Mechanical Hazards

INTRODUCTION
Industrial workers move in plant consisting of
several mechanical equipment's, machines,
auxiliary system, material handling and
transportation equipment, high pressure
equipment etc. Some workers work with
machines having rotating, sliding, edge, hard,
surface, gears, chain drive etc. Factory areas are
several unsafe conditions with reference to
mechanical hazards.
Mechanical hazards involve possibility of
physical injury to human body due to moving
objects ,fall of workers etc. Mechanical hazards
are most common in industry. The result is
injury ,disability and possible death of workers.
Some injuries damage body parts such as
hands, legs, eyes, nose, face, head etc. some
mechanical accidents result in disability, where
as some are fatal. The safety management aim
at zero mechanical accidents.
The of main cause mechanical hazards:-
• Failure of components of a mechanical system due
to faulty design, faulty assembly lack of repair and
maintenance.
• Inadequate safeguards on the machines.
• Unsafe use of PPE.
• Unsafe on the part of workers at point of
operations.
• Note:- The chief sources of mechanical hazards
originate from flywheels ,moving machinery,
pressure vessels, belt, chain, lift, shafts, hand
tools, power tools.
Machine guard and safety devices:-
Machines guards are basically mechanical guards
which serves as barriers to prevent the entry of any
portion of the body of a workers from coming in to
contact with the danger points or hazard zones.
Machines guards can be broadly classified:-
• Totally enclosed
• Enclosed type with provision of adjustable access
• Enclosed type with provision for limited access
• Enclosed type with interlocking devices
(mechanical/electrical)
The basic requirement for mechanical guards are as
follows:-
• It must be study to prevent damage to the
guard from external sources or interference
with the operation of the machine.
• It must be properly mounted. The mounting
must be rigid to prevent objectionable rattles or
interference with working parts. The
maintaining should be strong enough so that
they will not fail under use.
• It should easy to inspect and, a periodic
checkup programme as a part of the
maintenance procedure for shop
equipment should be established in order
to continue it effectiveness.
Safety devices
A safety device is a controlling mechanism or
device associated with the following function.
• It can stop function of the machine. Itself if
there is any fault in the working zone.
• It can prevent the workmen to reach the hazard
zone.
• It can dissociate the hands or limbs of the
workmen from to the hazards zone,the moment
machine starts.
General precaution for using the safety device:-
• Checking of the guards or safety devices daily
before beginning of the works.
• Tinkering, adjusting or removing of the guard
should be strictly prohibited for all operators
• Regular repair maintenance ,surveillance and
monitoring are needed to keep the whole system.
• The worker should have an easy and quick
access to the controlling mechanism (starting &
emergency switches)
• PPE must be ensured .the use of lose garment
must be prohibited.
 Hand tools and power tools:-
Hand tools:- Tools which are operated
manually by workers or operator e.g.:- hacksaws
chisels, file, hammers, screw drivers hand-drills.
• The potential hazards in hand tools operations
consist of danger from sharp edge of tools
flying, splinters during chipping operation
abrasive nature of work surface and slipping of
tools.
The following precautionary measures are suggested
in connection with hand tools:-
• The work bench should be of adequate dimensions
to facilities all operations
• Workers should work with due connection on the
job.
• Hand tools must be kept in their proper places in a
systematic manner.
• Hand tools which are sharp ,pointed or heavy
should be handled with care (e.g. chisel ,sledge
hammers, hacksaws etc. and the sharp and pointed
must be kept adequately covered to prevent injury.
Power tools:- (operated by electrical motors or
by air compressors).
e.g.:- power drills ,grinders etc. are safer to use
as compared to hand tools.
Safety devices for some important machines
and instrument in industry:-
• Rope:- steel wire rope are commonly used in
industry. Ropes made of nature fibers. Ropes
have a limited use. Steel wire ropes find their
use in lifting tackles, hauling operations.
Following precautionary are necessary for
safety ropes:-
• The choice of the rope should be on the
manufacture’s specification
• The strength should be sufficient to sustain to
load or force.
• Bending action on the ropes must be avoided
specially the reverse bending, that will induce
fatigue in the material
• Handling of steel wire ropes should be proper
so that neither kinks.
• Through inspection must be carried at regular
intervals so that a worn out rope must be
immediately replaced.
• Maintenance of steel wire rope must be
regularly done.
• Never overloaded wire rope .
Portable ladders:- Portable ladders are extensively
used during repair, maintainence or in case of
some jobs for doing such job to workers has to
perform work at certain height.
Some of the precautionary measures to adopted
to use of ladders:-
• The ladders must be appropriate length without
any defects or overloading.
• The ladders must be sufficiently strong and
non-slippery.
• It should not be used during storms,gales
heavy gusts of wind.
• Metal ladders in proximity of line electric wires
should be used.
• The end of the ladders must be placed non-
slippery surface.

Chain: - chains are used for hoists, marine etc. it

is made from wrought iron and free of any
admixtures of iron scarp or steels.
The following points need careful consideration in case
of chains:-
• Through and regular inspection of the chains
should be done by experts having adequate
knowledge and experience .
• chain should use if defective
• The material used in chain must be as per
specification and the load carrying capacity of
the chain has to be ascertained and clearly
marked.
Fly wheels:- flywheel contribute to the
development of excessive centrifugal force which
can cause serious accident if not property
attended to.
The following precautionary measures should be
taken to minimize hazards due to flywheels:-
• Controlling the speed of the flywheels is very
important consideration. Flywheel turning at
excessive speeds are fraught with danger. Hence
speed control devices or mechanisms must be
provided as for example governors to control the
speed of the prime movers etc.
• Suitable enclosures or barriers must be used for
protecting the operators from accidental contacts
with the flywheels in motion.
• Regular inspection of the components of prime
movers should be done by qualified and
experienced experts .
• Proper maintenance of the whole system
• The design and construction of the flywheel itself
need attention and care and any defect on this
count could be disastrous.
Lifting tackles and lifting devices :-Lifting tackles
such as cranes and hoists may be a cause of
accidents due to mechanical failure or unsafe
operating practice.
The following precautionary measure are to be
adopted to avert or minimize accidents:
• Frequent periodic inspection and maintenance
of such parts as chain, wire, ropes, gears
clutches, brakes, bearing and other
fundamental elements for efficient
performances.
• Mechanical failures of the components should
be avoided through proper design,
construction and materials specification.
• Regular inspection of lifting tackles and
equipment by qualified and experienced
experts is another important.
• Improper or defective operating procedures
have to be avoided.
• PPE use specially helmets etc.
 Mechanical handling equipment

Mechanical handling equipment are extensively

used in industries for carrying out various
operations including that of materials handling
for example Transportation of materials in bulk
like iron, cartons, coals etc. The mechanical
handling equipment may be in the form of
conveyors and ropes ways, elevators, lift trucks
etc.
Conveyors:-Precautionary measures for
conveyors
• The operators and workers working in the
proximity must be thoroughly trained.
• To avert any possible accident the conveyors
must be provided with guard at all vulnerable
position.
• To prevent injury to workers from falling
material from conveyors. Proper barriers
should be installed in the vicinity of all working
areas and passage ways.
• All cut out in the flooring system should be
properly guarded.
• Warning signals must be displayed at the
points or positions which are vulnerable.
• Regular inspection by experienced persons
must be done for timely replacement of
defective components.
Ropes ways:-

Precautionary measures for ropes ways.

• The attachment of the carriage to the
ropes must be fool proof.
• The load caring capacity of the carriage
must not exceed.
• The steel wire ropes must be of right
specifications.
Elevators/Lifts:-Elevators is a lifting devices.
The following precautionary measures may be
adopted for elevators
• The hoist way or the lift must be provided with
suitable enclosure
• The lift landing should have proper illumination of
100 Lux at the lift landing would be reasonable.
• Safe carrying capacity, the safe working load or
number of passengers to be carried must be
prominently displayed. No relaxation on this
count should be permitted.
• The landing door controlling access to a lift
must be provided with suitable locking
arrangements with proper interlocking system.
It must be ensured that the movement of lift
does not occur when the door is open
• The entrances or the gates of the lift must
remain closed except when loading or
unloading of materials
• Regular inspections and maintenance of lift are
essential to contain or minimize hazards.
 Fork lift trucks:-
The following consideration or precautionary
measures may be adopted for fork lift trucks
• Maintenance and inspection of the trucks must be
done at regular intervals to ensure that all the
components of the trucks as for example Brakes,
Gears, Lighting system etc. are in perfect working
conditions.
• The driver or truck operators must be well
conversant with the proper use and safety norms
for fork lift trucks.
• In order to avoid excessive loading of materials
at the rear portion of the truck, a suitable
barrier may be provided to achieve this goal
• The operators may be protected from injury
caused due to falling objects from the fork lifts
by providing a sufficiently strong overhead
protection
Prevention of accidents in general due to mechanical
handling equipment:-
• Proper training of operators
• Adequate illumination of work areas
• Safety device including guards, railings etc.
• Proper layout and planning including convenient
demarcation of passage ways
• Safe operating condition or procedures
• Regular maintenance of the whole system of
mechanical handling equipment
• Provisions of personal safety equipment including
safety belts, helmets etc.
Pressure hazard and pressure vessels:-

Pressure hazards:- Pressure hazards are

caused due to both compressible and
incompressible fluids .pressure hazards
may be classified
• Low pressure hazards
• High pressure hazards
Low pressure hazards:-
Low pressure hazards can occur at high altitude. The
hazards may be characterized by bleeding from the
nose and problems related to hearning capacity
High pressure hazards:-
Explosions, sudden ejection of liquids or gases under
high pressure, production of water hammer etc. are
some of the hazards associated with high pressure.
water hammer in pipe line may occur due to sudden
closing of valve carrying an incompressible
fluid.sudden increase in the pressure momentarily
which can cause damage in the pipe line system
Pressure vessels:- Pressure vessels are
containers meant for storing fluids under
pressure. These pressure vessels can classified
as follows
• Unfired pressure vessels
• Fired pressure vessels
1. Unfired pressure vessels:-
These pressure vessels are always stored away
from source of heat. LPG cylinders, Acetylene,
Cylinders, Oxygen cylinders etc. are some of the
example of unfired pressure vessels.
Hazards in unfired pressure vessels:-
•Increase in pressure which can cause damage to
the container resulting in the leakage of fluids.
•The materials of the vessels may get corroded
after long use.
•Sudden rupture of the pressure vessels due to
excessive building up of pressure if uncontrolled.
NOTE:-This may lead to failure of the container
characterized by flying fragment or splinters causing
injury to person in the vicinity of the pressure
vessels.
Hazards and safety measures in the use of gas
cylinders (unfired pressure vessels):-
In industries (oxygen + acetylene) gases are
generally used to generate flames. This flame is
extensively used in welding and cutting operations of
metals. Hazards can result from these
cylinders(oxygen/acetylene) on account of the
pressure as well as the flammability of the stored
gases.
Precautionary measures for gas cylinders:-
• Identification
• Storage
• Transportation
• Design pressure of cylinder
• Testing
• Non return valve
• Regulation
 Fired pressure vessels :-
Fire pressure vessels are used for generating
gaseous materials as for example steam. Boilers
are examples of fired pressure vessels. Fired
pressure vessels in general are more hazardous in
nature as compared to unfired pressure vessels.
Boilers can be classified as fire tube boilers and
water tube boilers. Fire tube boilers are commonly
used for mobile units as for example locomotive
boilers etc. Water tube boilers which process
quick steam raising capacity and are used as
stationary boilers in thermal power stations.
 Hazards in fired pressure vessels:-
• Increase in the pressure beyond permissible
limits which can cause damage to the container
resulting in the leakage of fluids
(steams, hot waters etc.)
• Improper heat control in the furnaces can result
in to furnace explosion.
• The material of the tank may be subjected to
fatigue after prolonged use resulting in the
weakness of the fired pressure vessels.
• Corrosion of the materials of the vessels after
prolonged use.
• Sudden rapture of the pressure vessels due to
excessive building up of pressure if
uncontrolled. this may lead to failure of the
container characterized by flying fragments or
splinters causing injury to person in the vicinity
of the pressure vessels.
• Lack of proper repair and maintenance are
potential hazards .leakages of all sorts example
leaking of tubes ,leaking and defective gaskets
at the joint, leaking of valves as well as poor
painting etc. can significantly contribute
towards a hazardous situation.
General safety provision of pressure vessels:-
• Inspection
• Recording instruments
• Safety vent
• Education and Training
• Testing
• Repair and maintenance