initiated as a result of a defective
2.2.5 Programming.
2.2.5.1 No movements must be initiated during programming which endanger a person in the work
area.
2.2.6.1 The starting of drive resulting from a defective command or invalid command input must be
prevented.
2.2.6.2 No dangerous movements or situations must be initiated by the movement or removal of the
workpiece or waste.
prevented.
2.2.7.3 Any movement of the machine on manipulation of the defective part must be prevented.
zones.
2.2.8.1 Starting the machine must be prevented.
2.2.8.2 Manipulation of the different parts of the machine must be possible manually or with tools
without any danger.
3. Machining centres

3.1.1 The work area must be safeguarded so that is impossible to reach or step into the danger zones of
automatic movements, either intentionally or unintentionally.
3.1.2 The tool magazine must be safeguarded so that it is impossible to reach or step into the danger
zones of automatic movements.
3.1.3 The workpiece magazine must be safeguarded so that it is impossible to reach or step into the
danger zones of automatic movements.
3.1.6 The possibility of reaching into danger zones of moving chip conveyors (screw conveyors, etc.)
must be prevented.
thereof.

· due to changing to the wrong workpiece

· due to inadmissible speed of rotation
· due to the tool flying out of the tool changer
· due to selecting the wrong tool
prevented.
3.2.1.3 It must be possible to manipulate the workpiece manually or with tools without any danger.
3.2.1.4 Where workpieces are changed in a clamping station, it must not be possible from this location
to reach or step into automatic movement sequences of the machine or workpiece magazine. No
movements must be initiated by the control while a person is present in the clamping zone. The automatic
insertion of the clamped workpiece into the machine or workpiece magazine is only to take place when
the clamping station is also safeguarded with a protective system corresponding to that for normal mode
of operation.
3.2.2 Tool changing in the spindle.
prevented.
3.2.2.2 It must not be possible for fingers to become trapped when putting in tools.
3.2.3 Tool changing in tool magazine.
3.2.3.1 Movements in the tool magazine resulting from defective commands or invalid command input
must be prevented during tool changing.
3.2.3.2 It must not be possible to reach into other moving machine parts from the tool loading station.
3.2.3.3 It must not be possible to reach into danger zones on the further movement of the tool magazine
or during the search. If taking place with the guards for the normal mode of operation removed, these
movements may only be of the kind designated and only executed for the period of time ordered and only
when it can be ensured that no parts of the body are in these danger zones.
standstill.
prevented.
3.2.5 Set-up.
3.2.5.1 If movements are executed during set-up with the guards for normal mode of operation
removed, then the operator must be safeguarded by another means.
3.2.5.2 No dangerous movements or changes of movement must be initiated as a result of a defective
3.2.6 Programming.
3.2.6.1 No movements must be initiated during programming which endanger a person in the work
area.
prevented.
workpiece or waste.
prevented.
zones.
without any danger.
4. Grinding machines

thereof.

4.1.5 No personal injury or fires must result from sparking.
4.1.6 No personal injury must result from flying parts of grinding wheels.

· due to inadequate clamping (flanges)
· due to using incorrect grinding wheel

4.2.1.2 The starting of a feed drive resulting from a defective command or invalid command input must
be prevented.
4.2.1.3 Personal injury caused by the rotating grinding wheel must be prevented when manipulating the
workpiece.
4.2.1.4 Personal injury resulting from a bursting grinding wheel must not be possible.
4.2.1.5 The manipulation of the workpiece must be possible manually or with tools without any danger.
4.2.2 Tool changing (grinding wheel changing)
4.2.2.1 The starting of a feed drive resulting from .a defective command or invalid command input must
be prevented.
4.2.2.2 Personal injury caused by the rotating grinding wheel must not be possible during measuring
procedures.
be prevented.
4.2.3.2 Personal injury caused by the rotating grinding wheel must not be possible during measuring
procedures.
4.2.4. Set-up.
4.2.4.1 If movements are executed during set-up with the guards for normal mode of operation removed,
then the operator must be safeguarded by another means.
4.2.4.2 No dangerous movements or changes of movement must be initiated as a result of a defective
4.2.5 Programming.
4.2.5.1 No movements must be initiated during programming which endanger a person in the work area.
be prevented.
workpiece or waste.
4.2.6.4 Personal injury caused by the rotating grinding wheel must be prevented.
prevented.
4.2.7.5 Personal injury caused the operator’s contacting or by the bursting of the rotating grinding wheel
must be prevented.
4.2.7.6 If, during troubleshooting, movements have to take place with the guards for the normal mode of
operation removed, these movements may only be of the kind designated and only executed for the
zones.
without any danger.
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UNIT – V SAFETY IN FINISHING ,INSPECTION AND TESTING
Heat Treatment Operations:

After hot or cold working of metal, stress and strain are produced in the metal.
Therefore heat treatment methods are required to remove these stresses.
Meaning and Types of Heat Treatment Methods:
Heat treatment can be defined as an operation of heating and cooling of metals in the
solid stateto induce certain desired properties into them. It is generally employed to
improve grain size,machinability, mechanical properties e.g. tensile strength, hardness,
ductility, resistance to wear heat andcorrosion, magnetic and electrical properties or to
relieve stresses in the metal produced because of coldor hot working. The common
heat-treatment operations are annealing, normalising,hardening,tempering, carburising
(case-hardening), cyaniding, nitriding, induction hardening and flame-hardening.
Heat treatment of rolled products are divided into two groups :

1. Processes involving holding for a long time at a specified temperature and slow
cooling annealing and tempering.
2. Processes where metal is only heated in a furnace to a specified temperature and
then cooled in air (normalising) or in liquid quenchers (hardening).
Some heat treatment processes are carried out with some chemical compounds as
under :
Case hardening : Wrought iron is heated in contact with potassium
ferrocyanide where the
ferrocyanide decomposes into carbon which hardens the surface of wrought iron to
make steel.
Nitriding process : Steel containing 1% aluminium is heated in atmosphere of
ammonia at 550600 °C. Nitrogen dissociated from ammonia reacts with iron and
aluminium to form on the surface, iron and aluminium nitrides which produce compact
and hard surface.
Sintering and Heat hardening : Sintering refers to a process wherein fuel is
mixed with the oreand burned on a grate. The product is a porous cake. Heat hardening
or induration is done by combustion of gases passed through the bed to harden the
pellets without fusing them together, as is done in the sintering process.
In addition to' agglomeration, carbonates and sulphates may be decomposed or sulphur
may beeliminated. Non-ferrous sinter is produced from oxides and sulphides of
manganese, zinc, lead and nickel. Heat hardening of green iron ore pellets is
accomplished in a vertical shaft furnace, a travelling grate machine or a grate-plus-kiln
combination.
Hazards and Safety Measures:
Hazards in heat-treatment are :
1. Burns due to high temperature heating (between 700 to 1100° C).
2. Hazards of chemicals like N2, NH3, NaCN, Na2CO3, NaCI.
3. Contact of quenching media like brine, water, oils, air and solution of NaOH or
H2SO4 in water
4. Hazards of various types of furnaces and temperature measuring instruments and
electrical apparatus.
5. Handling of machine parts viz. steel castings, forging (shafts, axles etc.) springs,
gears,
wires,drills, screw taps, hammer dies, die moulds, high speed cutting tools and speed
etc.
for heattreatment purposes.
6. Lifting and travelling mechanism and their unguarded agency parts.
7. Dust exposure.
8. Hot surfaces and high air temperatures.
9. High humidity and air velocities.
10. High voltages and electromagnetic radiation.
11. High noise levels.
12. Infra-red radiation.
13. Excessive brightness of illuminated surfaces etc.
Control Measures are as under:

1. Exhaust ventilation to remove chemical vapours, fumes, gases, flammable or
explosive dusts,vapours etc. An enclosing hood projecting over the entire tank and
enclosed on two to three sides is preferable. A lateral exhaust (slots in top edge of the
tank walls for horizontal air movement), convenient canopy hood, general room
ventilation and a push- pull system (where out door air isblown across the tank into
the exhaust hood) can also be employed. Exhaust hoods or slots should be so located
that harmful fumes or dusts should not enter the breathing zone.
2. Flameproof or non-sparking fans and motors should be utilised in flammable area.
3. Monitoring of HCN or NaCN is necessary.
4. Excessive heat should be removed away.
5. Air supply to the furnaces should be uninterrupted and well controlled.
6. Adequate methods of storage, handling and disposal are desired.
7. Furnaces, ovens, dryers etc. should be gas fired or heated electrically. The use of
solid or liquid fuel may be allowed in exceptional and justified cases.
Hazards and Control from Treatment Media:

carbon with some sulphur, phosphorous, silicon and manganese, wrought iron contains
carbon and other impurities, steel contains carbon and manganese. Table 20.1 gives
percentage of chromium, tungsten, nickel molybdenum and silicon. In steelmaking
processes it is also mentioned that impurities of Mn, Si and C burn to give MnO2,
SiO2, CO and MnSiO3, furnace lining of SiO2 andCaO.MnO give slag and in electric
arc furnace phosphate and other slag is poured out.
explains heat treatment with chemical compounds like potassium ferrocyanide, iron
and aluminium nitrides, carbonates and sulphates and nonferrous sintering with oxides
and sulphides of manganese, zinc, lead and nickel. Hazards of chemicals like N2 NH3,
NaCN, Na2CO3, NaCI, NaOH,H2SO4 are also indicated.
Above chemicals behave as treatment media in the form of impurity, alloying material,
furnace lining and chemical for direct reaction. NaCN may evolve HCN a poisonous
gas.
CO and NH3 are also toxic. All metal waste and carbon, lime, phosphate, sulphate,
chromium, nickel and cyanide waste are hazardous. It cannot be disposed off here and
there. Cyanide being very toxic needs incineration i.e. controlled burning. Gaseous
waste like CO and HCN should be passed through incinerator or flare and burnt. CO2
is vented off through chimney. Solid toxic waste should be treated to make less
hazardous and then buried in permitted land with proper lining to prevent its
penetration to spoil soil. From top it should be covered safely. Non-toxic slag/waste
may be used for non-fertile land filling. CaO waste, because of its alkalinity, is useful
to grow some plants (not all). Steel slag is used to make tough roads. Liquid
waste/effluent should be treated by appropriate chemical or biological methods and
discharged with safe limits prescribed. Special disposal methods should be employed
depending on type of chemical, its concentration and biological effect.
Thus heat treatment operations should end in safe disposal-of final waste for the safety
of people, bioculture and environment.
Health Precautions:
They include
1. Eliminate and prevent long time exposure to the hazardous fumes due to heat
treatment.
2. Medical health check up of workers.
3. Provision and maintenance of effective controls for fumes and chemicals.
4. Use of personal protective equipment.
5. Training to workers and prompt supervision.
Need Of Safety In Engineering Industry
Man and Machine are two important ingredients of Industrial Safety. Man needs
machines which many times bring hazards and accidents. This has created the need of
industrial safety. It is most important to eliminate or minimise the contact between men
and machines. Machines are the product of engineering and therefore engineering
occupies the pioneering place in industrial safety. Without engineering industries, no
machine, no guard and no mass production is possible. The history of machine is old
and interesting. In Chapter-7, Part-1, old engineering branches of India are mentioned
and another historical part is given in Chapter-33. Weapons and vehicles expected by
Yajurveda and fixed and
movable machines in Kautilya’s times were not possible without engineering industry.
Modern engineering technology is much advanced and many other industries are
dependent on it.
Out of 86777 90523 91437 Deaths due to machinery 1037 999 970
Percentage 1.19% 1.10% 1.06% Table 5.8, chapter-5, causes I to 3 state that there were
28% and 23.64% injuries in engineering industry in 1990 and 1991 respectively.
From Table 5.6, it can be concluded that 31.65% fatal and 23.40% non fatal injuries in
India, in 1992, were in engineering processes. Table 5.22, last row Causation No. 101
to 112 and 122 give total 5008 accidents out of 15683 i.e. 31.93% accidents due to
machinery, in 1994, in Gujarat. Table 5.20 shows fatal accidents as 9.8% in 1996 and
20% in 1997 in engineering industry in Gujarat. Thus a share of accidents in
engineering industry is about 25 to 30% which needs attention.
Colour Code and Safety :

Indian Standards :
IS to be followed are : Code of practice for safety colours and safety signs 9457,
Pipelines,
identification, colour code 2379, Standard colours for building and decorative finishes
1650, pipelines in thermal power plants 9404, Identification for canisters and cartridges
8318 and Gas cylinders and related medical equipment 3933.
Colours to Identify Hazards :
Colour coding is most desirable and useful for safety purposes. Standard colours are
used to
identify hazards as follows :
Red - Fire protection, prohibition, danger, emergency stops on machines,
red cross on medical facilities.
Yellow - Risk, danger or caution, hazards of slipping, falling, striking etc.,
flammable liquid storage, yellow band on safety cans, material handling equipment
viz. lift trucks, cranes, crane hooks, caution,transport equipment, obstructions, change
in floor level, stair nosing etc.Green - Safety equipment not identified elsewhere, safety
board, safe
condition.
Blue - Warning and information signs, bulletin boards, rail road uses. It indicates
safety colour only if used with a circular sign. Orange - Dangerous parts of machines
or energized equipment such as exposed edges of cutting devices, inside of movable
guards,
enclosure doors, transmission guards, electric installations. Purple - Radiation Hazards
Black & White - Housekeeping and traffic markings. Also used as contrast colours.
White is a contrast colour for red, green and blue. Black is a contrast colour for yellow.
Content in the piping Colour
Flammable or water for fire protection Red
Dangerous (hazardous chemical) Yellow
Safe (water, air) Green
Protective material (inert gas) Blue
The proper colour may be applied to the entire length of the pipe or in bands 20-25 cm
wide near valves, pumps and at repeated intervals along the line. The name of the
specific material should be stencilled in black at readily visible locations such as valves
and pumps. Piping less than 3/4 inch diameter is identified by enamel on metal tags.
Anti-resistant colours should be used where acids and other chemicals may affect the
paints.
Material Colour
1. Water Sea green
2. Steam Aluminum, IS 2339
3. Air Sky blue
4. Acids Dark violet
5. Alkalis Smoke grey
6. Gases Canary Yellow
7. Hydrocarbons/ organic compounds Dark admirality grey
8. Mineral, vegetable and animal oils, combustible liduids. Light Brown
Painting of Plant and Machinery :

No lighting scheme can be fully effective unless well-chosen (and well-maintained)
finishes are provided on main interior surfaces such as ceilings, walls, plant and
equipment. The main object is to use colours which will reflect rather than absorb
light. Diffused light thrown back in this way can contribute substantially to the total
illumination on the work. It also improves the quality of the lighting by softening
shadows and minimising harsh contrasts in the field of view, thus contributing to visual
comfort and efficiency.
Because of full reflection of light, to paint the plant and everything by white colour is
not
advisable, because 'only white' .premises and equipment cause fatigue and boredom
and are no incentive for active or creative work if there is no combination of other
colours. Any extreme should also be avoided.
For ceilings, the reflection factor should be at least 75% which means white or near-
white. A matt finish is preferable.. Aluminium paint is not recommended.
Walls are best finished in light pastel colours in the 50-75% range, except in the case
of very
brightly lit walls (e.g. those adjacent to a large window) which may need toning down
to 40% or less to prevent them from becoming too glaring. Conversely, walls
containing windows (but which receive no direct light themselves) cannot often be
painted white with advantage. Furniture should preferably have a reflection factor of at
least 20%, and the modern blond (pale yellow) wood finishes and light grey paints for
steel cabinets are preferred to the old-fashioned dark stained wood and dull olive green
finishes. On desk and table tops which form a background to the work, it is important
to guard against distracting reflections. Floors should not be too dark. Practical
considerations usually govern the nature of the floor
finish, but 20-25% or so is. generally a satisfactory figure. Floor finishes which are
very much lighter than this should be treated with caution since they can sometimes
cause glare
A well painted machine inspires feeling of personal pride and proper maintenance is
encouraged. Under the General Code of Practice for Machine Guarding it has been
provided that: Colour schemes for machines be so selected as to cause least visual
disturbance to the operator. Colour schemes should provide quite finishes of medium
reflectance and should separate critical from non-critical areas of the machine. Critical
'areas are those which might constitute danger points or which need to be instantly
visible. These should be painted in local colours i.e. colours which command attention
(Red, Orange, Yellow). Non-critical areas are those which should be kept in the
background.
These should be painted in "Static" colours (Cream, Stone Grey, Pale Green, Pale
Blue). Control areas should be painted in suitable colour to provide a neutral
background for coloured indicator plates. Guards should be regarded as part of the
machine and should be painted in the same colour as the colour of the machine.
Colouring recessed surface of machines with lighter shade than used for the outer
surfaces help to minimise the effect of shadows on the inner surfaces (Example : Static
grey for outer surfaces, static stone for recessed surfaces).
Identification colours on machines should be reserved for things which really matter,
such as stop buttons and other safety tripping devices which must be found quickly in
an emergency. "Safety colours" must also be used with great restraint. Dangerous
moving parts should be guarded, not coloured, and when guarding is impossible,
colour should be used to highlight the actual hazard and not merely as a general
warning.
HEALTH AND WELFARE OF Engineering Industry

Occupational hazards and diseases relating to construction work are mainly dust
hazards (Silicosis due to silica dust, Siderosis due to iron dust, Anthracosis due to coal
dust and Cement Pneumoconiosis due to cement dust), noise and vibration, heat and
humidity, electricity, hazardous chemicals, work atheights and depths (in a confined
space), material handling, lifting machinery, transport vehicles, radiation hazards,
biological hazards etc. First-aid boxes and occupational health services at workplace or
nearby are most desirable.
Dust Hazards :
While handling building materials, workers can be exposed to four types of dusts
which by
inhalation can cause following lung diseases (Pneumoconiosis) :
Silicosis : Silica (SiO,) dust (respirable size 0.5 to 3 micron) causes fibrotic changes,
modulation in both lungs, shortness of breath, decreased chest expansion, reduced
capacity for work and in advanced case impairment of total lung capacity. The effect is
irreversible and no effective treatment is available. It is a notifiable and compensable
disease under the law.
The effect of exposure, varies with the concentration of dust, time period, working
conditions, body resistance, control measures etc. Chest X-ray shows a snow storm
appearance in lung fields. But it should be confirmed by a history of prolonged
exposure of silica dust and symptoms of dry cough, dysponea, chest tightness and
difficulty in breathing. Regular medical examination of workers and engineering
controls to minimize exposure are necessary.
Siderosis is caused by inhalation of iron dust (Iron oxide). Electric arc welding, dry
grinding of iron, buffing, polishing and shot-blasting produce iron dust. It seldom
causes serious symptom unless there is coexistent silicosis. Anthracosis (Coal workers'
pneumoconiosis) is caused by inhalation of coal dust. Foundry workers, coal handlers,
couple collie, boilermen (sealers), furnacemen, railway firemen, graphite workers etc.
are exposed to coal dusts. The first phase (requires about 12 years of work) causes little
ventilator impairment, but the second phase causes progressive massive fibrosis (PMF)
resulting in severerespiratory disability and tending to death. Early diagnosis and
change in occupation offers the best hope. Other treatment like chemotherapy should
be as per doctor's advice. Cement (Benign) Pneumoconiosis, silicosis with associated
pulmonary tuberculosis, bronchitis and emphysema are possible with cement or cement
and free silica dust (e.g. acid resistant cement).
Noise and Vibration :
Crushers, grinders, compressors and heavy lifting machinery in construction industry
causehigh noise. Continuously working near such high noise causes hearing loss,
deafness, annoyance/change in heart rate, blood pressure, sweat rate, work
performance etc. and also psychological and psychomotor effects. High frequencies are
more serious than low frequencies. Noise level should be kept below 90 decibels by
using quieter machinery and processes, enclosures and silencers. If this is not possible,
workers should be given ear plugs or muffs of good quality.
Heat and Humidity :
Steel mills, forge shops, furnaces, boilers, hot asphalt, tar, steam, hot water, damp clay,
underwater work etc. expose heat or humidity. In dry hot atmosphere, thermal balance
can be maintained by evaporation of sweat but in moist hot atmosphere as in cotton
mills, process of perspiration (sweat evaporation) slows down due to humidity and
workers feel great discomfort and their productivity gets down due to heat stress. Main
three types of heat stresses are heat stroke, heat exhaustion and heat cramp.
Insulation of hot processes and parts, lagging of hot pipes, shielding against radiant
heat, localexhaust ventilation, improvement in general (natural or mechanical)
ventilation, spot cooling of hot object, isolation or segregation of hot processes,
replacement of workers near furnaces or giving frequent
recesses and adequate supply of drinking water are some of the remedial measures.
Other Hazards :
Use of solvents, thinners, paints, varnishes etc. cause fire hazards. See Chapter-13 for
fire safety. Use of chemicals, pigments, radioactive substances and biological agents
pose peculiar types of hazards. Their effects and control are explained in Chapter-24.
Work permit and special precautions are required
First-aid and Health Services :

At all work sites, first-aid boxes containing prescribed medicines, antidotes and
equipment are most essential. Trained first-aiders should also be employed. They
should be proficient in the use of resuscitation and other life-saving techniques and in
rescue procedures. Necessary equipment including stretchers should be readily
available.
All workers should be subject to health surveillance. Work area monitoring should be
carried out. Health services should be available at workplace or nearby. See Chapter-
24 for further details. See Chapter XXIV, Rules 223 to 232 of the BOC Workers Rules,
1998, for medical facilities. It requires medical examination, construction medical
officer, OHC, ambulance room, ambulance van, stretchers, FAB, emergency treatment,
notice of occupational diseases etc.
Welfare :
At or near work site, adequate supply of drinking water, sanitary and washing facilities
or
showers, change or cloak room, lunchroom or canteen, rest room or shelter, facilities
for food and drink and suitable living accommodation should be available to workers.
The size and number of such facilities may vary according to the number of workers.
Where necessary separate facilities should be provided for male and female workers.
See Chapter XXVID, Rules 242 to 247 of the BOC Workers Rules, 1998, for statutory
provisions regarding above welfare facilities.
Accident Reports and Records :
Where prescribed, as in case of factory premises, all accidents to construction workers
should be reported to the authorities where absenteeism due to accident lasts for more
than 48 hours. All fatal accidents should also be reported to police and the family of
the deceased. Where format is prescribed (e.g. Form 21, GFR), it must be reported in
that form only.
Record of non-reportable accidents including near-misses should be maintained for
internal use. All accidents should be thoroughly investigated by a team of concerned
officers including Safety Officer and their conclusions should be used as remedial
measures to prevent future accidents. Non-factory construction sites should report their
accidents to the authorities prescribed. A good record of all such accidents and their
costs should be maintained for a long time. It may be useful to draft a law or to make
internal rules and regulations.
Radiation Protection Rules, 1971:

The Central Government u/s 30 of the Atomic Energy Act, 1962, made these rules
applicable from 3010-1971, to the whole of India. A summary of these 56 rules is,
given below: Section-2 defines adequate protection, competent authority,
contamination, employer, radiation worker, operational limits, radiation installation,
radiation surveillance, Radiological Safety Officer, sealed and unsealed source, source
housing, useful beam etc.
Other provisions are as under :
1. Radioactive material is to be handled as per terms and conditions of a licence.
2. Luminous compounds on watches, instruments etc. are exempted.
3. No person below the age of 18 years can be employed as a radiation worker.
4. Licence can be issued on request under the Act, if the equipment, facilities and work
practices afford adequate protection and if the incharge person has adequate
qualification to direct the work.The validity of licence is 3 years. It can be revoked,
modified or withdrawn by the competent authority after giving a show cause notice and
an opportunity to make a representation. Radioactive material shall be used only for
the purpose, location and quantities specified in the licence. Radiological Safety
Officer shall be designated by the employer (himself or an employee) with the
approval of competent authority to perform following duties and functions :
(1) Steps to ensure that operational limits are not exceeded.
(2) To instruct the radiation workers about hazards of radiation and safety measures to
minimise exposure to radiation and contamination.
(3) To carry out leakage tests on sealed sources as specified in rule 34.
(4) To regulate the safe movement of radioactive materials including waste.
(5) To investigate and suggest remedial measures in respect of any situation that could
lead
to radiation hazards.
(6) To make available' necessary reports and remedial measures to his employer.
(7) To ensure the safe disposal of radioactive wastes in a manner approved by the
competent
authority.
6. Hazardous situation is to be reported to the competent authority.
7. Radiation surveillance procedure notified by the competent authority is to be
followed by
the employer.
(1) Design, construe don, operation and use as per specifications and prior approval of
the
competent authority.
(2) Working conditions, monitoring and personal protective equipment.
(3) Personal monitoring of radiation workers.
(4) Medical examinations of the radiation workers as per rule 19 or 20.
(5) Records of radiation and radioactivity level measurements, personal monitoring and
Medical examinations stipulated by the competent authority.
(6) Any other procedure specified by the competent authority.
8. Prior approval before any modification to the plant or any change in working
conditions.
9. Radiation symbol to be displayed at workplaces and on containers containing
radioactive
materials. Its colour shall be as may be specified by the competent authority.
10. History records of radiation workers to be maintained in a form specified by the
competent authority.
11. Pre and periodical yearly medical examinations of radiation workers, of blood,
excreta,
skin, hands, fingers, finger nails, eyes and chest (X-ray). The frequency* and types
of
above examinations may be modified by the competent
authority where necessary (Rule 19 & 20). Complete records of above
examinations
shall be maintained. Its excerpts shall be sent to the competent authority in the
fospecified
by him. The competent authority shall preserve such records for the life time of the
worker or for 20 years after he ceases to do work of radiation, whichever is shorter.
12. The competent authority may specify steps to reduce the excessive exposure and
the employer shall comply with them and also provide the exposed worker an
alternative work not involving radiation exposure. If such worker is declared fit to
resume radiation work, his employer shall permit him to do that work. Then his work
shall be planned by the competent authority.
13. The competent authority or a person duly authorised by him has wide power to
inspect new, modified or running radiation installation, work being conducted,
protective device, transport etc. and make tests, measurements and other things to
verify adequate protection.
Power includes power to seal or seize radioactive material or equipment and give
directions for compliance.
14. Registers of particulars of sealed and unsealed sources shall be maintained (Rule
33).
15. In case of leakage of a sealed source, the Radiological Safety Officer shall place
that leaking source in a properly shielded leak-proof container with care to prevent
spread of contamination, act to safeguard the workers and others, vacate affected area,
clean up contamination if any, and inform the employer. Lost or missed radioactive
material shall be searched and the competent authority shall be informed immediately.
17. Telegamma sources shall be covered with appropriate source housing. In case of
power failure, the useful beam should be automatically cut off. Manual device to
interrupt the useful beam is required (Rule 37 to 39).
18. In medical institutions where radioactive material remains on or inside the body of
the patient, separate rooms and wards for the treatment shall be provided.
19. Where gamma radiography is done, the area shall be cordoned off to control entry
into it of other persons.
20. Sealed source devices such as static eliminators, thickness, density or level gauges,
package monitors shall be provided with efficient cover plate, shutter or shield capable
of being easily operateable to attenuate the useful beam.
21. Interlock switches in radiation installations should be of the fail-safe type.
22. Unsealed sources shall be kept in securely closed container and properly labelled.
Radiological Safety Officer has to take more precautions where unsealed sources are
handled such as safe working methods, facilities to minimise radiation level and
airborne
contamination, forbidding wrong working habits (mouth operated devices, open
wounds,
smoking, eating, drinking, application of cosmetics etc.), appropriate protective
clothing, safe use of PPE and checking contamination on it and safe collection of
radioactive wastes .(R.44 & 45).
23. Ventilating systems should be enclosed with ducts and filters to avoid spread of
any airbornecontamination.
24. In case of spillage, steps to arrange decontamination of affected personnel and
areas, steps to prevent further spread of contamination and informing the employer.
25. Other provisions for experiments on animals, luminising compounds, approved
procedure for mining, processing etc., disposal of animal carcasses, autopsies of
cadavers, licence, personnel monitoring and power to exempt are given in rules 48 to
56.
Boilers Act-1923
The Boilers Act (No. 5 of 1923) was notified on 4-12-1923. It came into force
from 1-1-1924. It has 34 sections. It is amended by the Act No. 49 of 2007 which
became effective by Notification dtd. 1312-2007. Section 2 of the Act defines as under
:
Boiler means a pressure vessel in which steam is generated for use external to
itself by application of heat which is wholly or partly under pressure when steam is
shut off but does not include a pressure vessel-
(i) with capacity. < 25 ltrs (such capacity being measured from the feed check valve
to ,the main steam stop valve)
(ii) with < I kg/cm' design gauge pressure and working gauge pressure or
in which water is heated below 100 °C.
 Boiler Component means steam piping, feed piping, economiser, super heater,
any mounting or other fitting and any other external or internal part of a boiler
which is subject to pressure exceeding I kg/ cm2 gauge.
 Economizer means any part of a feed-pipe that is wholly or partially exposed to
the action of flue gas for the purpose of recovery of waste heat.
 Super heater means any equipment which is partly or wholley exposed to flue
gases for the purpose of raising the temperature of a steam beyond the saturation
temperature at the pressure and includes a reheater.
 Steam Pipe : means any pipe through which stream passes if (i) The pressure at
which steam passes through such pipe exceeds 3.5 kg/ m2 above atmospheric
pressure or (ii) Such. pipe exceeds 254 mm in internal diameter and pressure > I
kg/cm2 and includes, in either case any connected fitting of a steam pipe.
 Accident as defined u/s 2(a) means an explosion of boiler or boiler component
which is calculated to weaken the strength or an uncontrolled release of water or
steam therefrom, liable to cause death or injury to any person or damage to any
property.
Sec. 18 requires report of accident and inquiry in case of fatal accident.
New definitions of Competent authority, Competent person.Inspecting authority.
Technical advisor and structural alteration, addition or renewal are added.
Now not only boiler inspector but competent person can also inspect and certify boiler
and its components during manufacture, erection and use. Inspecting authority can do
this job during manufacture.
Unregistered or uncertified boiler shall not be used save as otherwise provided in
the Act. Prior sanction of the Chief Inspector is necessary before carrying out any
structural alteration, addition or renewal in or to any boiler or steam pipe. Any accident
to a boiler or steam pipe shall be reported to the Inspector within 24 hours. His report
shall be in form E (Rule 48).
Section 27A provides to form a Central Boiler Board consisting of members,
nominating by the Central Government the representatives from the Central
Government, Bureau of Indian Standards, Boiler and boilar component manufacturers.
Users and other interests.
Section 28 provides power and matters of regulations by the Board.
Sec. 28Aand 29 are for the rule making power of Central and State Govt.
respectively.
Central Boilers Board makes and notifies regulations consistent with this Act.
The main duties of the Boiler Inspector are the inspection and examination of boilers
and steam-pipes in accordance with chapter IX of the Regulations and Chapter IV and
V of the Gujarat Boiler Rules 1966. Reduction of pressure can be suggested. Sanction
for repairs to boilers shall be obtained beforehand. Provisional orders should be issued
after hydraulic tests.
Penalties have been increased up to Rs. 1 lac or /and 2 years imprisonment u/s 24
Static and Mobile (Unfired) Pressure Vessels Rules, 1981
U/S.5 and 7 of the Explosives Act 1884, the' Central Government notified these
rules w.e.f. 5-21981. They have 8 chapters, 69 rules, 3 appendices, 2 schedule and 5
forms.
Definitions : Out of (a) to (z) definitions, majority are scientific and therefore they are
reproduced below.
1. "Permanent Gas" means a gas whose critical temperature is lower than 10°C.
2. "Liquefiable Gas" means any gas that may be liquefied by pressure above 0°C, but
will be completely vaporised when in equilibrium with normal atmospheric pressure
(760 mm HG) at 30°C;
3. Cryogenic liquid means liquid form of permanent gas having normal boiling point
below minus 165° C.
4. Critical temperature means the temperature above which gas cannot be liquefied by
the application of pressure alone.
5. "Compressed gas" means any permanent gas, liquefiable gas or gas dissolved in
liquid or cryogenic liquid under pressure or gas mixture, which in a closed pressure
vessel exercises a pressure exceeding one atmosphere (gauge) at the maximum
working temperature and includes Hydrogen fluoride. In case of vessels without
insulation or refrigeration, the maximum working temperature shall be considered as
55°C.
6. “Design" includes drawings, calculation, specifications, models, codes and all other
details necessary for the complete description of the pressure vessel and its
construction;
7. LPG i.e. Liquefied Petroleum Gas includes hydrocarbon gases in liquefied state at
normal ambient temperature by the application of pressure, and conforming to the IS :
4576.
8. Dispenser means an equipment installed in LPG dispensing station, meant for
dispensing LPG as automotive fuel to motor vehicles;
9. "Design pressure" means the pressure used in the design calculations of a vessel for
the purpose of determining the minimum thickness of the various component parts of
the vessel;
10. "Filling density" means the ratio of weight of liquefiable gas allowed in a pressure
vessel to the weight of water that the. vessel will hold at 15°C;
11. "Flammable compressed Gas" means gas 13 percent or less of which when mixed
with air forms a flammable mixture or whose flammable range with-air is greater than
12 percent;
12. "Gas Free" in relation to a pressure vessel means the concentration of flammable or
toxic gases or both if such pressure vessel is within the safe limits specified for persons
to enter and carry out hot work in such vessels;
13. "Pressure Vessel or Vessel" means any closed metal container of whatever shape,
intended for the storage and transport of any compressed gas which is subjected to
internal pressure and whose water capacity exceeds 1000 litres and includes inter
connecting parts and components thereof up Fundamentals of Industrial Safety and
Health 28- 22 Specific Safety Laws to the first point of connection to the connected
piping and fittings but does not include containers wherein steam or other vapour is or
is intended to be generated, or water or other liquid is or is intended to be heated by the
application of fire or the product of combustion or byelectrical means, heat exchangers,
evaporators, air receivers, steam-type digesters, steam-type sterilises, autoclave,
reactors, calorifiers, pressure piping components such as separators or strainers and
vessels containing a liquid under a blanket of compressed inert gas.
14. "Safety relief device" means an automatic pressure relieving device actuated by
the pressure upstream of the valve and characterised by fully opened pop action,
intended to prevent the rupture of a pressure vessel under certain conditions of
exposure;
15. "Source of ignition" means naked lights, fires, exposed incandescent materials,
electric welding arcs, lamps other than those specially approved for use in flammable
atmosphere, or a spark or flame produced by any means;
16."Water Capacity" means capacity in litres of the pressure vessel when completely
filled with water at 15°C.

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BHARATH NIKETAN ENGINEERING

M.E - Industrial Safety Engineering

IS5010 – SAFETY IN ENGINEERING INDUSTRY

III Semester - R 2017

Basic mechanical motions and actions that can potentially be hazardous:

Focus Your Efforts to Reduce Losses:

• Provide frequent supervision of newly-hired and inexperienced employees.

SAFETY PRINCIPLES FOR CNC MACHINE TOOLS:

International Safety Requirements

Demands and Safety Measures for Machine Accessories

Requirements and Safety Measures for the Automation of Machine Tools

Requirements and Safety Measures in Normal and Special Modes of Operation

Demands on Safety Control Systems

Main Features of the EEC Machinery Directive

· Each individual state must integrate the directive in its legislation.

1.1 Normal mode of operation

· due to insufficient clamping

· due to material defects

1.2 Special modes of operation

2.1 Normal mode of operation

· due to insufficient clamping

· due to material defects

2.2 Special modes of operation

3.1 Normal mode of operation

· due to insufficient clamping

· due to material defects

4.1 Normal mode of operation

· due to insufficient clamping

· due to inadmissible rotation speed

4.2 Special modes of operation

Heat Treatment Operations:

Heat treatment of rolled products are divided into two groups :

Control Measures are as under:

Hazards and Control from Treatment Media:

Colour Code and Safety :

Painting of Plant and Machinery :

HEALTH AND WELFARE OF Engineering Industry

First-aid and Health Services :

Radiation Protection Rules, 1971:

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