Dr GNR Prepared Study Material

UNIT II - Industrial Safety and Occupational Health

UNIT II - INDIAN LAWS GOVERNING INDUSTRIAL SAFETY: Factories act, State rules there under building and other
construction workers acts and rules, Gas cylinders’ rules, Explosives acts, Petroleum act, Static and Mobile pressure
vessels (Unfired) rules, Indian Boiler acts and rules.
EMPLOYEE SAFETY: Concept of Man-Machine system, Applications of human factors engineering, Human
behaviour, Individual difference, Unsafe Action Factors, Personal Factors, Psychological and Psychosocial Factors,
Motivation, Frustration and Conflicts, Attitudes and Learning concepts.
PERSONAL PROTECTIVE EQUIPMENT: Types, specifications, standards, testing procedures, maintenance.
PRINCIPLES OF ERGONOMICS: Application of ergonomics in a work system.
TEXT BOOKS
1., Fundamentals of Industrial Safety and Health, 1st Edition, Siddharth Prakashan, 2008
No. Hours of Teaching: 10
Sl. Content Page No. Remarks
No. Dr. K.U. istry
1 INDIAN LAWS GOVERNING INDUSTRIAL
SAFETY: Factories act,.
Factories Act and Case Law 27.1 - 27.30
Factories Act and Rules 11.2
Factories Act and Rules 15.10
2 State rules there under building and other 22.1 – 22.22
construction workers acts and rules,
3 Gas cylinders’ rules, 2004 28.16
4 Explosives acts, 28.11
5 Petroleum act, 1934 28.5
6 Static and Mobile pressure vessels (Unfired) 18.70,
rules, [18.105-
18.106 ]
7 Indian Boiler acts and rules, 1950 28.2
8 EMPLOYEE SAFETY: Concept of Man- 3.28, 6.59, Pdf file notes should be referred
Machine system, 14.30 . 19.20,
19.21,, 20.13,
24.69
9 Applications of human factors engineering, 14.21
10 Human behaviour, Individual difference, 3.14
11 Unsafe Action Factors, 3.15
12 Personal Factors,. 3.17
13 Psychology and Psychosocial Factors, 3.1 – 3.5
14 Motivation, 3.19 – 3.32
15 Frustration and Conflicts, 3.9 and 3.10
16 Attitudes and Learning concepts 3.7
17 PERSONAL PROTECTIVE EQUIPMENT: 25.3 – 25.23
Types,
18 specifications, 25.2
19 standards, 25.30
20 testing procedures, 25.30
21 maintenance. 25.24
22 PRINCIPLES OF ERGONOMICS: Application 22.41 22.47,
of ergonomics in a work system 14.27 - 14.29
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UNIT-III - PRINCIPLES OF MACHINE GUARDING: Machine Safety risk assessment, Physical guard assessment and
allied Controls. 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 to ensure controls.
TEXT BOOKS
1., Fundamentals of Industrial Safety and Health, 1st Edition, Siddharth Prakashan, 2008
No. Hours of Teaching : 06
S Content Page No.
l. No. Dr. K.U. istry
1PRINCIPLES OF MACHINE GUARDING: 14.1 - 14.24 Chapter – 14
Machine Safety risk assessment
2Physical guard assessment and allied Controls. 14.1
3 Guarding during maintenance, 14.22
4Zero Mechanical State (ZMS): Definition. 14.4 Notes included in study material
policy for zms,
5Guarding of hazards - point of operation 14.4
protective devices,
6machine guarding, types 14.2 , 14.3
7fixed guard, interlock guard, 14.1 - 14.24 Check from text book
8automatic guard, trip guard, 14.1 - 14.24
9electron eye, positional control guard, 14.1 - 14.24
fixed guard fencing, guard construction, 14.1 - 14.24
guard opening. 14.1 - 14.24
Selection and suitability to ensure controls 14.30 -14.31 Questions : 14.31 – 14.33

PRINCIPLES OF MACHINE GUARDING

October 31, 2017

Machine guarding for safety

Point of operation:-

That area in a machine where the material is positioned for recessing by

the machine and where work is actually being performed on the material.

Zero Mechanic state (ZMS):-

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Mechanical state of a machine in which every power source that can

produce a machine member movement has been Shut/locked off. This means
d energized, pressurized a neutralized condition of machine or equipment
which provides maximum protection against the unexpected mechanical
movement.

Power off:-
The state in which power (electric, pneumatic, hydraulic, atomic, etc.)
cannot flow to the machine is considered a power-off stage.

Power-locked off:-
The state in which the device that turns the power off is locked in the off
position with the padlock of every individual who is working on the machine.

Guarding:-

Any means of effectively preventing personnel from coming in contact

with the moving parts of machinery or equipment which could cause physical
harm to the personnel. In case of a power-press, a cover on point of
operation(die and punch) is called guard while those on other danger zones
are called enclosure or safeguard.

Safety by guarding is most important as other methods are not always

possible. Depending upon the dangerous part, its Size, position, speed, etc, a
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guard should be selected generally the parts to be guarded fall within three
categories.

1. [Link] prime mover,

2. Transmission part form the, prime mover to the machine and the
transmission parts in the machine itself. It is desirable to minimize them and
enclose completely.
3. Operating parts of a machine, which the points of dangerous
operation need effective guarding.

A machine guarding:-
Means any sure, barrier or device constructed to prevent a person or his
clothing coming into contact with dangerous parts of the machine. The point
of operation is that part of the working machine at which cuffing, shaping,
forming or any other necessary operation is accomplished. A guard for that
part is known as the point of operation guard.

Enclosures:-
Guarding by fixed physical barriers that are mounted on or around a
machine to prevent access to the moving parts.

Fencing:-
Guarding by means of a locked fence or rail enclosure which restricts
access to the machine except by authorized personnel. Enclosures must be a
minimum I m (42 in) away from the dangerous part of the machine.

Safety by Position or Location:-

It is a guarding as a result of the physical inaccessibility of a particular
hazard under normal operating conditions or use. Words safe location or safe
by position are used to denote safety by distance.

The words safe by position are used section-21 of the Factories Act. It
means the situation (out of reach) or position in such a way that normally it is
not possible to touch dangerous parts. However intentional should be
prevented. Moving geed opening be made safe by position if gravity or remote
feeding device is applied. But, then, it is of indirect guarding. A distance of 2.6
m or 8” , 6” is considered safe by position.
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Ingoing (in-running) Nips:-
A hazard a created by two or more mechanical components in opposite
directions in the same plane and in close conjunction or interaction calendar
rolls, inuring rolls of textile or machines.

Safety by Construction:-
It indicates parts constructed as to cause no hazard, shift sliding and link
mechanism so located or slow speed that their contact is not dangerous Built-
in. safety is a similar word for the design and construction of new machinery
in such a way to make the dangerous parts safe by housing or position etc.

Elimination of Hazard:-
Hazards form machinery are generally following types:

Crushing, shearing, cutting or seven entanglements, drawing-in or

trapping, impact, stabbing or puncture, friction or abrasion, injection of mate
from the machine, contact with moving part, hot sun or sharp edge, free fall
of any material, tool equipment and high pressurized.

The basic steps to prevent accidents are:-

1. Eliminate the hazard from the machine, method material, structure,

etc.
2. Control the hazard by enclosing or guarding at its source.
3. Train personnel to know that hazard and follow the safe job method
to avoid.
4. Use personnel protective equipment necessary.
Thus machine guarding is one of the basic to eliminate hazard. Actually
the machine should so designed and constructed that all safety points
incorporated by built-in safety principle and necessary extra guards should be
minimum.

Types of Machine Guards

There are several different types of machine guards. Guards are materials that keep
workers from having direct contact with moving parts and other dangerous areas of a machine.
Some guards also protect workers from shavings, flying shards or metal sparks created by
working machines. The Occupational Safety and Health Administration (OSHA) requires any
machine part that could cause injury to be guarded. Guard design and material will vary from
machine to machine and from tool to tool. The most common types of machine guards are:
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 Fixed guards
 Interlocking guards
 Adjustable guards
 Self-adjusting guards

Fixed Guards
Fixed guards are permanently attached to the machine or tool, don’t have any moving
parts, and can’t be moved while the machine is in use. They’re most often used to enclose the
point of operation, or other hazards that the operator doesn’t need to interact with, like fan blades
or flywheels. Because fixed guards are permanent features of the machine, they must be
disassembled and removed to perform any kind of adjustment or maintenance.

Adjustable Guards
Adjustable guards, like fixed guards, are permanent, but they can be adjusted to allow the
machine to handle different sizes of material. They must be manually adjusted and locked into
place, so all employees who will operate adjustable guards must be trained on their use. If
improperly adjusted or locked, adjustable guards can fail to prevent contact with moving parts,
causing serious or even fatal injury.

Self-Adjusting Guards
Self-adjusting guards serve the same purpose as adjustable guards, but automatically
adapt to the size of the material. When the machine is at rest, these guards sit all the way down.
When the machine is in use, the operator feeds material into the machine, which opens the guard
just enough to let the material in. These guards are commonly found on table saws and
woodworking tools.

Interlocking Guards
Interlocking guards, also known as barrier guards, automatically shut off or disengage the
power source when the guard is open or removed. These are particularly useful in situations
where operators need to be able to open the guard or access the guarded parts of the machine,
such as when clearing jams. These guards allow safe access to interior parts of the machine
without requiring a total disassembly. However, they can be easy to open on accident and require
careful adjustment and maintenance.

General Safety Precautions

To avoid potentially life-threatening injury, employees should receive proper training
before operating any machines or power tools. Employees must never operate machinery without
prior training. Employees must:

 Inspect all tools and guards before each use

 Follow all proper lockout/tag out procedures when necessary
 Use proper procedures when setting up a machine, adjusting a machine, clearing
jams, and cleaning or lubricating parts
 Never remove guards while operating a machine
 Tag all damaged guards and machinery “Do Not Use” and report them immediately
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Summary
The majority of machine-related injuries are completely preventable. To keep your
workplace safe and avoid costly injuries and lawsuits, provide all employees with proper training
before they operate any machinery or guards and keep up with regular maintenance and repairs.
Instruct employees to never remove machine guards before or while operating a machine.

Requirements: Machine Guarding

Identify all the potential hazards in your workplace that require machine safeguarding
and ensure they adhere to OSHA regulations.
Moving machine parts create workplace hazards and potential machinery-related
injuries, making machine guards vitally important. All machines consist of three fundamental
areas – the point of operation, the power transmission device and the operating
controls. Machine safeguarding helps protect workers from preventable injuries in all three
areas.
The Occupational Safety and Health Administration’s (OSHA’s) requirements for
machine guarding are found in 29 Code of Federal Regulations (CFR) 1910 Subpart O,
Machinery and Machine Guarding as detailed below;
 1910.211 — Definitions

 1910.212 — General requirements for all machines

 1910.213 — Woodworking machinery

 1910.214 — Cooperage machinery [Reserved]

 1910.215 — Abrasive wheel machinery

 1910.216 — Mills and calendars in the rubber/plastics industries

 1910.217 — Mechanical power presses

 1910.218 — Forging machines

 1910.219 — Mechanical power-transmission apparatus

General Requirements
29 CFR 1910.212(a)(1) states that one or more methods of machine guarding must be
used to protect operators and other employees from hazards, including those created by
point of operation, in-running nip points, rotating parts, flying chips and sparks.
Hazardous Mechanical Motions and Actions
Identifying hazards is the first step toward protecting workers and promoting safety in
the workplace. The basic types of hazardous mechanical motions and actions are:

Motions Actions

Rotating Cutting
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In-running nip
Punching
points

Reciprocating Shearing

Transversing Bending

Examples of Hazardous Mechanical Motions

A rotating motion can be dangerous. Even smooth, slowly rotating shafts can grip
clothing, and through mere skin contact, force an arm or hand into a dangerous position.
Collars, couplings, cams, clutches, flywheels, shaft ends, spindles and horizontal or
vertical shafting are examples of common hazardous rotating mechanisms. The danger
increases when bolts, nicks, abrasions and projecting keys or setscrews are exposed on
rotating parts.

Rotating parts cause hazards such as in-running nip points. There are three main
types of in-running nip points. Parts can rotate closely to each other in opposite directions
while their axes are parallel to each other. When they run closely, the stock fed between two
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rolls produces a nip point. This danger is common on machines with intermeshing gears,
rolling mills and calendars.

Rotating and tangentially moving parts also cause nip points. Potential hazards include
the points of contact between a power transmission belt and its pulley, a chain and its
sprocket, or a rack and pinion.
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Nip points also occur between rotating and fixed parts, spoked hand wheels on
flywheels, screw conveyors and the periphery of an abrasive wheel - and create shearing,
crushing or abrading actions.
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Reciprocating motions cause a back-and-forth or up-and-down action that can strike a

worker or catch a worker between a moving and a stationary part.
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With transverse motion – movement in a straight continuous line – moving parts can
catch or strike a worker in a pinch point or shear point.

Examples of Hazardous Mechanical Actions

Cutting action hazards involve rotating, reciprocating or transverse motion, where
finger, head and arm injuries can occur and where flying chips and scrap material can strike a
worker’s eyes or face. Cutting actions are dangers with bandsaws, circular saws, and boring
or drilling machines.

Punching action results when power is applied to a slide (ram) for the purpose of
blanking, drawing or stamping metal or other materials. The danger occurs where stock is
inserted, held and withdrawn by hand as with power presses.
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Shearing action involves applying power to a shear or knife to trim or shear materials
such as metal. The danger is where stock is inserted, held and withdrawn, as with
hydraulically or pneumatically powered shears.

Bending action results when power is applied to a slide to draw or stamp metal or other
material. This is a threat where stock is inserted, held and withdrawn, as with equipment such
as power presses.

Requirements for Safeguards

Machine safeguards must meet these minimum general requirements:
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1. Prevent contact: The safeguard must prevent hands, arms or any other part of a
worker’s body from contacting dangerous moving parts.

2. Be secure: Workers should not be able to easily remove or tamper with the
safeguard. Guards and safety devices should be made of durable materials that will
withstand normal use. They must be firmly secured to the machine where possible or secured
elsewhere if attachment to the machine is not possible.

3. Protect from falling objects: The safeguard should ensure that no objects can fall
into moving parts.

4. Create no new hazards: A safeguard defeats its own purpose if it creates a

hazard such as a shear point, a jagged edge or an unfinished surface. Edges of safeguards
should be rolled or bolted so that they eliminate sharp edges.

5. Create no interference: Any safeguard that impedes a worker from performing a

job quickly and comfortably might be bypassed or disregarded. Proper safeguarding can
enhance efficiency because it relieves a worker’s injury apprehensions.

6. Allow safe lubrication: If possible, the machine should be able to be lubricated

without removing the safeguard. Locating oil reservoirs outside the guard, with a line leading
to the lubrication point, will reduce the need for the operator or maintenance worker to enter
the hazardous area.
Types of Safeguarding
The type of operation, the size or shape of stock, the method of handling, the physical
layout of the work area, the type of material and production requirements or limitations help
determine the best method for safeguarding.
Safeguards are classified as either guards or devices
Guards
Guards are barriers which prevent access to dangerous areas. There are four general
types of guards:
1. Fixed guards are permanent parts of a machine. These guards are preferable
because they’re simple and permanent.
2. Interlocked guards automatically shut off or disengage power through a tripping
mechanism when it is opened or removed. The machine cannot cycle or start until the guard
is replaced.
3. Adjustable guards are useful because they accommodate various sizes of stock.
4. Self-adjusting guards allow the opening of these barriers to be determined by the
movement of the stock. As the operator moves the stock into the danger area, the guard is
pushed away, providing an opening that only is large enough for the stock.
Devices
Safety devices perform several functions. They may stop a machine if any part of a
body is inadvertently placed in the danger area. They may restrain or withdraw an operator’s
hands from the danger area. They may require both hands on a control, therefore keeping
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both hands out of the danger area. They may also provide a synchronized barrier with the
machines operating cycle to prevent entry into the danger area.
Devices include:
 Presence-sensing devices are divided into two groups. Photoelectrical devices
use light sources and controls that can interrupt the machine’s operating cycle.
Radiofrequency or capacitance devices use a radio beam that is part of the machine control
circuit. When the capacitance field is broken, the machine will stop or not activate.
 Electromechanical sensing devices have a probe or contact bar that descends to
a predetermined distance when the operator initiates the machine cycle. If there is an
obstruction preventing it from descending to its full, predetermined distance, the control circuit
does not start the machine cycle.
 Pullback devices use cables attached to the operator’s hands, wrists and/or
arms. They are used primarily on machines with stroking-action hazards. When the slide/ram
is up (between cycles), the operator has access to the points of operation. When the
slide/ram begins to descend, a mechanical link automatically assures that the operator’s
hands move away from the point of operation.
 Restraint (hold-back) devices allow the operator’s hands to travel only in a
predetermined safe area and prevent the operator from reaching into a danger area. Cables
or straps are attached to the operator’s hands and a fixed point. No extending or retracting
actions are involved.
 Safety trip controls, such as pressure-sensitive body bars, safety tripods and
safety tripwire cables, quickly deactivate a machine in an emergency.
 Two-hand controls require both hands and constant pressure on the controls for
the machine to operate.
 Two-hand trip requires in sync application of both the operator’s control buttons
to activate the machine cycle after which the hands are free. To be effective, both the
controls and trips must be located so that the operator cannot use two hands or one hand
and another part of their body to trip the machine.
 Gates are movable barriers that protect the operator at the point of operation
before the machine cycle starts. To be effective, gates must be interlocked so that the
machine will not begin a cycle unless the gate guard is in place.
Though not actual guards or devices, location and distance can keep employees safe
by placing a machine in an infrequently traveled area or where it’s dangerous moving parts
are not accessible. A thorough hazard analysis of each machine and situation is essential
before using this safeguarding technique
Guard Construction
Guards designed and installed by the machine producer are desirable because they
conform to the design and function of the machine, and they can be designed to strengthen
the machine or to serve some additional functional purpose.
User-built guards are sometimes necessary and have some advantages. Often, with
older machines, they are the only practical solution. They also might be the only choice for
mechanical power transmission apparatuses in older plants, where machinery may not be
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powered by individual motor dries. User-built guards can be designed and built to fit unique
and changing situations and can be installed on individual dies and feeding mechanisms.
They also permit options for point-of-operation safeguards. When workers design and install
machine guards, they develop a better knowledge of those guards and how they work.
However, there are some disadvantages. User-built guards might not conform well to
the configuration and function of the machine and might be poorly designed or built.
Guard Materials
Metal, plastic, wood or any other material that is substantial enough to withstand
impact and prolonged use are all used as construction materials for machine guards. In many
circumstances, metal is the best material for guards. It might also be feasible to use plastic
where higher machine visibility is required. Guards made of wood are generally not
recommended because of their flammability and lack of durability and strength.
29 CFR 1910.219 Mechanical power-transmission apparatus, states that wood guards
can be options in woodworking and chemicals industries, and in industries where vapors or
gases or other conditions could deteriorate metal guards. Wood guards also may be used in
construction work and in outdoor locations where extreme cold make metal guards
undesirable. In all other industries, wood guards are not allowed, per 29 CFR 1910.219
(o)(2).

Q: What is the point of operation?

A: The point of operation is where work is performed on the material, such as cutting,
shaping, boring, or forming of stock.
Q: When must the blades of a fan be guarded?
A: The blades of a fan must be guarded when the periphery of the blades is less than
seven feet above the floor or working level. The guards must not have openings larger than
one-half inch (29 CFR 1910.212(a)(5)).

Date: 2nd MAY 2023

Place: BMSCE, Bengaluru