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 INDEX

Sl. No. TOPICS PAGE

1 Introduction to Industrial safety 3-5

2 The Factory Act 1948 6-8

3 Elements of OH&S 8

4 Accidents and their causes 9-12

5 Work permit system 13-14

6 Safety in handling of materials 15-25

7 Electrical hazards and preventions 26-28

8 Fire hazards and preventions 29-32

9 Safety in chemical storage & handling 33-38

10 Occupational diseases and preventions 39-43

11 First Aid 43-48

12 Role & responsibility of safety officers 49-51

13 Personal Protective Equipments (PPEs) 52-57

14 Safety inspection & audit 58 - 63

15 House keeping - 5S system 64 - 70

16 DO's And DON'T's of accident preventions 71-113

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 INRODUCTION TO INDUSTRIAL SAFETY

"A STITCH IN TIME SAVES NINE" - is the motto of a safety.

Industrial safety and Health is one of the most important aspects of an

organization's smooth and effective functioning and also ensures an accident free
industrial-environment. With the continuous and untiring effort of various legislative
authorities as well as NGOs, the awareness of Safety and Health-has improved in India
considerably. Organizations have started attaching the same importance to achieve
high safety performance as they do to other key aspects of their business activities, this
demands adoption of a structured approach for the identification of hazards, their
evaluation and control risks.

SOME TERMINOLOGY as per IS 18001 : 2000

ACCIDENT : Unplanned event giving rise to death, ill health, injury, damage or other
losses to personal or property.

HAZARD : A source or a situation with a potential to cause harm in terms of human

injury or ill health, damage to property or environment or a combination of these. ,

INCIDENT : Unplanned event which has the potential to lead to accident.

RISK : The combination of frequency or probability of occurrence and consequence of

a specified hazardous event.

SAFETY : State in which the risk of harm to persons; or damage to property is limited to
a tolerable level.

REHAB ELATION: The managed process of maintaining injured or ill employees in or

returning them to suitable employment.

DEVELOPMENT OF THE SAFETY MOVEMENT

The safety movement developed in five distinct stages :

1st stage : Improvement of environment or the removal of physical hazards.

2nd stage : Improvement of personal practices.

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3rd stage : Direct involvement of management, ie. setting up of various departments
charged with responsibility of ensuring safety and health.

4th stage : Development of safety movement. Safety cannot be viewed in isolation but
has to be considered as an essential element in an integrated approach to the planning,
organization and operation of an industrial enterprise.

5th stage : A cooperation effort on the part of industries to prepare codes and standards
to pool and disseminate information of technical aspects relating to safety.

WHAT IS INDUSTRIAL SAFETY ?

Any method or technique or process which can minimize unwanted events

(accident) in an industrial concerned is called Industrial Safety.

WHAT IS INDUSTRIAL SAFETY MANAGEMENT ?

INDUSTRIAL SAFETY MANAGEMENT is that branch of management which is

concerned with reducing, compiling and eliminating hazards from the industries
industrial units.

The following fields come under this management:

• All nuclear installations

• All construction projects
• All power houses
• All chemical industries
• All steel plants
• All mining and blasting operations
• Any other industry not exactly falling under the above categories.

SAFETY HIERCHY IN ORDNANCE FACTORIES :

Ordnance Factory Board (OFB), Kolkata , has decided to reframe and issue the
Corporate Safety Policy to match the corporate mission of organization. In this
organization . Health & Safety function would be geared to the prevention of all
accidents. OFB accordingly would accord the health and safety functions equal
importance with other activities and functions.

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AIMS & OBJECTIVES OF OFB's SAFETY PLAN :

• To ensure the working environment in every factory is safe and free from risks
and hazards.
• Accidents are to be eliminated and Zero Fatality Potential (ZFP) are to be
achieved in the OFs and OEFs with total loss prevention.
• Safety is the key word of the top management and pervades the whole factory as
an organizational culture.

TO ACHIEVE AIMS & OBJECTIVES :

To achieve Safety, Health & Environment Protection, OFB has categorized 40

Ordnance factories into six technology groups for comparison of their achievements
regarding implementation of various Acts, Rules & Regulations and Norms laid down by
the Central Government and other Statutory agencies like NSC, NPC, LP A, etc.

1. A & E Group (10 nos) - CFA, AFK, HEF, OFDR, OFBA, OFCH, OFV,
OFLOFK, OFBL

2. Heavy Engg. Group (7 nos) - HVF, OFMK, VFJ, GCF, OFAJ, OFC,
FGK
3. Medium Engg. Greup (6 nos) - GSF, EFA, RFI, SAF, OFT, MTPF

4. Light Engg Group (6 nos) - OFDC, OFBH, OCFC, HAPP, OLF,

OFDUN

5. Metallurgical Group (5 nos) - MSF, OFA, OFM, OFKAT, GIF

6. OEF Group (6 nos) - OEFC, OPF, OCFS, OCFAV, OEFHZ

Accordingly four Regional Controller of Safety (RCS) have been formed to audit and
monitor the activities of the factories regarding Safety.

1) RCS(NR)-15fys
2) RCS (CR) - 8 fys
3) RCS (SR) - 6 fys
4) RCS (WR) - 10 fys

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THE FACTORY ACT 1948 :

A commission was set up in 1875 by the Bombay Government recommending for

the prohibition of children under 8 years and a 12 hours/day for adults. Philanthropist
Shri S. S. Bengalee fought tenaciously for labourer's cause and the long agitation of
labour movements in India made so many changes in Acts and rules to provide better
treatment to the labours. The inauguration of the ILO in 1919 led to adoption of
conventions in hours , minimum age, night work of women and young persons etc. In
1948 some further improvements have been made in the factories Acts to bring factory
legislation in line with the legislations in the industrially advanced countries.

The main objectives of the Factories Act 1948 is to ensure adequate safety
measures and to promote the Health and Welfare of the workers employed in factories.
Government has taken various measures from time to time and consolidated and
amended the law regulating the safety, health and welfare of workers and labours in
Factories. The following topics are covering in this Act :-

Chapter -1: Preliminary

Chapter - II: The Inspecting staff
Chapter - III: Health
Chapter-IV: Safety
Chapter - IV-A : Provision relating to hazardous processes
Chapter-V : Welfare
Chapter - VI : Working hours of adults
Chapter - VII: Employment of young persons
Chapter - VIII: Annual leave with wages
Chapter - IX : Special provisions
Chapter - X : Penalties and procedures
Chapter - XI: Supplementary

Sections of Chapter HI - HEALTH (Sec. 11 to Sec. 20)

Sec. 11- Cleanliness

Sec. 12 - Disposal of Wastes & Effluents
Sec. 13 - Ventilation & Temperature
Sec. 14 - Provisions for exhaust appliances
Sec. 15"- Artificial humidification
Sec. 16-Over crowding
Sec. 17-Lighting
Sec. 18 - Drinking water
Sec. 19 - Provisions for latrines & urinals be made at convenient place
Sec. 20 - Spittoons

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Sections of Chapter IV - SAFETY (Sec. 21 to Sec. 40-B)

Sec.21. - Fencing of machinery

Sec. 22. - Work on or near machinery in motion
Sec.23 - Employment of young persons on dangerous m/c without training
Sec.24 -Striking gear & devices for cutting off power
Sec.25 - Self-acting machines
Sec. 26 - Casing of new machines
Sec.27 - Prohibition of employment of women and children near cotton
openers
Sec.28- Hoist & lifts
Sec.29 - Lifting machines, chains, ropes and lifting tackles
Sec.30 - Revolving machinery
Sec.31 -Pressure plant
Sec.32 - Floors, stairs and means of access
Sec.33 - Pits, sumps, openings in floors, etc.
Sec.34 - Excessive weights
Sec.35 - Protection of eyes
Sec.36 - Precautions against dangerous fumes, gases, etc
Sec.36-A - Precautions regarding the use of portable electric light
Sec.37 - Explosive or inflammable dust, gas, etc.
Sec.38 - Precautions in case of fire
Sec.39 - Power to require specifications of defective parts or tests of
stability
Sec.40 - Safety of buildings and machinery
Sec.40-A - Maintenance of buildings
Sec.40-B - Safety officers
Sec.41 - Provisions relating

Sections of Chapter IV-A - HAZARDOUS PROCESSES (Sec. 41-A to Sec. 41-H)

Sec. 41-A - Constitution of site appraisal committees

Sec. 41-B - Compulsory disclosure of information by the occupier
Sec. 41-C - Specific responsibility of the occupier in relation to hazardous
processes
Sec. 41 -D - Power of Central Govt. to appoint inquiry committee
Sec. 41 -E - Emergency standards
Sec. 41-F - Permissible limits of exposure of chemical and toxic substances
Sec. 41-G - Worker's participation in safety management
Sep 41 -H — Right of workers to warn about imminent danger

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OCCUPATIONAL HEALTH & SAFETY (OH&S):

What is OH&S management system ?

That part of overall management system which includes organizational structure,

planning activities, responsibilities, practices, procedures, processes and resources for
developing, implementing, achieving, reviewing and maintaining the OH&S policy and
so managing the OH&S risks associated with the business of the organization.

ELEMENTS OF OH&S : (as per IS: 14489 :1998)

1. OH&S policy
2. OH&S organizational setup
3. Education and training
4. Employees participation in OH&S management
5. Motivational and promotional measures for OH&S
6. Safety manual and rules
7. Compliance with statutory requirements
8. New equipment review/inspection
9. Accident reporting analysis investigation and implementation of
recommendations
10. Risk assessment including hazard identification
11. Safety inspection
12. Health and safety plan/target
13. First aid facilities
14. Personal protective equipment provision
15. Good house keeping
16. Machine and general area guarding
17. Material handling equipment
18. Electrical and personal safe guarding
19. Ventilation, illumination and noise
20. Prevention of occupational diseases through periodical medical
examination
21. Work environment monitoring systems
22. Safe operating procedures
23. Work permit system
24. Fire prevention, protection and fighting system
25. Emergency and preparedness plans
26. Process/plant modification procedure
27. Transportation of hazardous substances
28. Hazardous waste treatment and disposal
29. Safety in storage and ware housing
30. Contractor safety system
31. Safety of customers

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ACCIDENTS AND THEIR CAUSES :

An unwanted event can't be anticipated in advance may be termed as an

accident. It is always a sudden process and not a gradual one. As per Factories Act
1948, industrial accident has been defined as "an occurrence in an in an industrial
establishment causing bodily injury to a person which makes him unfit to resume his
duties in the next 48 hours."

CAUSES OF ACCIDENTS :

A large number of factors combine to cause accidents. Each of these factors is

different in different situations. The basic factors responsible fo causing accidents are :

(1) Unsafe acts

(2) Unsafe working conditions
(3) Multiple causes

1. UNSAFE ACTS:

• operating without authority, failure to secure or warn

• operating or working at unsafe speed
• making safety devices inoperative
• using unsafe equipments
• unsafe loading, placing, mixing, combing etc.
• taking unsafe position or posture
• working under or near overhead loads without taking due care
• carelessness during maintenance and repair work
• working on moving or dangerous equipments

2. UNSAFE CONDITIONS :

• inadequate guarded
• unguarded
• defective condition
• unsafe design of constructions
• hazardous arrangements, process etc.
• inadequate illumination
• inadequate ventilation
• unsafe dress or apparel
• unsafe methods

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3. MULTIPLE CAUSES :

• harsh and domineering behavior of the management or supervisors

• excess/long duration of work
• smog in the atmosphere
• excessive heat/cold in the factory environment
• reduced hearing capacity of the workers
• defective/reduced vision of the workers
• feeling of job security among workers
• alcohol addictions
• working under stress

SOME HUMAN FACTORS CAUSING ACCIDENTS :

carelessness, hurry, impulsiveness, laziness, failure to perceive danger, not using

personal protective equipments, lack of skill and experience, inadequate training, lack of
attention, physical disabilities, over confidence, etc.

REPORTNG OF ACCIDENTS :

The procedure of the reports of accidents should be as below :-

1. Whenever any accident/incident occurs to any employee/property inside the

factory or estate, the matter should be immediately brought to the notice of the
in-charge or Divisional Officer of the related area.

2. Injured person should be given First-Aid and to be sent to Factory Health Clinic
with the specified hospital certificate form no.

3. Safety section as well as Security should be intimated immediately about the

accident and subsequently a report is to be sent on Form No xxx (format shown )
duly signed by the Head of section on the same day itself.

4. In-charge of the section / group where the incident occurred should also
simultaneously submit a report of accident in form no IAFZ 3068 (7 copies) duly
signed by section officer on priority basis to the Medical Officer.

5. Medical Officer should forward the forms after completion to Labour Bureau
within 24 hours of accident.

6. In case the accident is in serious nature (grievous) , Div. Officer should report to
the GM who will order a Board of Enquiry.

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7. The spot of accident should be isolated till the Board of Enquiry gives all clear to
resume work.

8. In case of fatal accident, Admin officer should inform to the Inspectorate of

Factories authorities immediately and also to the District Magistrate or Sub
Divisional Officer and the Officer In-charge of Police having jurisdiction over the
area.

9. When the injured person returns to the work without any disablement before the
expiry of 21 days after the occurrence of incident, the joining report should be
given to the Inspectorate of Factories authorities within 7 days of return to the
work giving all particulars.

10. When the injured person does not return to work before the expiry of 21 days
after the occurrence of incident , Admin Manager should inform the Inspector of
Factories within 28 days of the occurrence in the specified form.

As per Tamil Nadu Factories Rule No 96 - all the reportable accidents should be
reported to Inspector of Factories and Rule No 97 - poisoning or occupational diseases
should be informed to Chief Inspector of Factories and also to Chief certifying Surgeon.

FORM OF REPORT OF ACCIDENT FORM NO XXX

1. SECTION :
2. LOCATION OF ACCIDENT :
3. M/C NAME & NO :
4. DATE & TIME OF ACCIDENT :
5. NAME OF PERSON & DESIGNATION : (who has met with accident)
6. NATURE OF INJURY/DAMAGE
7. CAUSE OF ACCIDENT IN DETAIL :
8. INVESTIGATION BY HOS :
9. NAME OF THE LINE INCHARGE OR ANY OTHER WITNESS
10. ANY OTHER REMARKS :

CHIEF SAFETY OFFICER HOS/SHOP

After receiving the Form of Report of Accident or any telephonic message, Safety
Officer /representative will rush to the accident spot and enquire/investigate how
accident occurred. In case of occurrences of serious nature Chief Safety Officer will
immediately report the same to GM with his view in line with safety aspects.

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CONDUCTING BOARD OF ENQUIRIES :

Based upon the Chief Safety Officer's report and Medical Officer's report Board of
Enquiry will be formed and the nominated enquiry officer will conduct the enquiry and
send the proceedings with his findings and recommendations to LB/Establishment.
Chief Safety Officer will receive the same reports from LB/Establishment for his views
and suggestions for remedial measures. CSO's suggestions and remarks will be
forwarded to GM for his approval. Finally the approval of GM will be sent to the section
where incident took place for the immediate implementation of remedial measures.
Safety section will follow the implementation of remedial measures if not they will force
to implement.

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WORK PERMIT SYSTEM:

INTRODUCTION :

Major accidents ,often resulting in fatalities have continue to occur repeatedly

while performing certain types of jobs under certain conditions.

Therefore ,to control and to prevent the repetitive accident occurrences ,some
positive means of safe guard and controlling measures is necessary. As a result, the
work permit system dawned from the experiences of several industrial workers who
have made supreme sacrifices for want of an established work permit system. The work
system proud to be one of the must satisfactory methods of ensuring positive controls
over hazardous operations performed in unfavorable conditions. More over ,the system
helped to affect greater controls on execution of jobs maintenance and repair works
performed simultaneously on the same equipment by different trades and sections
under separate supervisions.

WHAT IS A PERMIT ?

Work permit is essentially a document that, categorically spells out the risk of equipment
involved, its location, personnel involved ,time limitations, precautionary measures to be
taken together with likely hazards to be encountered if any.

USEFULNESS OF PERMIT

Work permits provide written information on the prevalent hazards connected

with the job performance. It spells out the suitable remedial measure to be adopted to
encounter the hazardous condition that are prevailing or that can be encountered while
performing the job .It also stipulates various conditions and limitations on the part of
reason actually required to perform the job. It indicates the various types of personnel
protective equipment to be used at different stages of work.

It serves as a pre determined check list for various safety precautions to be taken.
It also serves as a media of information to all concerned in advance. It proves a written
record of the operation including the personnel who were involved in the authorizing and
carrying out the operations. The permit system which necessitates carrying out the
various tests and safe guards instills a snsce of security from accidents in the winds of
the crew performing the job.

In a nut shell the work permit system offers one of the best methods to meet all
the various conditions required for making a hazardous operation safe and easy to
perform.

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TYPES OF PERMIT

Depending on the type of industry and the hazardous operations carried out
various types of permits have been developed to the individual industries needs.
However the most commonly work permits are

(a)Fire permit or hot work permit

(b)Safe entry permit or vessel entry permit
(c)Excavation permit
(d)Electrical work permit
(e)Acid area work permit
(f)Safe work permit or work at height

WHO ISSUES PERMITS & TO WHOM ?

Permits are issued by the in-charge having proprietary responsibility in the areas
and equipments. It is generally issued on the name of a supervisor or technician who is
to carry out the required job under the known hazardous condition.

WHAT DOES A PERMIT CONTAIN ?

A permit contains written information and instructions pertaining to hazardous that

are to be avoided in a particular operation. It also indicates that all hazards have been
considered in advance and foreseeable appropriate precautionary measures have been
taken. People responsible to execute a job defined in the permit are review them from
the point of compliance. It also indicates that the people executing the job have
reviewed the permit and accept responsibility of adhering to the instructions and
limitations stimulated. Thus a permit finally become a document of consent by both
parties, the proprietor and job executor.

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 SAFETY IN HANDLING OF MATERIALS

Materials handling in factories is carried out by two methods.

1. Manual handling of materials.

2. Mechanical handling of materials.

1. MANUAL HANDLING OF MATERIALS

Following are the types of accidents due to unsafe / wrong handling :

STRAINS

Stretching a muscle beyond its proper limits. When you feel the pain it is too late to do
anything about it. The muscle is already injured.

SPRAINS

A weakening of a joint and related muscles by sudden or excessive exertion,

HERNIAS

Protrusion of an organ (often the intestines) because of a pulling apart of the body's
muscle lining.

WOUNDS

Cuts and bruises usually on hands, fingers, feet or toes.

FRACTURES

Breaking or cracking bones-usually the result of jamming fingers- or dropping objects

on toes.

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 ALL THESE ABOVE MEAN SUFFERING AND MAY REQUIRE MEDICAL
ATTENTION AND HOSPITALIZATION.

To avoid the wrong ways of manual handling, every person handling materials should
ask the following 3 Questions about any materials to be handled :

i) How to pull the material ?

ii) How to push the material ?
iii) How to carry the materials ?

The basic safety tips for manual handling are as below :

1. GET HELP

If there is any doubt about your ability to move the object by yourself.

2. WEAR SAFETY SHOES

With steel toes to prevent injuries from dropped objects.

3. KEEP HANDS CLEAR

Fingers can be crushed when load is put down carelessly.

4. WEAR GLOVES

To protect against cuts, scratches and burns.

5. LIFT WITH YOUR LEGS

6. GET A GOOD TRIP

To make carrying easier and to protect your fingers and toes.

THE PERSON HANDLING THE MATERIAL IS SAFE WHEN -

1. He plan the move.
2. He knows the right way to lift.
3. He knows how to carry objects,
4. He knows how to set them down.
5. He knows the proper way to push and pull.

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METHODS OF PLANNING MATERIALS HANDLING

1. DECIDE in advance how you are going to do the job.

2. PLAN the route you will take --- free from tripping hazards.

3. DETERMINE where the object will be set down --- whether help is needed.

4. LOOK OVER the objects to see where and how to hold it.

5. REMOVE grease and oil from load so it is as dry as possible.

6. CONSIDER the distance the load is to be moved. Plan rest stops if necessary.

7. BE SURE that there is enough space to handle the object safely.

8. USE lift truck or conveyor for things not meant to be moved by hand.

KNOW HOW OF LIFTING (MANUAL)

1. LOOK OVER Look over the object to be lifted. Make sure it is not
too heavy or too clumsy for good balance.

2. STAND CLOSE Stand close to the load with foot apart for good
balance. One foot alongside the load --- one behind.

3. BEND YOUR KNEES Straddle the load somewhat. Keep your back as
straight as possible.

4. HAVE A GOOD GRIP Many lifting accidents occur when the load slips from
hand.

5. LIFT GRADUALLY Straighten your knees and stand. Use your leg
muscles. Avoid quick motions.

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WHAT IS TEAM LIFTING ?

If an object is too heavy, large, bulky, long, hard to handle, or has to be placed high up,
then try TEAM LIFTING.

Workers should be of same height. One man should give signals so that all work
together.

KNOW HOW TO CARRY

1. Keep the load close to your body to take full advantage of the mechanical
leverage of your body.

2. Always have clear vision over the load and if the load interferes get help.

3. Avoid twisting your body if you have to change direction, do it by moving your
feet.

4. Do not change your grip on the load unless its weight is

supported.

5. Face the spot your load is to rest on Turn your feet and whole body in the right
direction.

6. Bent your knees To lower the load keeping your back straight and the weight
close to your body.

7. Watch your fingers Allow room for the load without danger to your fingers.

8. To deposit load on Bench or table Place it on the edge and push it forward
with arms and body.

9. Be sure the load is secure Where you put it down, will it fall, tip over, roll off or
be in someone's way,

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KEEP THE STRAIN OFF YOUR BACK —- LET YOUR BODY'S WEIGHT AND YOUR
LEG MUSCLES DO THE WORK FOR YOU

1. Get a good grip on the item.

2. Keep your back as straight as possible.
3. Brace your feet for maximum leg power.
4. Bend your knees to get the best use of your body weight to move the object.

HANDLING SPECIAL SHAPED OBJECTS, BARRELS ETC.

One man can roll a heavy barrel.

BOXES AND CARTONS Grasp opposite bottom comers and draw object
into body,

SACKS Carry on shoulder braced by hand.

OR ,
Hold at opposite ends and rest load against your
hip and stomach.

1. Know Yourself Only one can judge how much you should move.
Only you know of physical conditions that might
prevent you from moving objects.

AND IF YOU

A. are under weight or overweight

B. Have deformities of the spine :

C. Are arthritic

D. Had previous injuries to joints BE EXTRA CAREFUL

E. Have special medical problems of any kind

(i.e. sick heart, high blood pressure, lung
disease etc.)

2. Know how to move materials Use your arms and legs instead of your back
and you will prevent sprains, strains, hernias
etc.

3. Know when to get help If a test "heft" tells yout the object to be
moved is too heavy, or too bulky, or too
awkward for you to move alone GET HELP

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 MATERIAL HANDLING (MECHANICAL)

1. Cranes, Hoists & Lifting Tackles :

The Factories Act deals with the safety requirements in respect of hoists, lifts, lifting
machines, chains, ropes and lifting tackles and requires that these should be of good
constructions, sound material and of adequate strength. These are to properly
maintained and thoroughly examined by a competent person at least once in every
period of 12 months, in the case of hoists and lifts once in 6 months.

Hoists and Lifts :

Every hoist or lift shall have the safe working load plainly marked on it and no load
greater than such load should be carried on it. The cage of every hoist or lift used for
carrying persons should be fitted with a gate on each side from which access is afforded
to a landing and such gates should be fitted with inter-locking i.e. electro-mechanical
interlock or other efficient devices to ensure that they cannot be opened except when
the cage is at the landing and that the cage cannot be moved unless all the gates are
closed. The legal requirements are laid down in the Factories Act relating to hoists and
lifts used for carrying persons which have been installed,

Overhead Traveling Cranes :

In the use of overhead cranes, great care should be given to the provisions of safe and
adequate means of access. It is necessary that all ladders and steps should be
provided with secure hand holds and foot holds. Stairways are preferably to ladders.
Proper landing or stages should be provided at the point of transfer from ladders to
driver's cabin.

While any person is employed or is working on or near the wheel-track of a traveling

crane, in any place where he would be liable to be struck by a crane, effective
measures shall be taken to ensure that the crane does not approach within 20 ft. of that
place.

Lifting Tackles :

According to the Factories Rules, no lifting machines, chains ropes and lifting tackles
should be taken into use unless it has been tested and all parts have been thoroughly
examined by a competent person and a certificate of such test and examination
specifying the safe working load or loads is kept. Also no lifting machine, chain, rope or
lifting tackle should be loaded beyond the safe working load.

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Many accidents have occurred in the factories through failure of lifting tackles and some
of these accidents could have been avoided if the users had possessed more intimate
knowledge of the strength of the lifting tackles, we mean, fiber rope slings, wire rope
slings, chain slings, hooks, rings, shackles and similar gear.

For the same working load, the chain is 5 to 6 times as heavy as wire rope but if has a
longer life, stands up better rough use and is almost 100% flexible. Today chain is
obtainable in many grades - Wrought iron, mild steel, high tensile steel and alloy steel.

The standard hook is either of a circular section or trapezoidal. The former is meant for
light loads up to 5 tons.

Power Trucks :

Power trucks usually operate on storage batteries or internal combustion diesel engines
and are extremely used in factories for handling of materials to and from stockpiles, to
and from machines and on through to warehouse or loading platforms. These trucks are
of many types, such as fixed platform, elevating platform, forklift, etc. The elevating type
of platform is inserted under skid elevated to lift it from the floor and the truck carries it
to some other point.

The fork-lift truck makes the lift by means of two forks instead of a platform and lifts the
load up and from the floor permitting high piling to conserve space. They could also be
fitted with special attachments for handling barrels, paper reels etc. Safety precautions
to be observed in operation of Fork Lift Trucks are :

A] The capacity of every lift truck should be marked on the truck and they should not
be over loaded.

B] Loaded or empty forks should be carried as low as possible but just; high enough
not to strike a ramp.

C] Care must be taken to avoid jerking when tilting a load forward or backward,
specially when the load is at a height.

D] Personnel must not be allowed to ride on the forks.

E] Forks should be driven well under the load, preferably full length or at least 2/3rd
of the length.

F] When there is a danger of falling objects-over-the operator, canopy guard should

be provided.

G] Aisles, floor, etc. should be maintained in good condition including proper

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 lighting.
OTHER FACTORS :

Safety in material handling involves more than the purchase and correct use of good
material handling devices. There are less obvious factors which must be considered
thoroughly. Some of these factors are considered below :

Floor : Depending upon the type of operations, the conditions of. the floor such as :

a) Slipperiness
b) Absorption Qualities
c) Colour
d) Durability will give great effect on material handing

Cleaning of Floor :

Clean floors are a necessity of any program, If debris are left lying on floor it may cause
falls and unhygienic conditions. The use of mechanical sweeping devices should be
more efficient than the conventional manual methods.

Floor Repairs :

The tendency is to permit cracks and pot-hoes in the floors to remain un-repaired until a
wide area become bad enough to warrant complete resurfacing. Nowadays, there are
several excellent patching materials available which can be applied to a floor and run
over almost immediately afterwards, with little interruption to normal traffic. However,
patching should not be misunderstood as permanent repairing. It should be considered
as only a temporary measure.

Floor Marking :

Lines marked on floors inside and outside the plant can do more good, than almost any
other precautionary measures to organize production activities in a plant so that they
are efficient and safe. Lines ensure safety by specifying areas for aisles, storage, raw
material areas, parking etc. Line marking devises are now days available which can cut
short the time spend in marking the aisle ways in a big plant. Self-adhering plastic tapes
can also be quickly and easily applied.

Aisles :

Aisles should be clearly marked. Corners should preferably be cut off on a diagonal. For
vehicular traffic, the width of the aisle should be atleast twice the width of the vehicle

22
with load plus 3 ft.
The following color are commonly used for marking :

Purple - The basic color for designating radiation hazards.

Black and White - Combinations of black and white used individually are for the
designation of the traffic and housekeeping markings. These colors will help to identify
dead ends or aisles, or passageways, location and width of aisle ways, stairways and
directional signs.

Yellow and Black - Combination of yellow and black strips are used to indicate danger
from constructions sudden chances of levels etc.

Lighting :

Poor lighting may not be the primary cause of an accident every time. But one can find
that inadequate light was a factor behind many slips and falls and other injuries which
occur in the industries. There are various types of light fittings available and these
should be selected and used for specific work or areas. The required levels of
illumination for definite operations are given in the Indian Standard B.I.S. 3646. The
lights and the floors and ceiling should be kept clean, as dirty conditions can reduce the
effect of lighting.

Ramps :

Ramps gradient should not exceed 1 in 10.

Obstructions :

Pipes, conduits, drains, valves, fire apparatus etc. are-necessary parts of plant
structures, yet they often cause hazards. In planning the Plant, such parts should be so
placed that they will cause a minimum of interference with persons or materials.

Ladders :

Do not climb on stock-piles, use ladders. If possible, fixed ladders are preferred.

Bridge Plates :

Bridge plates should be of adequate strength and they should always' be properly
anchored.

23
SAFETY WHILE WORKING ON HEIGHT :

Several fatal and serious accidents are caused yearly by fall of persons engaged
in jobs ,which are required to be performed at heights. In jobs such as building
construction works, engineering and maintenance and repair of building, plant or
equipment, men have to work at heights and unless adequate safety precautions are
adopted, serious accidents can happen.

STAIR WAYS :

The preferred slope of stair way is between 30° and 35° with horizontal. The slope
should never exceed 50° The tread width should be not less than 24 cm plus a non slips
gosling of 2.5 cm. The riser height should be not more than 20 cm and not less than
12.75 cm and should be constant for each flight. All stairways should be fitted with
railings on the open sides and handrails on sides which are otherwise enclosed.

RUNS,RAMPS AND GANGWAYS :.

The slope or runs, ramps ,gangways etc., should be as small as possible and the
recommended slope maximum is 15° to the horizontal Cleats not more than 40 cm
apart, should be provided on ramps with steep slopes.

FLOOR:

The design should take into consideration all types of load in the form of materials,
persons and other forces acting on the floor. Acid proof bricks laid in the acid resisting
plaster should be the choice of flooring for a work room in which acids are handled.

WORKING AT ROOFS :

* Serious accidents happen due to fall of persons working on roofs .Fall through
fragile roof sheeting ,loss of balance due to the slope of roof and insufficient care while
working at the edge of the roof constitute the principal causes for these accidents which
could be prevented by adopting the safety measures.

* Falls through fragile roofing materials :

* The common practice of walking along with purling cannot be relied upon. The best
way to prevent falls through such materials is to use roof ladders .A permit work system
under the control of responsible person can help to ensure that men are not allowed to
work roofs without taking appropriate safety measures.

* Falls from sides of roof

* In the case of fiat roofs, it may be either the standard railings and toe boards or a
complete barrier to a minimum height of 90 cm. For sloping roofs, the barrier may be in
the form of scaffold boards extending to a minimum height of 40 cm above the roof
surface and a guard rail at a height not less than 90 cm or more than 120 cm.

24
LADDERS:

Ladders may be classified under two broad categories, the portable and the fixed Since
the portable ladder is a rather hazardous piece of equipments, every effort should be
made , wherever possible ,to replace it by fixed stairs, fixed ladders, scaffolding or any
other suitably arrangement. Not using ladders where required is a common cause of
serious accidents involving falls. Men climb on machines, equipments ,boxes or make
other dangerous improvisations to get access to places above the floor and thus get
involved in accidents.

* Step ( swing back) ladders and folding trestle ladder

In situations where there is not suitable facility to lean the ladders ,a step ladder
or a trestle ladder should be the choice .Step ladders are generally provided with a
convenient platforms and a hand rail at top.

* Fixed ladders

Wherever the length of a fixed ladder exceeds 9 m, it is necessary to provide a crinoline

for ensuring the safety of the user.

* Transport ladders

Ladders should be carried always with the leading and at least 2 m above the ground
long and heavy ladders should be carried by two or more persons.

* Securing ladders

About 50 % of all accidents are due to the feet of the ladder slipping. This can be
prevented by lashing the ladder at the feet or top, fitting non slip ladder shoes to the
stiles or having another worker "to foot the ladder".

* Non slip devices for ladder feet

Slipping of the feet of the ladder can be prevented by fixing non slip ladder shoes to the
stiles. The soles may be of rubber ,cork, leather, felt or lead

* Climbing ladders
A person ascending or descending a ladder should always face the ladder.

* Work on ladders

Working from the top of a single ladder can be particularly dangerous when the person
required the use of both hands. The safer way, where the person sands on a rung about
a meter below the top rung to which his safety belt is attached .The equilibrium of ladder
can be easily upset if one means sideways.

25
ELECTRICAL HAZARDS & PREVENTIVE MEASURES :

INTRODUCTION :

The energy in the form of electricity is most desired as it is easy to transport,

easy to control and can be easily converted into any form of energy. Electrical energy
has become synonymous with progress after independence in India. Availability of
electrical energy and its per capita consumptions regarded as an index of national
standard of living. The electricity when allowed to pass in an uncontrolled manner might
cause catastrophe. To ensure the safety of users number of rules and regulations ,
standards and code of practices are formulated and enforced.

ELECTRICAL HAZARDS :

1. PRIMARY
(a) Electric shock - a condition of acute peripheral circulatory failure due to
derangement of circulatory control or loss of circulatory fluid brought about by a
sudden and accidental flow of current. This effects are slight sensation, pain, loss
of muscular control, breathing become difficult, etc. The effects depend on the
quantity of current flowing and parts of the body becoming path for such flow and
duration of time.

REASONS FOR ELECTRIC SHOCK :

• Contact with live/bare conductor

• Contact with poor insulated conductor
• Contact with equipment or tool that had fallen and its body got charged
• Contact with equipment that have static electrical charge
• Lighting discharge

SHOCK PREVENTION METHOD :

• Isolation of electrical equipment from approach

• Fencing of H V equipment
• Encasing of live parts
• Marking of dangerous electrical equipments with caution boards
• Insulate properly the dangerous electrical parts
• Wherever overhead line exists, extra care is required while operating crane, metal
ladders, working in rooftops, etc.
• Provide automatic discharge of static charge.

26
(b) BURNS - There are two types of burns (i) Joules burns and (ii) Flash over burns.

(i) JOULES BURNS : this is caused by the dissipation of heat produced by the
passage of current. According to Joules law, the dissipated is directly
proportional to c2rt where c = the current in amp, r = the resistance when contact
with a live conductor is made and t = the duration of flow of current in second.

(ii) FLASH OVER BURNS : when a conductor at a high voltage accidentally or

otherwise is brought close to earth conductor, the insulation of the air between
them breaks down and giving rise to spark resulting ionization which sets up an
arc. If a human being come too close to a high voltage line he will be burnt by the
arc without coming in contact of HV line. The victim is subjected to flame burn
from the arc as well as electric shock from the flow of current.

(c) FIRE & EXPLOSIONS DUE TO SPARK/HEAT - overheating, arc and sparking leads
to fire in equipment and surrounding, over current due to short circuits or surges over
heat will cause explosion to fuses, switch gears, circuits, transformers, etc.

(d) FIRE & EXPLOSIONS DUE TO STATIC ELECTRICITY - Electricity present on the
surface of a non-conducting body is trapped or prevented from escaping is called static
electricity. This charge some time reach a potential of several thousand volts and
sparks off causes ignition of flammable mixture of gases, vapours or even powders with
air which happen to be present in their path can cause explosions.

(e) LIGHTING - It is a massive discharge of static electricity. Lighting arrester provides

an easiest path for such discharges.

A person in a boat or ship or standing in open field, beneath a lone tree are
easy targets for a lighting strokes.

PRECAUTIONS AGAINST LIGHTING STROKES :

• Avoid using above mentioned locations during inclement weather

• Always take shelter in a protected building
• Avoid using unprotected metal structure as a shelter
• Avoid contact with metal fences
• In case one happens to be in outdoor, it is better to lie down.

27
2. ELECTRICAL HAZARDS - SECONDARY :

Electric hazards occurs due to dropping of tools and objects or any substance
like this comes under this group.

STATUTORY REGULATIONS OF ELECTRICAL HAZARDS :

Generations, transmission, distribution and utilization of electrical energy is

governed by :-

i) The Indian Electricity Act 1910

ii) Indian Electricity Supply Act 1948
iii) Indian Electricity Rules 1956

In addition to the above statutory regulations, each organization lay down their own
safety rules, standing instructions/orders, safety manuals for the guidance of staff and
workers for safe operation and maintenance.

GENERAL SAFETY PRECAUTIONS FOR ELECTRICAL HAZARDS :

DO's

• The electrical installations should be specified standards and approved quality.

• Installations and maintenance should be done in accordance with
regulations/code of practice.
• Earth leakage preventor should be provided to transformers.
• All electrical circuit, equipments should be tested periodically.
• Safe guard to be provided to all electrical equipments.
• Before replacing or handling, the supply should be switched off.
• Tag or lock main switch before making repairs
• Use earthing rods or chains before commencing work on line
• Always wear rubber gloves when working around circuits of 110 volts or over
• Keep all electric connections tight
•

DONT's

• Do not work without safety/protective equipments

• Do not use sub standards appliances
• Do not use bare wire to socket along with sticks/packings
• Do not use appliances on loose wiring or poor insulations.
• Do not overload or over fuse circuits
• No repairs are to be made by any one except qualified / authorized electricians

28
FIRE HAZARDS AND PREVENTIVE MEASURES :

In order to contain fire hazards, the following measures may be adopted

1. PLANNING OF THE BUILDING - An improper planning of the building will increase

the risk of hazards. The position of staircases and lifts in the building must be decided in
a judicious manner so that in case of fire there is proper scope of evacuation of the
inmates within a reasonable time. The following norms may be followed for the
staircases of industrial buildings :-

• Minimum width of stair = 1.5 cm

• Minimum width of tread = 30cm
• Maximum rise for risers = 15 cm
• Maximum number of risers in a flight =15
• Floor area ratio must be exceeded

2. TYPE OF CONSTRUCTION :

The type of construction plays a very important role in containing fire hazards. Proper
selection of the type of materials used in constructions will help to make the building fire
resistant and in the prevention of rapid spread of fire. So far as materials are concerned
brick masonry is superior to R.C.C. or steel constructions.

3. FIRE CONTROL AND FIRE FIGHTING.

CLASSIFICATION OF FIRES

Classification of fire may be based on the type of combustible materials etc.,

1. Fires caused due to combustible solid materials. Example cloth, wood, wool,
etc.,

2. Fires caused due to flammable liquids. Example petrol, organic solvents etc.,

3. Fires caused due to flammable gases .Example butane, acetylene etc.,

4. Fires caused due to combustible metals. Example Lithium ,sodium,

potassium, magnesium etc.,

5. Fires caused due to electrical gadgets and equipments. Example fuse boxes,
switches computers etc.

29
CLASSIFICATION OF FIRES BY TYPE.

1. CLASS - A

These are fires involving solid materials normally of an organic nature(compound of

carbon) in which combustion generally occurs with the formation of glowing embers
class "A" fires are the most common and the most effective extinguishing agent is
generally water in the form of a jet of spray.

2. CLASS - B

These are the fires involving liquids of liquefiable solids. For the purpose f choosing
effective extinguishing agents, flammable liquids may be divided into two groups.

(i)Those that are miscible with water, and

(ii)Those that are immiscible with water.

Depending on (i) and (ii) the extinguishing agents include water spray ,foam, light water,
vaporizing liquids , carbon dioxide and dry chemical powers.

3. CLASS - C

These are fires involving gases of liquefied gases in the form of a liquid spillage or a
liquid or gas leak, and these include methane ,propane, etc., Foam of dry chemical
power can be used to control fires involving shallow liquid spills.(Water in the form of
spray is generally used to cool the containers.)

4. CLASS - D

These are fires involving metals. Extinguishing agents containing water are in effective,
and even dangerous, carbon dioxide and the bicarbonate classes of dry chemical
powders may also be hazardous if applied to most metal fires. Powdered graphite ,
powered talc, soda ash, limestone and dry sand are normally suitable for Class "D"
fires. Special fusing powders have been developed for fires involving some metals,
especially the radioactive ones.

30
5. ELECTRICAL FIRES :

It is not considered ,according to present day ideas, that electrical fires constitute a
class, since any fire involving ,of started by , electrical equipment must ,in fact , be a
fire of Class A,B,C,D, The normal procedure in such circumstances is to cut off the
electricity and use an extinguishing method appropriate to what is burning. Only when
this cannot be done with certainty will special extinguishing agents be required which
are non-conductors of electricity.

CLASSIFICATION OF FIRES BY SIZE :

According to the Central Fire Brigades Advisory Council, the size of a fire is as below :-

1. Major fire 20 + jets

2. Large fire 8-19 jets
3. Medium fire 3 - 7 j ets
4. Small fire 1 - 2 jets, or 3 + hose reels
5. Minor fire 1-2 hose reels or hand extinguishers

COMBUSTIONS :

Combustion is a chemical reaction in which heat and light are evolved. For
combustion, three factors are required - oxygen, heat and a combustible substance.
Removal of one of them leads to collapse of the triangle and combustion stops.

IGNITION TMPERATURE :

(a) FLASH POINT : It is the lowest temperature at which there is sufficient

vaporization of the substance to produce a vapour which will flash momentarily
when a flame is applied.
(b) FIRE POINT : It may be defined as he lowest temperature at which the heat from
the combustion of a burning vapour is capable of producing sufficient vapor to
enable combustion to continue.
(c) SPONTANEOUS IGNITION TEMPERATURE : It is the lowest temperature at
which the substance will ignite spontaneously ie. without the introduction of
ignition source.
(d) SPONTANEOUS COMBUSTION : Certain materials especially organic material
based on carbon, may react with oxygen at room temperature.

31
FIRE EXTINGUISHING MEDIUMS :

(a) WATER : Despite the many new techniques which have come to the assistance
of firemen, water is still the most efficient, cheapest and most readily available
medium for extinguishing fires.

(b) STEAM : Steam in large quantities can be used to smother a fire and in a
situation where it is readily available. It can be used in fixed installations.

(c) FOAM & FOAM MAKING COMPOUNDS : Some of the most hazardous' liquid
substances whose specific gravity is lower' than water lowers the temperature
momentarily (except methylated spirits) when mixes with water and then sinks
below the surface where any further affect is lost.

(d) VAPOURISING LIQUIDS : The halogenated hydrocarbons used for extinguishing

fires have the property of vapourising readily when heated are known as
vapourising liquids. It is specially used for extinguishing fires involving electrical
equipments as they are non conductors of electricity. The most common
substances are used - CBM (chloro-bromo methane), BCF (bromochlorodifluoro
methane) and BTM (bromotrifluoro methane).

(e) CARBON DIOXIDE & INERT GASES : At normal temperature, carbon dioxide
gas is 1-5 times denser than air. It is easily liquefied and bottled under a pressure
of aprox. 50 bar. It acts in a same manner of Vaporising liquids as a fire
extinguisher.

(f) DRY CHEMICAL POWDERS : Some materials like plastics, fabrication of

titanium, zirconium, breyllinium metals where water can not be used , powdered
chemicals are used. The base of most chemical powders are sodium bicarbonate
and metallic stearate as a water proofing agent. It is stored in cylinders under
pressure which can be released whenever required. Some special powders have
been developed for some metal fires specially for the radio active metals.

(g) SAND : Some burning materials which can not be extinguished by water may be
dealt with dry sand, earth, powder graphite, powder talc, soda ash of lime stone,
etc.

(h) BEATING OUT : Small fires in materials such as textiles, etc. may be
extinguished by beating them out or by rolling and screwing up the burning
material tightly to exclude the air.

TYPE OF EXTINGUISHERS :

Portable fire extinguishers can be divided into five categories according to extinguishing
medium they contain :-

32
(i) water, (ii) foam, (iii) powder, (iv) halon and (v) carbon dioxide

33
 SAFETY IN CHEMICAL-STORAGE . HANDLING & TRANSPORTATION
(SODIUM CYANIDE NaCN)

A chemical hazard is a situation involving chemicals which has potential to cause

damage to human / animal health, life, crop, property and/or environment. A chemical
creates hazards because it is reactive, corrosive, toxic, flammable and explosive in
nature.
In most cases chemical hazards are realised in the following way:-

i) There is release of the hazardous chemical.

ii) Vaporisation takes place in case of a liquid,
iii) Dispersion of the gas / vapour / dust occurs.
iv) A hazard in the form of fire, explosion or toxic concentration or their combination.

Based on the hazardous nature, dangerous substances are divided into 9 (Nine)
classes by the United Nation as under:-

Class 1 Explosives
Class 2 Gases compressed, liquified and dissolved under Pressure
Class3 Flammable liquids
Class 4 Flammable Solids
Class 5 Oxidizing substances, Organic peroxides
Class6 Poisonous (Toxic) and infectious substances.
Class 7 Radioactive substances
Class 8 Corrosive substances ,
Class 9 Substances not covered elsewhere.

To make dangerous substances recognizable from a distance, UN, labeling system is

followed world wide on the container or packet which are black symbols each
representing a particular risk e.g. the flame denoiing risk of fire.

Safety in Industry involving chemicals is achieved by

a) Recognition of hazard.
b) Elimination of hazard
c) Containment of hazard where elimination is not possible
d) Personal protection where adequate containment can not be achieved &>
e) Establishing mitigation strategies in anticipation of an accident.

34
USES :

Industrial uses of sodium cyanide are:-

i) In the extraction of gold and silver from ores,

ii) In the heat treatment of metals
iii) In the process of electroplating
iv) In the photographic development
v) As an ingredient of pesticide
vi) In production of chemicals.

CHARACTERISTIC PROPERTIES

Physical State:- White solid in the form of crystals, eggs, granules, fused pieces.

Odour :- Odourless when dry. With slight bitter almond odour of hydrocyanic
acid when moist. Odour of ammonia also may prevail in moist
NaCN.

Corrosive :- Corrosive to skin due to strong alkalinity.

Solubility :- Very soluble in water.

Boilling Point :- 1496°C Melting Point:- 564°C

Hygroscopic Characteristics Hygroscopic upto 450°C

Reactivity

a) When NaCN dissolves in water, a mild reaction takes place and small quantities of
highly toxic HCN gas is released. Since the released gas is in small quantities it is not
hazardous except in an enclosed space.

b) NaCN reacts with acids and acid salts liberating HCN gas.

c) Solution of NaCN in contact with appreciable amounts of C02 gas also liberates
Hydrocyanic acid or HCN gas.

Health Hazards:

a) Sodium Cyanide is extremely poisonous. Ingestion of as little as 180mg lead to

immediate death.

When NaCN impringes on the uncovered skin of an individual and the person is
perspiring, the sweat formed reacts with the Cyanide forming free HCN acid which
easily penetrates through skin. HCN combines in the tissues with enzymes influencing
cellular oxidation. As a result oxygen becomes unavailable to the tissues leading to

35
asphyxia.

36
 The resultant effect is very quick. The affected person suffers from headache,
dizziness, unsteadiness of gait and a feeling of suffocation. As the poisoning
progresses, there may be breathing difficulty, followed by unconsciousness, cramps and
ultimate death.

b) NaCN coming in contact with moist surface of the eyes, will liberate cyanide ion
which can be absorbed and caused systematic poisoning. Also because of its corrosive
nature, it may cause damages like irritation, redness, pain and Corneal burns.

c) Strong aqueous solution of NaCN or the solid itself can be absorbed through the
skin and cause deep ulcers.

Precautions in storage:-

i) NaCN must be kept in an isolated enclosure purposely built for the substance
only. No acids or acidic salts should be stored in the same area so that highly
poisonous HCN acid gas is liberated.

ii) The storage area must be well ventilated / provided with exhaust fan.

iii) The chemical must be kept under lock and key with complete record of entry and
exit of person and date wise quantity received and issue for consumption.

iv) The enclosure must be kept clean and access should be restricted to authorised
persons only. Appropriate hazard warning sign should be displayed.

v) Before entering the storage area it should be ensured that toxic concentration of
NaCN are not present in the atmosphere.

vi) The chemical must be stored in air tight containers. The labels provided by the
supplier for the identification of the poisonous contents should not be removed or
replaced.

vii) The chemicals must not be stored or transported along with food, drinks, chewing
materials or any other article meant for human consumption.

viii) Finally all regulations and local requirements for storage should be observed.

37
SIEPS FOR SAFETY:-

Before handling NaCN , make sure that the following steps are taken:

i) Amyle nitrite capsules, 3% solution of H202, 0.2% solution of KMn04

(detoxification of cyanide adhering to PPE) are all kept ready in the operational
area.

ii) Ferrous Sulphate and soda ash mixture is available for detoxification of cyanide
present in the wash water.

iii) A Medical officer is available in the Dispensary / Hospital in case of emergency.

iv) An ambulance is readily available in case of emergency.

v) Supply of fresh air / breathing apparatus is ensured.

vi) Inhalation and detoxification system are in operating condition.

vii) Only one container should be handled at a time.

viii) Only the required numbers of containers should be brought from the main store
and kept in safe custody in the handling section.

ix) NaCN in the form of granules, eggs or flakes only should be used. Dust should
be avoided.

x) The persons to handle NaCN should be examined and free from any cuts, burns
or injury and / or any other type of aliments.

xi) Persons so selected should put on complete uniform (PVC suit, gloves, gum
boots, and positive pressure breathing mask.)

xii) The container taken out should be weighed on the balance kept in the shop for
this purpose.

xiii) The lid of the container should be opened. The required quantity should be
weighted and the excess material to be left in the container(in safely closed
condition)

xiv) Any type of damage to skin while handling NaCN should be avoided.

xv) NaCN should be charged into the reactor / electroplating chamber, taking much
care that there is no spill THI the floor and no dust disperses into the air. Then the
ventilation system should be switched on.

38
xvi) The empty container (when the entire lot has been used) along with the lid
should be put into the chamber containing ferrous Sulphate and soda ash
mixture for detoxification (3 Hrs.)

xvii) When the solution in the chamber shows negative reaction for cyanide, the
container should be taken out and washed with water.

xviii) All personal protective appliances should be washed with KMn04 solution
followed by water.

xix) Before wearing usual clothes, the person handled NaCN should take shower
bath.

xx) The spillage of NaCN should be washed into a pit with water'

xxi) The floor wash should be sucked into a receiver having Ferrous sulphate and
Soda ash mixture. Before it is drained into the sewer, the treated floor wash test
should indicate negative.

xxii) Storage and consumption of food stuffs in the area of NaCN handling should be
forbidden.

Personal protective equipment: Respiratory:-

a) Dust respirator
b) Industrial canister type gas mask.
c) Air or Oxygen mask

Non Respiratory:-

i) Safety hat.
ii) Chemical safety goggles
iii) PVC full suit '
iv) Leather or rubber safety shoes
v) Dry cotton gloves
vi) PVC gloves.

39
FIRST AID?-

I) Inhalation or Ingestion:-

i) Removal of the victim from the site of poisoning to an uncontaminated area,

taking all precautions for the personal safety of the rescuer.

ii) Make the victim lie down and keep him quiet and warm.

iii) The following first aid should be administered by trained first-aid attendants, till
the medical officer arrives:-

a) If the victim is conscious / unconscious and breathing :-

Break an Amyle nitrite pearl in cloth and hold lightly under the victim's nose for 15 sees.
Repeat 5 times with a break of 15 sees, in between. If necessary repeat this cycle every
3 minutes using fresh pearls, until 3 or 4 cycles are over. Pearls must not be over 2
years old (There should be no source of ignition near the place of administering Amyle
nitrite).
During .Amyle nitrite administration, have the B.P of the victim recorded, lest the systolic
B.P fall below 90 mm of mercury duration of inhalation and frequency should be
reduced for heart patients..

b) If the breathing is difficult or stopped:-

Administer artificial respiration by a suitable rion mouth to mouth method.

Simultaneously administer Amyle nitrite also as detailed above.

c) If the victim has swallowed sodium cyanide and is conscious and breathing:-

Induce vomiting by giving an emetic of warm salt water (1 table spoon salt / cup water).
Repeat until vomit fluid is clear. Then have the victim drink one pint of 1% solution of
sodium thiosulphate. Repeat after 15 minutes.

d) If the victim has swallowed the chemical and is unconscious:-

Vomiting could hot be induced, stomach wash is to be resorted with 1 % sodium

thiosulphate or sodi-bicarb.

II Skin Contact:-

Remove the contaminated clothing and shoes. Flush the affected areas with plenty of
water, make use of emergency shower. The clothing should be thoroughly cleansed
before reuse. No ointment should be applied for 24 hrs.

40
OCCUPATIONAL DISEASES :

WHAT IS OCCUPPATIONAL DISEASES?

When workers engaged in various industrial operations or processes in working

areas may be exposed to such environment which can have adverse effects on their
health and are liable to become victims of various diseases Galled Occupational
Diseases or termed as Industrial diseases.

CLASSIFICATION OF OCCUPATIONAL DISEASES :

1. Diseases caused by physical conditions

2. Diseases caused by dust
3. Diseases caused by biological agents
4. Diseases caused by hazardous chemicals
5. Occupational Darmatoses
6. Misc. diseases not falling under the above categories (e.g. Conjunctivitis,
Allergic, Cancer, Blisters etc.)

LIST OF NOTIFIABLE DISEASES :

(by the Factories Act 1948, see section 89 & 90 of the third schedule)

1. Lead poisoning or their sequel

2. Lead tetra-ethyl poisoning
3. Phosphorous poisoning or their sequel
4. Mercury poisoning or their sequel
5. Manganese poisoning or their sequel
6. Arsenic poisoning or their sequel
7. Nitrous poisoning or their sequel
8. Carbon bisulphide poisoning or their sequel
9. Benzene poisoning or their sequel
10. Chrome ulceration or their sequel
11. Anthrax
12. Silicosis
13. Halogens poisoning or their sequel
14. Pathological manifestations due to radio active substances
15. Primary epitheliomatous cancer of the skin
16. Toxic anaemia
17. Toxic jaundice due to poisonous substances
18. Oil acne or dermatitis due to mineral oils

41
DETAILS OF OCCUPATIONAL DISEASES :

1. DISEASES CAUSED BY PHYSICAL CONDITIONS :

a) Excess temperature or heat - heat stroke, heat exhaustions etc.

b) Excess cold - colds, sinusitis, bronchitis, etc.
c) Sudden change in temperature
d) Defective illumination - problems related to eyes, annoyance, impaired vision,
etc.
e) Radiation - (a) Acute : loss of appetite, nausea, bleeding from nose & ears,
diarrhea, etc. . , ,. ...
(b) Chronic : sterility, malfunctions of glands, skin cancer, opacity
of eye lens, etc.
f) Excess noise and vibrations - loss of hearing, nausea, headache, increase in
blood pressure, etc.
g) Working under pressure greater or rare than atmospheric conditions

PREVENTIVE MEASURES FOR :-

Heat stroke/Exhaustion :

• provide artificial ventilation

• drink plenty of cold beverages ,
• wear suitable protecting clothing
• acclimation to the heated environment
• reducing the total work period

Excess cold:

• Personal to be selected who can withstand excess cold

• provision of warm clothing
• acclimation to the cold environment

Defective illumination :

• increasing surface area of reflecting surfaces

• shading shining objects
• using sun breakers

Radiation :

• use of shields (made of lead)

• avoid exposure to radiation
• periodical medical examination
• periodic radiation survey

42
Noise and Vibrations :

• plugging of ears
• use of acoustic baffles or partitions
• using silencers, vibration dampers, sound absorbents
• selection of suitable personnel

Atmospheric pressure :

• suitable special suits

• oxygen kits

DISEASES CAUSED DUE TO DUST :

Dust may be harmful or harmless depends on the following factors :-

• Particle size (0.1 to 5 mm are harmful)
• Concentration
• Duration to exposure
• Susceptibility

Generally dust borne diseases called PNEUMOCONIOSES. Some of the common

diseases are :-

1. SILICOSIS : due to presence of silicon dioxide in the dust. Workers working in

potteries, mines, refractories, foundry, sand blasting etc.

2. Asbestosis : duo to presence of asbestos in the dust. Workers working in

asbestos sheet, asbestos papers and boards, gaskets, break linings, etc.

3. Siderosis : due to presence of excess of iron particles in dust. Workers working

in cotton & wool industries, jute & textile industries, paper & cupboard industries,
etc.

PREVENTIVE MEASURES FOR DUST :

• Proper exhausting system to be provided

• proper masks to be provided to the workers
• Periodical medical checkup
• clean environment

43
DISEASES CAUSED DUE TO BIOLOGICAL AGENTS :

Some of the common diseases are :-

• SEPTIC INFECTIONS : cuts and wounds are very common among industrial
workers. If uncared can lead to Tetanus.

• FUNGAL INFECTIONS : very common who are working in tanneries, dyeing

industries, etc.

• BRUCELLOSIS : very common who are working in dairy industries

• ANTHRAX : very common who are working in tanneries, wool, brush, carpet, fur
makings, etc.

PREVENTIVE MEASURES FOR DUST :

• Proper exhausting system to be provided

• proper masks to be provided to the workers
• Periodical medical checkup
• clean environment

DISEASES CAUSED DUE TO CHEMICALS :

Chemicals may be classified as below :-

1. ASPHYXIANS : (a) Simple - carbon dioxide, nitrogen, hydrogen, etc.

(b) Chemical - carbon monoxide, hydrogen cyanide,etc.
Both causes breathing troubles.

2. IRRITANTS : (a) Primary - ammonia, chlorine, sulphur dioxide, etc.

(b) Secondary - hydrogen sulphide, carbon disulphide,
etc.
Both causes irritation of lungs, throat, eyes and other parts
of body.

3. ANAESTHETICS : (a) Primary - ether, alcohol, gasoline, etc.

(b) Secondary - carbon tetrachloride, benzene,
naphthalene, etc.
Both causes semi/unconsciousness, damage of the optic
nerves and lever.

44
4. MISC. GROUP : (a) Inorganic - lead, arsenic, chromium, manganese, etc,
(b) Organic - aromatic/aliphatic hydrocarbons,
phenol, cresol, etc.

PREVENTIVE MEASURES FOR CHEMICAL DISEASES :

• Proper exhausting system to be provided

• proper masks to be provided to the workers
• Periodical medical checkup
• clean environment
• Good house keeping
• Use of proper safety/protective equipments
• Periodical survey and monitoring

OCCUPATIONAL DERMATOSES

It is the most common occupational diseases which includes any abnormality of the
skin. The common causes are:-

1. Primary irritants
2. Mechanical & chemical factors
3. Sensitizers
4. Biological factors
5. Radiation factors.

PREVENTION & CONTROL

1. Should be educated / trained about hazards

2. Identify the areas of the hazards activities
3. Hygiene, neat & cleanliness to be maintained
4. Personal protective equipments to be used
5. Use of barrier creams
6. Periodical medical examination and health check up.

FIRST AID :

INTRODUCTION :

Even though methods of first aid have been practiced perhaps ever since a man
desired to help another in sickness or after injury, an organized world wide effort at
giving first aid came only in the year 1877 with the formation of St John's Ambulance
Association of England. Text book of First Aid was first written by prof. Esmarch, a
German surgeon for war victims. The concise First Aid Manual was first published by Sir
James Cantlie in the year 1912.

45
The Principle of First Aid :- It is the immediate treatment given to the victim of an
accident or sudden illness, before medical help is obtained. The first aider has to
diagnose, treat and dispose a casualty.

1. Diagnosis - It is based on history, symptoms and signs. History is how the

accident occurred. Symptom is what the casualty complains -1,, pain, shivering
etc. Signs is what the first aider feels and finds out - ie. bleeding of injured part,
swelling part, etc.

2. Treatment - It is the framing which helps the first aider to see that the casualty is
comfortable .Promote recovery and see that the condition does not become
worse.

3. Disposal-The casualty has to be taken to nearest hospital by the quickest means

transport. A carefully worded message to the relatives, as to his condition and
also to what place he is being taken, must be sent.

HANDLING AND TRANSPORT OF INJURED PERSONS

Before moving a casualty, unless life is endangered by fire, falling debris or a

poisoned atmosphere, if he is unconscious, it is important to systematically examine
head and neck, spine and limbs at the accident spot itself. Any fractures noticed should
be immobilized especially, spine injuries.

Ideally a casualty should be carried with the help of a stretcher with sand bags
placed on either side of neck in suspected case of cervical spine injuries.

LOADING AN UNCONCIOUS CASUALITY :

The stretcher is placed by the side of the casualty. The neck of the casualty is to
be stabilized by some body and two other persons will roll the casualty on the side away
from the stretcher. A fourth person pushes the stretcher as close to the back of he
casualty as possible and the casualty is rolled back on the stretcher.

CARRYING A LOADED STRETCHER :

It can be carried by two or four persons, the leader will decide the position and
movement of the stretcher. All the bearers will face in the same direction and not each
other. Then the casualty is lowered at the desired place or loaded, into an ambulance .

If stretchers are not available, then it can be prepared with help of locally available
materials like blankets, gunny bags, a piece of ply wood, etc.

46
SOME IMPORTANT POINTS WHILE CARRYING VICTIMS :

• Remove the victim's spectacles

• Make sure that both his legs are straight
• Open the airway by tilting the head and lifting the chin
• Place the arm nearest to you at right angles to his body
• Bring his far arm across the chest
• check breathing regularly

BASIC LIFE SUPPORT:

The term Basic Life Support (BLS) refers to maintaining airway potency and
supporting breathing and the circulation without use of equipment. It comprises four
elements combining together is called Cardiopulmonary Resuscitation (CPR). Four
elements are :-

1. Initial assessment of ABC (airway, breathing, circulation)

2. Airway maintenance
3. Expired air ventilation (rescue breathing)
4. Chest Compression

The purpose of BLS is to maintain adequate ventilation and circulation until means can
be obtained to reverse the underlying cause to arrest. The following sequence of
actions of" BLS recommended by European Resuscitation Council is to be followed :-

• Ensure safety of rescuer and victim

• Check the victim and see if he responds
• If he does not respond , shout for help and open his airway by tilting his head and
lifting his chin
• Look for chest movements
• Listen at the victim's mouth for breath sound
• If he is breathing, turn him into the recovery position
• If he is not breathing, send someone for help
• Turn the victim on his back
• Remove any visible obstruction from the victim's mouth
• Give two rescue breaths
• Take a breath and place your lips around his mouth and blow steadily for 1.5 - 2
seconds and repeat it to give 2 effective breath.
• Combine rescue breathing and compression until any help arrives.

47
EFFECTIVENESS OF CPR:

• The pupils constrict

• Patient's color improves
• Carotid pulse can be felt during compression
• Spontaneous of heart beat
• Spontaneous gasping respiration
• Consciousness returns

WOUND AND BLEEDING:

WOUND :

A wound is an injury to tissues of the body caused by mechanical violence with or

without loss of continuity. The depth of the wound is more important than its area. The
aim of first aider in a wound is to arrest bleeding.

MANAGEMENT OF WOUND :

• Clean the wound with plenty of clean running water

• Pick any foreign material from the wound
• Cover the wound with dry gauze or laundered piece of cloth. Do not let cotton
come in contact with the wound
• Bandage the wound

BLEEDING : Bleeding is a common cause of death in accidents. There are three types
of bleeding :-

1. Arterial bleeding - it comes out from arteries in jets as it corresponds to the beat
of the heart and it is bright red in color.
2. Venous bleeding - it comes from veins in continuous stream and is dark red in
color.
3. Capillary bleeding - it comes from capillaries and oozes out slowly.

PRESSURE POINTS TO STOP BLEEDING :

1. Carotid points - they are two in number on either side of Adam's apple (prominent
point in center of the neck) are responsible to supply blood to brain. It can be
pressed against the cervical vertebra behind it with the thumb.

2. Brachial points - they are on the middle third of either arm along the inner border
of the biceps and can be pressed against the humors with the tip of the fingers.

48
3. Femoral points - they are on the midway in the groin fold and can be pressed
against the public bone by bending the knees slightly, grasping the thigh with
both hands so that both the thumbs meet at the centre of the groin. Place one
thumb over the other at that point and apply pressure.

DRESSING AND BANDAGES :

DRESSING - A dressing is a protecting covering applied to a wound to prevent

infection, absorb discharge, control bleeding and avoid further injury.

There are two types of dressings - (a) Adhesive dressing which consists of a pad of
absorbent gauze of cellulose with adhesive material & (b) Non adhesive dressing
consists of layers of gauze covered by a pad of cotton /wool.

Precautions :-

• Wash your hands thoroughly

• Avoid touching any part of the wound
• Do not talk, sneeze or cough over wound or dressing.

BANDAGE - A bandage is the material that is used to secure the dressing over the
wound and prevent it from slipping or restrict movement or provide support for a lamb or
joint.

There are two types of bandages - (a) Triangular bandage which is made by cutting a
piece of calico 100cm square from corner to corner so as to give two bandage. It is
most often used as a sling to support injured arms, (b) Roller bandage which is made of
flannel or cotton material with lose mush in various widths, there are four methods of
applying roller bandage (i) Simple spiral, (ii) Reverse spiral - for leg and forearm , (iii)
Figure of eight - for knee , joints and elbows , (iv) The spica - for hip, shoulder, grom
and thumb.

FRACTURES :

A fracture is the partial or complete breakage of a bone. There are three types of
fractures - (a) Simple or closed fracture, (b) Compound or open fracture , (c)
Complicated fracture.

In a Simple and Compound fracture they are in contact with outside air. In a
Complicated fracture , major organs like blood vessels or nerves are also injured along
with fracture.

49
SIGN & SYMPTOMS OF FRACTURE :

• Pain and swelling of the area and discoloration

• Lose of normal movement of that part
• The affected parts may lose its normal shape
• Irregularity of the bone can be felt.

MANAGEMENT OF FRACTURE :

• Support the injured part so that no movement is possible

• Immobilize the facture area and joints on both side of the fractures
• Do not bandage over the fracture site
• Wherever available use splints (a piece of wood or stick) to immobilize the injured
part.

BURNS AND SCALDS :

BURNS - the injuries that result from dry heat like fire, a price of hot metal or contact
with wire carrying electric current, chemicals, etc.

SCALDS - the injuries caused by moist heat due to boiling water, hot oil, etc.

MANAGEMENT OF BURNS & SCALDS :

• Remove the casualty away from the source of fire

• Put out the flame by covering the casualty with blanket or thick bedspread and
fix the casualty to ground.
• Smother the flame by gentle pats over the covering
• Water should be used if accessible to put out the flame and to cover the burnt
area.
• Keep the involved parts above the level of the heart
• Remove quickly from the body anything of a constricting nature like rings,
bangles, belts , boots, etc.
• Put the casualty in recovery position
• Maintain airway, breathing, heart beat until the casualty is handed over to
medical help.

50
 ROLE AND RESPONSIBILITIES OF SAFETY
OFFICERS UNDER FACTORIES ACT 1948

Safely Officers are to be appointed under Section 40-B of Factories Act 1948. In
every factory where - (a) one thousand or more workers are ordinarily employed OR (b)
in the opinion of state government, any manufacturing process or operation involves
any risk of bodily injury, poisoning, diseases or any hazard to health to the persons
employed in the factory.

DUTIES OF SAFETY OFFICERS :

1. To advice the concern departments in planning and organizing measures

necessary for the effective control of personal injuries.
2. To advise on safety aspects in all job studies and to carry out detailed job safety
studies.
3. To check and evaluate the effectiveness of the action taken or proposed to be
taken to prevent personal injuries.
4. To advise the purchasing and stores department in ensuring high quality and
availability of personal protective equipments.
5. To advise on the matters relating to plant Safety Inspections.
6. To observe the physical condition of work, work practices and procedures and
render advise on measures to be adopted for removing unsafe physical
conditions and preventing unsafe actions by workers.
7. To investigate all accidents.
8. To render advise on matters related to reports of investigation of industrial
accidents and diseases.
9. To investigate the causes of industrial diseases.
10. To maintain the records related to accidents, dangerous occurrences and
industrial diseases.
11. To promote setting up of Safety Committees, and act as advisor to such
committees.
12. To organise, in association with the concerned department, campaigns,
competitions and other activities.
13. To design and conduct suitable training and education programmes either
independently or in collaboration with the training department for the prevention
and personal injuries.

ROLE OF SUPERVISORS TO ENSURE SAFETY :

1. To guide workers properly in doing the job

2. Should demonstrate how to do the job to the worker if the same is new
3. Should train the workers how to read the technical drawings

51
4. Should provide patient hearing to their official and personal problems arrange to
solve them
5. If you can not solve their problems , should show concern to their problems and
bring to the notice of higher officials to keep the morale of workers at high level
6. Should arrange proper personal protective equipments to the workers under you
and ensure the same is used by them.
7. Should identify all the unsafe conditions in you area and arrange to eliminate
them
8. Should arrange regular trainings to the workers to inculcate safe working habits
in them to avoid accidents.
9. Should identify hazard and risk analysis before allotting job to the workers to
keep them appraised of the risk involved in doing that work.
10. Should arrange proper tools and correct quality materials before allotting
the job to the worker.
11. Should ensure all the guards of the machines is in place and in working order
before allotting the work.
12. Should not allow any worker to take undue risks.
13. Should arrange periodical plant inspection and safety audit checks.
14. Should insist workers to follow strictly the lubricating schedule of the machines to
avoid accelerated deterioration resulting to unsafe conditions.

LP.C. PROVISIONS TOWARDS SAFETY :

Indian constitution has made certain provisions to protect and ensure safety of
personnel through the following Articles :-

• Article no. 23 : Prohibition of traffic in human beings and forced labour

• Article no. 24 : Prohibition of employment of children in factories etc.
• Article no. 38 : State to secure a social order for the promotion of welfare of the
people
• Article no. 39 (e): The state shall direct its policy towards securing the health and
strength of workers
• Article no. 39 (f) : The childhood and youth are protected against exploitation
• Article no. 42 : Provisions for just and humane condition of work and maternity
relief
• Article no! 47 : Duty of state to raise the level of nutrition and the standard of
living and to improve public health
• Article no. 48 : Organization of agriculture and animal husbandry
• Article no. 49 : Protection of monuments and places and objects of national
importance
• Article no. 268 : Causing public nuisance - e.g. community injury, danger or
annoyance to the public, any obstruction to any persons, etc.
• Article no. 270 : spreading infection of diseases dangerous to life - shall be
punishable

52
• Article no. 272: Adulteration of food or drink intended for sale
• Article no.273 : Sale of noxious food or drink
• Article no.274 : Adulteration of drugs
• Article no. 275 : Sale of adulterated drugs
• Article no. 277 : Fouling water of public spring or reservoir
• Article no. 278 : Making atmosphere noxious to health
• Article no. 279 : Rash or negligent driving of vehicle as to endanger human life or
likely to cause hurt or injury to any person
• Article no. 284 : Negligent conduct in respect of poisonous substance
• Article no. 285 : Negligent conduct in respect of fire or combustible matter
• Article no.286 : Negligent conduct in respect of explosive substances
• Article no. 287 : Negligent conduct in respect of machinery
• Article no. 288 : Negligent conduct in respect of pulling down or repairing building
causing any danger to human life
• Article no. 289 : Negligent conduct in respect of animal
• Article no. 304 -A : Causing death by negligence
• Article no. 320 : Causing grievous hurt.

53
 PERSONAL PROTECTIVE EQUIPMENTS

1. LEGAL REQUIREMENTS:

In the Factories Act 1948, there are specific provisions for providing the Personal
Protective Equipment to the workers who are exposed to unsafe and unhealthy
operations and 'processes. Those are framed in such a spirit that the workers working
on the operations and in the processes are protected against possible hazards.

2. NEED FOR PERSONAL PROTECTIVE ; EQUIPMENT(PPE)

In Industry it may be possible

- to substitute a dangerous substance with a safer substance,

- to isolate the process,
- to have automatic and mechanical handling of the substance,
- to have controlled ventilation of the process or
- to plan and arrange operation that PPEs are not necessary. v

But sometimes it may not be possible to introduce such measures and it

becomes necessary to use Personal Protective Equipment. It must be borne in mind
that PPE do not eliminate the hazard. These devices are designed to interpose an
effective barrier between a person and harmful substances or radiation's.

3. REQUIREMENTS OF PERSONAL PROTECTIVE EQUIPMENT

Requirements of suitable Personal Protective Equipment can be listed as under:

a. Nature of Hazard
b. Severity of the Hazard
c. Type of Contaminant
d. Concentration of the Contaminant
e. Duration of Work
f. Location of the contaminated area with respect of a source of respirable air
g. Expected activity of the wearer
h. Operating characteristic and limitation of equipment i. Reliability of the Equipment
i. Acceptance of the Wearer
k. Cost of the Equipment

54
4. TYPES OF PERSONAL PROTECTIVE EQUIPMENT

Personal Protective Equipment may be divided into two broad groups:

i. Non-respiratory Protective Equipment
ii. Respiratory Protective Equipment

NON-RESPIRATORY PROTECTIVE EQUIPMENT

Personal Protective Equipment for various parts of the body can be divided into
five broad groups:

1. HEAD PROTECTION:
Head Protectors may be hard hats and caps made of Aluminium, PVC Fibre
Glass, Laminated plastic or Vulcanized fibre. They may be fitted with brackets for fixing
welding masks, protective face screen, or a lamp. The hats and caps are provided with
replaceable harness which provides sufficient clearance between the top of the head
and shell.

Equipment: Hats, Caps and Helmets

MA TERIAL HAZARD

1. Asbestos Sparks, hot materials and heat

2. Plastic and Rubber Moisture,Acids,Alkalis,Electric shocks and dermatitis.
3. Cotton Wool Sparks and dust
4. Metal Falling objects, Flying particles, Cuts and Abrasions.

2. EYE AND FACE PROTECTION

Numerous eye injuries are caused by dust, flying particles, splashed and harmful
radiations. It is difficult to cover precisely the various processes in which the workers
may be required to wear goggles. The hazards encountered with Sledding, caulking,
dressing, wood working, casting of metals, galvanising and dripping of molten metals,
Chemicals, gas welding and cutting/arc welding.

Eye protection may be achieved by using:

a) Safety spectacles,
b) Mono goggles,
c) Impact goggles,
d) Welding goggles,
e) Foundry goggles,
f) Chemicals goggles,
g) Gas tight goggles,
h) face shields and
i) welding helmets etc.

55
3. HAND AND ARM PROTECTION:
Protection of hands and arm becomes necessary when workers have to handle
materials having sharp end. sharp edges or when hot and molten metals, chemicals and
corrosive substances have to be handled. The Protective Equipment may be gloves,
wrist gloves, mittens, hand pads and thump guards and sleeves.

Equipment: Sleeves, Whistles, Hand Gloves

MATERIAL HAZARD

1. Asbestos Sparks, hot materials, heat

2. Chrome Leather Sparks, hot materials, hot liquids,
flying particles, cuts and abrasions
3. Plastic Moisture, acids and alkalis
4. Rubber Moisture, acids and alkalis, electric shock
5. Chemical Resistant Materials Acids and alkalis
6. Reflective Fabric Hot liquids

4. FOOT AND LEG PROTECTION:

Adequate protection may have to be provided to the workers employed in certain
jobs. Risk of injury may be in handling of heavy materials, caustic and corrosive liquids,
wet conditions, molten metals etc. Common foot and leg protective equipment are
safety shoes and boots, legging, foot-guards and leg guards.

Equipment: Shoes and Boots

MATERIAL HAZARD

1. Steel Toe Caps Falling Objects

2. Non-Skid Shoes Wet Surface
3. Wooden Soles Hot materials, heat, hot/cold surface,
moisture, acids and alkalis, slips & falls.
4. Chrome Leather Sparks, hot materials, heat and hot
liquids
5. Rubber Hot Liquids, moisture, acids &
alkalis, electric shock and dermatistis.
6. Conductive Rubber Explosive.

5. BODY PROTECTION
Sometimes it becomes necessary to provide special protective equipment for the
body in the form of aprons, overalls jackets and complete head to toe protective suits.
Although complete coverage of the body and legs is not needed since many cases and
unnecessary safety clothing may hamper the efficiency of the user, no compromise
should be made with strict safety requirements.

56
EQUIPMENT : COATS, APRONS

MATERIAL HAZARD

1. Asbestos Sparks, hot material and heat

2. Chrome Leather Sparks, hot materials, hot liquid,
flying particles, cuts and abrasions
3. Plastic &Rubber Moisture, acids and alkalis,
electric shock and dermatitis.
4. Canvas Flying particles, cuts and abrasions.

Classification of hazards & selection of respiratory equipments:

The type of hazards to which a worker is exposed is the basis of selection of the
right type of respiratory equipment. The hazards may be classified as under:

a. Oxygen Deficiency:

Atmosphere in confined spaces such as vats, tanks, holds of the ships etc. may
contain air with oxygen content much lower than the normal (21% by volume ). This
may be due to dilution or displacement of the air by other gases or vapors or because of
loss of oxygen due to decay or organic matter, chemical reaction and natural oxidation
over a long period of time.

b. Gaseous Contaminants:
This may be toxic or inert gases. The toxic gases may produce harmful effect
even if they are present in relatively low concentration. The inert gases produce
undesirable effects primarily by displacement of oxygen.

i) Gaseous contaminants immediately dangerous to life

ii) Gaseous contaminants not immediately dangerous to life.

c. Particulate contaminants (Dusts, fumes, smokes, mists etc.)

1) Toxic particulate contaminants

2) Fibrosis-producing dusts
3) Nuisance Dusts

d. Combination of gaseous and particulate contaminants.

Types of Respiratory protective Equipment

Respiratory protection equipment may be classifies as :

1. Air Respirator
2. Suction Hose Mask
3. Pressure Hose Mask
4. Self-contained compressed air or oxygen breathing apparatus.

57
Oxygen Regenerating Re-circulating Type Self

In this apparatus moisture content from the wear's exhaled breath reacts with
granular chemical in a canister to liberate oxygen. Also the exhaled carbon dioxide is
adsorbed by the chemical in the canister. This oxygen enters the breathing bag from
which the wearer inhales through a corrugated breathing tube connecting the bag to the
face-piece.

AIR PURIFYING RESPIRATORS

Canister Gas Mask : This consist of a canister, containing appropriate chemical, a full
face-piece and body harness to hold the canister in place on the body of the wearer. Air
is drawn through the canister by the wearer and during its passage through the canister
the contaminant present in the incoming air is absorbed in the chemical. The canisters
are designed for specific gases and it is very important that the appropriate type is used.

SELF-RESCUE TYPE RESPIRATORS

This is designed to provide the greatest possible respiratory protection consistent

with the practicability of carrying the device at all times so that it is always available for
use during escape. It consists of a small filter element, a mouth piece, a hose clip and
means of carrying conveniently on the body. The filter elements are similar to chemical
cartridge. The extent of protection afforded is between that provided by canister gas
mask and that provided by a chemical cartridge respirator.

CARE OF RESPIRATORS

Instruction in the use of respirators, among other thing, should include the following
aspects :

a. Why it is to be used
b. How it is to be used
c. Checking that it is in good operating condition
d. Fitting of respirator
e. Proper use and maintenance of the respirator.

58
59
 SAFETY INSPECTION & AUDIT

In any organization, the Authority/Management would consider that its financial

statement truly reflected the firm's position only when the accounts have been duly
audited and certified by a qualified Auditor. The Stores Controller would be working in
the dark were it not been placed for periodic stock taking. Similarly, the Engineers are
rightly concerned "that the equipment is regularly inspected and checked.

Safety Audit is a method which will give a reasonable indication on how well an
organization's Safety Programme is working in all its aspects. The identification of areas
of specific hazards is of fundamental importance in preventing accidents or disasters.
Audits of various types are normal management tools and it is appropriate to carry out
the safety audit of the plants.

Safety Audit is a tool for ensuring that the plant operation and maintenance
procedures match the design intent and standards. It keeps operating personnel alert to
the process hazards, reviews operating procedures for necessary revisions,- seeks to
identify equipment or process changes that could have introduced new hazard- s and
initiates application of new technology to existing hazards 4 and review adequacy of
maintenance and safety inspections.

Methodology of conducting Safety Audits:

Safety Audit team should have Pre Audit and Post Audit meetings with the
Chief Executive of the organisation to explain objectives, methodology to obtain his
support and highlight the major deviations observed during the audit.

Types of Audit :-

Broadly the type of Safety Auditing System presently being undertaken in

India/Ordnance Factories may be classified into two categories: -

(A) Internal Audit

- Level-1 - at factory level

- Level-II - team from sister Fys nominated by OFB
- Level-Ill - RCS team

(B) External Audit

(a) Govt. - CL1 / RL1 of DGFASLI, Fy. Inspector

(b) PSU-ElL, FEDO
(c) Semi govt. etc.-NSC, LPA,1CMA
(d) Private Consultants - Private companies / Consultants.

60
Designed Check list. The results of safety audit should be prepared in format report with
action plans for implementation.

SAFETY AUDIT PROCEDURES:-

Name of the Auditor : ......................................................................................
Factory Audited : ...................................................................................
Date/Period of Audit : ....................................................................................
Factory Officers associated with the Audit :........................................................

[1]. MANAGEMENT COMMITMENTS

1.1 Safety Policy:

Every occupier shall prepare and as often as may be appropriate, revise a written
statement of his general policy with respect to the health and .safety of the workers at
work and the organization and arrangements for the time being in force for carrying out
that policy, and to bring the statement and any revision thereof to the notice of all
workers in such a manner as may be prescribed.

(Ref: FA. Sec 7(a) 3 & MFR 73L, OFB Lr. No. 202/COS/GS/Fys dtd 30.04.96 &
No. 300/COS/TS/GS dtd 17/24.1089)

(a) Whether available ?

(b) When last revised and circulated ?
(c) Whether all officers / HOS aware of this 9

1.2 Safety Organization & Nomination of Safety Officers:-

No of workers No. of Safety Officers

Upto 1000- Only if specified
1001 to 2000 1
2001 to 5000 2
5001 to 10000 3
Above 10001 4

OFB Norms: One Safety Officer for every 2000 workers.

(Ref: FA. Sec. 40B , Mah. S.O. Rules'1982 & OFB Lr. No. 300/COS/TS/GS dtd
17/24.10.89 & No. 202/COS/GS/Fys dtd 18.02.94)

(a) Required No. of CLI/RLI trained safety officers - as per Factories Act
- as per OFB norms
(b) How many qualified safety officers are actually posted in safety section ?
(c) Name, Degn. of CSO & whether qualified ?
(d) Name, Degn. of SO & whether qualified ?
(e) How many CLI/RLI qualified officer exist in factory other than Safety section

61
1.3 Safety Manual
(Ref: OFB Lr..No.. 202/COS/GS/Fys dtd 26.04.95)

(a) Whether available ?

(b) When last revised and circulated ? :
(c) Whether available in sections ?

1.4 Disaster Management Plan

Every occupier shall, with the approval of the Chief Inspector , draw up an onsite
emergency plan and detailed disaster control measures for his factory and make known
to the workers employed therein and to the general public living in the vicinity of the
factory, the safety measures required to be taken in the event of an accident taking
place.

(Ref: FA Sec. 41B (4), MFR : 073 Q & OFB Lr. No. 211/COS/ACDNT/Fys dtd 29.10.92)

(a) Whether available ?

(b) When last revised and circulated ?
(c) Availability in concerned sections to act in emergency ?
(d) When last mock drill on DMP was conducted ?
(e) Any deficiencies noted & DMP amended ?

1.5 Safety Committees

The occupier shall, in every factory where a hazardous process takes place or
where hazardous substances are used / handled, set up a Safety Committee consisting
of equal number of representatives of workers and management to promote co-
operation between the workers and the management in maintaining proper safety and
health at work and to review periodically the measures taken.

(Ref: FA Sec. 41& 41 G & MFR : 073 J & OFB Lr. No. 202/COS/GS/Fys dtd 08.04.91 &
22.04.91)

Central Safety Committee Meetings

(a) Held regularly

(b) Whether chaired by GM/OITC/AGM ?
(c) Whether accident analysed and discussed ?
(d) Whether status of audit observations and implementation of BOE discussed ?
(e) Whether minutes recorded and forwarded to RCS ?

62
Shop Safety Committee Meetings

(a) Frequency
(b) Whether safety deviations discussed
(c) Minutes recorded and forwarded to factory Safety cell ?

1.6 Training in Safety & Fire Fighting.

(Ref: OFB Lr. No. 202/GS/TRG/COS/ dtd 15.06.95 & Member/TS's D.O. dtd 30.04.96)

(a) Whether annual plan for training exists ?

(b) Persons trained during last 12 months
(c) Duration of training.

[2]. STATUTORY REQUIREMENTS

2.1 Machinery Guarding.

In every factory, the moving part of a prime mover and every flywheel connected
to a prime mover, whether the prime mover or flywheel is in the engine house or not,
shall be securely fenced by safeguards of substantial construction which shall be
constantly maintained and kept in position, while the parts of machinery being fenced
are in motion or in use.

(Ref: FA Sec. 21)

(a) Availability of Guards for moving parts ?

(b) Availability of Interlock guards ?
(c) Availability of emergency stops / inching Buttons ?

2.2 Hazardous Materials Storage/ Operations

Where the State Government is of opinion that any manufacturing process or

operation carried on in a factory exposes any person employed in it to a serious risk of
bodily injury, poisoning or disease, it may make rules, applicable to any factory,
specifying the manufacturing process or operation and declaring it to be dangerous.

(Ref: FA Sec. 87 and MFR : 114)

(a) Availability of Material Safety Data Sheet 9

(b) Availability of SI /Dos & DON'Ts and whether displayed at work spot ?
(c) Whether hazardous operations identified ?
(d) Whether hazardous materials list with annual consumption figure available ?
(e) Instructions for storage and issue available ?

63
(f) Leakage/Fire detection and preventive systems available ?

2.3 Work Permit system

In 'any factory, no person shall be required to work on fragile roof or at height/in

confined spaces /on electrical equipment/ in pipe lines containing
flammable liquids / gases etc, unless a permit to work is issued to him each time he
is required to work thereon by a responsible person of the factory concerned.

(Ref: FA Sec. 36, MFR : 73F)

(a) Whether work permit systems exists for working

- at height
- on fragile roofs
- in confined spaces
- in pipe lines containing flammable liquids / gases
- on electrical equipment as per OFB SI on electrical safety. .

2.4 Lifting Machines & equipments:

No lifting machine, chain, rope of lifting tackle etc. shall be taken in use unless it
has been periodically tested and all parts have-been thoroughly examined and certified
by a competent person specifying the SWL, and the test certificates has been obtained
and kept available for inspection.

64
65
HOUSE KEEPING

5-S SYSTEM

66
67
68
69
70
71
72
 DO'S & DON'TS
FOR
ACCIENT PREVENTION

73
 INDEX

Sl.No. TOPICS PAGE NO.

1 Preface 02
2 Safety, Health & Environment 03
3 Fire Safety 05
4 Fire Extinguishers 07
5 Construction Safety 09
6 Safety in Hospital 10
7 Radioactive Safety 12
8 First Aid 13
9 Road Safety 14
10 Manual Material Handling 15
11 Safety in Lift 17
12 Safety in Machining 18
13 CNC Safety 21
14 Safety in Grinding 25
15 Safety in Press Operation 26
16 Safety in Handling of Gas Cylinders 27
17 Safety in Welding 28
18 Safety in Painting 30
19 SAFETY IN Wood Working 31
20 Electrical Safety 32
21 Chemical Safety 34
22 Safety in Electro plating 35
23 Safety in Clothing 37

74
 PREFACE

It is well known fact that accidents do not occur but are caused due to ignorance
and lack of knowledge of the workers. In order to prevent accidents and create safe
working environment . in Ordnance Factories, RCS (Regional Controllerate of Safety) is
conducting systematic, structured and exhaustive safety audits as per factory Act 1948
and also actively pursuing safety promotional activities. These efforts led to
considerable reduction in number of accidents in all the Ordnance factories.

RCS (NR) has taken up a challenging task of preparing DO'S and DON'TS for
most of the trades of Industrial Employees in Ordnance factories to benefit the workers.
This book has been prepared by OFEL Avadi on the basis of that book for the purpose
of training. It is our firm belief that this book will serve as an important guide in preparing
shop wise hoardings to be displayed at prominent places to guide and educate the
workers about safe practices at shop floor,

75
 SAFETY, HEALTH ATCD ENVIRONMENT

Your Safety and Health is in your hands. Any unsafe act or behaviour by you may
endanger not only your own life but sometimes others too. Your first responsibility on
the job is to avoid unsafe acts. Here are some tips, which will help you in preventing
unsafe acts.

SAFETY:

Do's :
1. Abide by rules laid down for your factory. Follow factory instructions about
Safety, Health & Environment.
2. Respect Signs/ Warnings.
3. Correct or report unsafe conditions.
4. Keep things clean and orderly. Provide hand bins for storing dust/ dirt from floors/
benches & overhead pipes, beams and machines particularly from bearings and
hot surfaces and scraps of various types.
5. Repair defective electrical wiring. Electric wires, ropes and pipelines to be laid
with proper support.
6. Provide colour code on pipelines.
7. No smoking zone should be earmarked.
8. Use prescribed protective equipments. Always clean and keep PPE's in good
working condition.
9. Proper guarding to be provided to all the moving machines.
10. Ensure free movements after wearing PPE's. Use rhythmic movements.
11. Repair unbalanced chairs/ stools.
12. Use right tools and equipments for the job safely.
13. Ensure good lighting and ventilation. Provide markings on slopes.
14. Beware of electrical cables before excavation.
15. While working in underground sewage lines, provide at least two stand by
workers per gang who will be available near by all the time with self contained
respiratory unit.

Don'ts :
1. Don't start any work without knowing the details. Don't take chances. If you do
not know, Ask?
2. Do not remove stickers, notices and tags.
3. Do not work in unsafe conditions.
4. Do not horseplay. Do not run. Avoid distracting others. Avoid throwing things.
Avoid storage of spillages, scrap, rubbish etc for prolonged period.
5. Do not obstruct approach to electric switches/ Panels, fire extinguishers and
emergency exit doors.
6. Never walk on pipelines. Do not throw or roll gas cylinders.
7. Do not smoke in restricted area. Do not flick Cigarette/bidi ends in salvage area.
8. Do not use loose clothing during work.

76
9. Do not remove guarding of machines especially hand tools and grinding
machines.
10. Avoid zigzag movements. Avoid bent, twisted and extended postures. Do not
keep any posture for a prolonged time.
11. Do not use unbalanced chairs/ stools.
12. Don't keep tools away from easy grasp.
13. Avoid glare on slopes.
14. Don't forget to barricade danger zones.
15. Do not allow any untrained worker to enter under ground sewage lines.

Health & Environment :

Do's :

1. Wash your hands and the exposed parts of the body regularly and take bath after
work. Ensure the cleanliness of your hair and nails. Change working clothes,
towels periodically. Clean your hands before eating.
2. Cooperate in keeping sanitary areas clean.
3. Stay away from work if you are suffering from any contagious disease.
4. Handle chemicals only after knowing physical & chemical properties and their
associated dangers.
5. Improve lighting levels and placement of light fittings to ensure even lighting of all
floor areas.
6. Eliminate smoke/ steam or control by redirecting it away from risk areas, improve
ventilation and display warning signal.
7. Eliminate pollution. Do not just shift it. Chemical as well as sewage waste to be
treated.
8. Always maintain first aid boxes and stretchers at prominent places.
9. Ensure proper disposal of Bio-medical/ hazardous solid waste.
10. Develop green plantation around workplace.

Don'ts :

1. Never use solvents, alkalis and machine oils to clean the skin. Never eat where
dangerous chemicals are used.
2. Do not enter sanitary areas without footwear. Do not leave the toilet un-flushed.
3. Never inhale dirt/ dust/ fiber dust. Always use facemask.
4. Never taste or inhale any chemical or its vapors.
5. Don't tackle toxic gas leak without breathing apparatus.
6. Do not wash hands with petrol/ kerosene. Use proper cleaning agent.
7. Do not ignore monitoring of ETP and its effluents.
8. Don't delay first aid.
9. Do not dispose wastes without the approval of Pollution Board.
10. Never cut trees.

77
11. Permissible noise level should never exceed 90 -115 db.

78
 FIRE SAFETY

FIRE LAYOUT PREPARATION/ PREVENTION/ SURVIVAL

I) FIRE LAYOUT PREPARATION:

(Familiarize with)

Do's :
1. Fire Order prepared by Organization.
2. Your role and responsibility during an emergency.
3. Emergency communication system.
4. Location of Fire Alarm points nearest to your work place.
5. Location of emergency kits, store, its keys and items available in it.
6. Location of first aid box and stretchers.
7. First Aid procedures.
8. Emergency telephone numbers of Fire stations, medical center and security main
gate.
9. Assembly point.
10. Location of fire extinguishers and its use in case of fire.
11. Location of fire hydrants, static tanks etc.
12. Escape routes.

II) FIRE PREVENTION:

Do's :
1. Ensure high housekeeping standards.
2. Cover trash containers tightly and empty them regularly.
3. Segregate flammable material from source of ignition.
4. Promptly eliminate oil/ gas leaks and clean spillage of flammable material.
5. Store incompatible chemicals separately.
6. Where flammables are stored and used, ensure adequate ventilation, prohibit
smoking and use flame proof electric equipment.
7. Lubricate, maintain and align all machines/ equipments to prevent generation of
heat.
8. Evacuation drills should be conducted at regular intervals and elementary fire
fighting training to occupants to be imparted.
9. Fire safety equipments should be maintained in high standards and checked at
regular intervals.
10. Use IS certified appliances of correct rating.
11. Use one socket for one appliance.
12. Switch off the electric supply of fire affected areas.
13. Fuses and switches should be mounted inside metallic cubicles for greater safety
against fire.
14. Replace broken plugs and switches immediately.
15. Keep the electrical wires away from hot and wet surfaces.
16. Switch off appliances after use and remove plugs from the socket.
17. Switch off the main switch when leaving the premises for a long duration.

79
Don'ts :

1. Height of slanting above factory doors along with approach roads should not be
hindrance to pass fire tenders.
2. Avoid multi socket connections.
3. Do not smoke in NO SMOKING area.
4. Never throw lighted cigarette/ Bidi butts.
5. Do not store LP gas cylinders against rules.
6. Do not apply any paint on fire detectors/ sprinkler heads.
7. Do not think that fire safety is others job.
8. Do not relax after hearing fire/ emergency call.
9. Don't use substandard fixtures/ appliances.
10. Never have temporary or naked joints on wiring.
11. Don't allow appliances, cords to dangle.
12. Don't place bare wire ends in a socket.
13. Do not lay wires under carpets, mats or doorways. They get crushed resulting in
short circuiting.

Ill) FIRE SURVIVAL:

Do's :
1. Stay calm.
2. Be concerned about own safety as well as that of others.
3. Put off small fire with the help of fire extinguishers.
4. Shout FIRE, FIRE and raise alarm.
5. Before escape and leaving premises, close doors and windows ensuring no one
is left behind. Assemble at Assembly point.
6. If in case you are trapped in your room, close the door and block any gap which
might let smoke or fumes through. Shout from the window to attract the attention
of rescue team as well as others.
7. If your clothes have caught fire, roll and use blanket.

Don'ts :
1. Do not shout or run. This tends to cause panic to others.
2. Do not use water against flammable material.
3. If you are entrapped in heavy smoke, never stand up and crawl low under the
smoke covering nose and mouth with wet cloth.
4. Never go back into a burning building for any reason.
5. Do not stop to collect belongings.
6. Teach children not to hide from Fireman. If someone is missing, tell the Fireman.
They are equipped to perform rescue safely.
7. Do not secure open fire and smoke, check doors as they limit the spread of fire
and smoke when in closed position.
8. Don't be tempted to clutter the stairs, corridors and lobbies as they are your
escape routes.
9. Never use lift in case of fire. Always use stairs and never go upstairs.

80
 FIRE EXTINGUISHERS

Fire extinguishers play an important role in first aid fire fighting and are not expected to
deal in large fire. They are all very valuable in the early stages of a fire when used
promptly and effectively. The usefulness depends upon the knowledge of person in
handling extinguishers, their selection and maintenance.

Fire extinguishers requirement, location and installation should be done as per IS 2190.

HOW TO USE FIRE EXTINGUISHERS :

Remember the acronym PASS which stands for :

P PULL PULL THE PIN OR SAFETY CLIP

A AIM AIM AT THE BASE OF FIRE
S SQUEEZE SQUEEZE/OPEN THE TOP HANDLE OR LEVER
S SWEEP SWEEP FROM SIDE TO SIDE

FOLLOWING PROCEDURE SHOULD BE FOLLOWED FOR QUARTERLY

MAINTENANCE, INSPECTION AND TESTING OF FIRE EXTINGUISHERS:

GENERAL:

- Make sure that the extinguisher is in proper condition and shall not be
accidentally discharged.
- Clean the exterior of the extinguisher, polish the painted portion with wax
polish, the brass parts
- with metal polish and chromium plated parts with silver polish.
- Check the nozzle outlet, vent holes in the threaded portion of the cap for
clogging and check that
- plunger is in fully extended position and is clean.
- Check the cap washer, grease the thread of cap and plunger rod.
- Check all mechanical parts thoroughly.
- Check the proper labels.

DRY POWDER TYPE FIRE EXTINGUISHER:

- Remove gas cartridge from the cap. Weigh the cartridge and compare its
mass with full mass of
- cartridge marked on it. If loss of mass, replace it.
- Examine the nozzle, hose, vent holes, piercing mechanism of cap,
cartridge holder, grease and
- wipe clean.
- Charge it and fit the cartridge and other fittings.
- Keep the SI. no. and record in proper register.

81
C02 TYPE FIRE EXTINGUISHER:

- Weigh the extinguisher; compare mass against the mass marked on it for
fully charged extinguisher. It should be sent for refilling if there is a loss of
mass.
- Examine hose, horn and valve assy.
- Give the SI. no. and record it in a register.

MECHANICAL FOAM FIRE EXTINGUISHER:

- Remove gas cartridge from the cap. Weigh the cartridge and compare its
mass with full mass of
- cartridge marked on it. If loss of mass, replace it.
- Examine the nozzle, hose, vent holes, piercing mechanism of cap,
cartridge holder, grease and
- wipe clean.
- Charge it and fit the cartridge and other fittings.
- Keep the SI. no. and record in proper register.

WATER C02 TYPE FIRE EXTINGUISHER:

- Remove gas cartridge from the cap. Weigh the cartridge and compare its
mass with full mass of
- cartridge marked on it. If loss of mass, replace it.
- Examine the nozzle, hose, vent holes, piercing mechanism of cap,
cartridge holder, grease and
- wipe clean.
- Charge it and fit the cartridge and other fittings.
- Keep the SI. no. and record in proper register.

ABC TYPE FIRE EXTINGUISHER:

- Check the pressure of extinguisher from the pressure gauge. If found less
than required pressure
- send for refilling.
- Examine the nozzle, hose, vent holes, piercing mechanism of cap,
cartridge holder, grease and
- wipe clean.
- Keep the SI. no. and record in proper register.

82
CLASSES OF FIRE

83
 CONSTRUCTION SAFETY

Do's :

1. While going to work at height for more than 3 meter, wear safety helmet &
antiskid shoes.
2. Use crawling boards or roof ladders while working on the roof of the
building.
3. Safety belt should be worn by the individual while working at a height
more than 3 Meter. Lifeline should be tightened to a fixed structure.
4. Safety net should be placed below the place of work at height.
5. Safety items like safety belt, safety net, safety helmet and lifeline should
be inspected periodically by the staff or Site In charge.
6. Ladders should be tightened to a fixed structure and have antiskid shoes.
7. Responsible staff should be present continuously at the work spot.
8. Scaffolds should be of good construction, sound material and adequate
strength.
9. Only trained and experienced workmen should be allowed to work at
height.
10. Ladder should always be hold by helper.

Don'ts :

1. Do not work without Work Permit and follow the safety instructions
enumerated therein.
2. Do not leave the tools on the roof top and other places where they are
liable to fall and cause injuries.
3. Do not use loose clothing while at work.
4. Do not smoke while working at height.
5. Do not forget to position First aid equipment in the work place.
6. Do not allow individuals having heart problems, giddiness to work at
height.
7. Work on the roof of the building shall not be carried out in rainy season,
windy condition and hot summer.
8. Do not allow anyone to work in the Shop floor area below the roof work so
that accidents can be avoided due to hit by fallen material from height.
9. Do not bend/ stretch the body outside the ladder/ platform.
10. Do not place the ladder where they can be struck by doors, vehicles.
11. Ladder should not have slope more than 4 vertical and 1 horizontal.

84
85
 BIOMEDICAL WASTE

1 Yellow bag Infected waste (Patients Incinerator / deep burial

Waste, infected dressing,
animals skeletons, micro
organisms and other
laboratory waste).
2 Red bag Infected plastic waste Autoclaving / Microwaving
(disposable syringe, tube, IV chemical treatment
bottle etc.)
3 Use white colour A. Broken glasses such as Autoclaving / Microwaving
puncture proof broken injection ampules, chemical treatment /
container for broken slides, syringes etc. shredding.
glasses and sharp B. Needle, blade, sharp and
metals separately blunt pieces of metals
4 Black bag Disinfected ordinary waste Disposal in secured land
(Eatable cups, plates, office fill area.
used card boards, metal
boxes, paper, plastic) etc.

Important:- Factories should obtain authority for Bio waste management from Pollution
Board.

86
 RADIOACTIVE SAFETY

Do's :

1. Display radiation symbols at entrance gate.

2. Wear film badge before starting work.
3. Examine & ensure that radiation source is in safe position.
4. Plan the work and try to remain in exposure room only for short while.
5. Try to maintain safe & long distance from radiation source.
6. Use servometer before & after the work to ensure that radiation source is in safe
position.
7. Close the exposure room in case of no work.
8. In case of more quantity on badge or if badge falls in radiation area/zone while
use, then report immediately to radiological safety officer/ department head for
return of film to R.P.A.D/B.A.R.C.

Don'ts :

1. Do not allow unauthorized persons to enter radiation zone.

2. Do not put off red light of danger area while exposure is on.
3. Do not use radiation source other than required objective.
4. Do not leave film badge in radiation zone in case of no use / work.

87
 FIRST AID

First aid may be defined as skilled assistance to the victim in case of accident or sudden
illness. The person who renders skilled assistance is called the first aider.

First aid is primarily a temporary measure to arrest the worsening of the victim's
condition till the arrival of a doctor.

First aid box with required medicines etc. & display of two first aider's names along with
stretchers, in good condition should be available at easily accessible place in shops/
offices.

Instruction to First aider:

1. Gather information as to how the accident or illness came about.

2. Look out for signs such as swelling, bleeding, immobility etc.
3. Look out whether the victim feels thirst, nausea, cold, pain, numbness etc.
4. Pay special attention to severe bleeding, failure of breathing & shock.
5. Arrange for speedy removal of the victim to proper medical care.

Do's :

1. Do the first thing first quickly, quietly and calmly.

2. Stop severe bleeding, if any.
3. Administer artificial respiration if required and continue it till the doctor arrives.
4. Treat for shock.
5. Boost up the morale of the victim to lessen his anxiety.

Don'ts :

1. Avoid crowding around the victim.

2. Unless required don't remove clothes.
3. Do not try to achieve too much.
4. Do not soak a victim to wake him up.
5. Unless victim complains of cold, don't wrap with blanket or coat.

88
 ROAD SAFETY
Do's :

1. Concentrate on driving. Follow signs and traffic lights.

2. Pedestrians should cross the road especially at highways carefully.
3. Driver should be alert and not under the influence of liquor.
4. At the time of halt during fog, driver should clean windscreen, lights, windows
and reflectors.
5. During driving in fog, always drive at a speed that allows driver to stop within the
distance of visibility.
6. Always leave parking lights on while parking in unlit or poorly lit areas
7. Vehicle with only one light could be a one eyed car instead of motorcycle. Hence
drive carefully.
8. Always use low beam when driving in fog or while following another vehicle.

Two Wheelers:

1. Always wear helmet of IS mark.

2. Always wear helmet visors, goggles or spectacles to protect the eyes.
3. Always wear clearly visible clothes for night riding.
4. Apply both brakes at the same time.

Loco Shunter :

1. Railway line should be clear of grass for clear visibility.

2. Speed breakers should be provided on cross roads with fluorescent marking.
3. Better illumination should be provided for clear vision in the night.

Don'ts:

1. Never drive vehicle when tired or tense.

2. Don't drive without license. Learner should accompany license holder while driving.
3. Avoid excessive speed.
4. Avoid following too close to other vehicles.
5. Avoid lane cuts. Signal every time you change lane or turn.
6. Avoid overtaking dangerously and that too from left side of the vehicle.
7. Avoid driving in fog or heavy rain.
8. Don't turn around to talk to rear passenger.
9. Never coast downhill with your gears or transmission in neutral.
10. Avoid eye contact with aggressive drivers.
11. Don't eat or drink while driving.
12. Don't use mobile phone while driving.

89
Two Wheelers:

1. Never position yourself in the blind spot of the other driver ahead.
2. Never negotiate a corner too fast. Reduce speed before entering the turn.
3. Don't forget to shift into the correct gear in advance.
4. Don't use only the front brake first.
5. Do not squeeze between two lanes or weave through traffic .

Loco Shunter:

1. Loco shunter should not be driven without helper having red and green flags for
waving enroute.
2. Shunter should not be driven without alarm especially near cross road.

90
 MANUAL MATERIAL HANDLING

Do's :

1. Think before acting. Remove obstructions before lifting. Examine surroundings

for what can happen.
2. Size up the job.
3. Lift correctly with your leg muscles and straight back. Take a good firm grip.
4. Use gloves when the load is with sharp edges/corner. Use right tools and tackles
wherever necessary. Ensure free movement after wearing PPE's.
5. Give each pile a firm foundation before stacking.
6. Allow ample room for passageways. Observe clearance rules at aisles and
corners.
7. Know the safe load limit of the floor of the building when piling heavy materials.

Don'ts :

1. Do not be unduly hasty.

2. Do not try to lift an object that is obviously too heavy and in that case take help of
others.
3. Do not lift using your back. Avoid bent, twisted and extended postures.
4. Avoid zigzag movement.
5. Do not pile too high. Do not store material over cupboards, almirahs and
makeshift racks.
6. Do not store rods and sheets projecting on to walkways. Do not obstruct the path
to fire fighting equipment.
7. Do not drag materials or remove from the bottom of a pile.

SAFETY IN MECHANICAL HANDLING

CRANE SAFETY:

Do's :

1. Use the right sling for the job. Check the following before taking the sling to
use:

1.1 How exactly it should be attached to the load.

1.2 The weight of the job being lifted and the permissible load of the sling and the
crane.
1.3 The condition of the rope, chain, lifting eye, splices, rings, thimble etc.
1.4 Evidence of test and certification.
1.5 See that the load is evenly balanced.
1.6 Keep the sling in proper storage, away from damp conditions/avoid corrosion.
1.7 When duplex hook (double saddle hook) is used, double sling must be used to

91
ensure equal distribution of load.

92
2. Before starting the crane the driver must check the following:
2.1 All brakes are working.
2.2 All controls of the cabin are smoothly working.
2.3 Emergency stop switches/ safety switches are working.
2.4 All limit switches are operating.
2.5 There is no visible damage to any part of the crane (wire rope, hook etc.). Always
use correct sling.
2.6 Various motions are correct.
2.7 Warning bell is working.
2.8 Cabin glass is completely clean for clear visibility.
2.9 Fire extinguishers are ready for use.
2.10 Emergency escape ladders are ready for use.

3. During Operation:

3.1 Controls should be operated smoothly.

3.2 Crane must be centered over load and hoisting rope should be kept vertical to
avoid swinging of load.
3.3 Rope must be set to the grooves of the drum and keep straight.
3.4 Passage Ways must be cleared for movement of load. Warning signal must be
provided.
3.5 All capacity and hoist brakes must be tested by returning the master switch in
OFF condition after raising the load a few inches above the ground.
3.6 Remove all slings and ropes when not in use.
3.7 Special care should be taken while carrying the load with electro-magnet.
3.8 Before closing main or emergency switch, all controls should be OFF.
3.9 Limit switches should not be blocked, adjusted or disconnected in order to go
higher than the switch will allow.

4. Before leaving the crane, operator must:

4.1 Stop the crane at approved place.
4.2 Place all controls in OFF position.
4.3 Keep main switch to OFF position.
4.4 Make visual check.
4.5 Raise all hooks to safe position.

5. During Operation:
5.1 Do not allow any unauthorized person to operate the crane.
5.2 Avoid jerky movement of load.
5.3 Block should not be lowered too much. At least two full wraps of rope should
remain on the drum.
5.4 Do not overload the crane.
5.5 Do not operate the crane if limit switches are out of order or the wire rope is
damaged.
5.6 Do not use make shift slings. Only a well designed, tested and certified sling
should be used.

93
5.7 Do not drag chains, slings, hooks or loads on the floor.
5.8 Don't keep the load suspended with power on if the operator is not in the cabin.
5.9 Crane operator should not use limit switch to stop hoist under normal conditions.
5.10 Don't carry the load over the people.
5.11 If electrical power is disrupted, don't leave the controls in ON position.
5.12 Do not attempt to use two controls at the same time.

6. BATTERY TRUCK/FORK LIFT:

Do's :
6.1 Only authorized persons should drive.
6.2 Check battery condition. Keep it charged.
6.3 Check pedal brakes before starting.
6.4 Pile load neatly and securely.
6.5 Shut off controls, remove the key and apply hand brakes before getting down
from the vehicle. Check support on slope.

Don'ts :
6.1 Avoid quick start, jerky steps and quick turns at excessive speeds.
6.2 Avoid operation in reverse as far as possible.
6.3 Never overload the truck above eye height.
6.4 Never park battery truck/ fork lift in an aisle or doorway.

SAFETY IN LIFT
DO'S :
1. To call, one should press Hall button safely.
2. Be away from Hoist way.
3. As soon as you enter lift, press gently the appropriate button and stand away
from the panel.
4. Tell the lift operator if he is available.
5. Lift operator is your guide. Listen to him carefully.
6. Remain calm in Lift. Lift operator should always be attentive.

Don'ts :
1. Do not press Hall button again & again.
2. Unless lift reaches designated place and doors are fully open, never enter in the
lift.
3. Do not remain standing between doors as it will delay the operation.
4. Never open doors forcefully. It is dangerous.
5. Never crowd before lift door. Keep distance.
6. Never bend forward before wall panels. Keep distance.
7. If lift stops in between, then don't panic. You are completely safe inside. Press
alarm button if necessary. Do not touch any other part of lift. Some body has
started for your rescue. Keep calm & cool. This interruption is only for few
moments.
8. Until very necessary do not use Stop button.

94
 SAFETY IN MACHINING

BEFORE STARTING OPERATOR SHOULD ENSURE THAT

Do's :

1. His hands are free from oil and grease etc.

2. All safety guards are in place and properly fixed.
3. All controls, movements of machines are working smoothly.
4. Job is securely and correctly fastened.
5. The tool is securely fastened.
6. Correct tool is being used.
7. He has worn safety shoes, goggles and apron.

DURING OPERATION THE OPERATOR SHOULD ENSURE THAT:

Do's :
1. Operator should use suitable holder for filing with emery paper.
2. Coolant should be applied at the cutting point.
3. Operator should ensure that power is isolated to avoid accidental running of the
machine.
4. Operator should use correct type and size of spanners. Extra care should be
taken when pipe is attached to the spanner.
5. Operator should only apply his hand force and not body force or foot.
6. Operator should stand at a distance from the cutting point when close
observation is not required.
7. Operator should be very careful when more than one tool is used.

DURING OPERATION THE OPERATOR SHOULD NOT:

Don'ts :
1. Leave the machine unattended while it is in motion.
2. Check the dimensions while machine is in motion.
3. Gauge the tool while machine is in motion.
4. Remove the chip while machine is in motion.
5. Clean the machine while it is in motion.
6. Clean/ remove the chips from machine by naked hands.
7. Allow any unauthorized person to operate the machine.
8. Run the machine idle except for trial/ test.
9. Use his hands or any part of the body as a brake to stop the machine.
10. Place Ms finger between the tool and the job.
11. Operate the machine in case of any abnormal sound from the machine and
report immediately to concerned staff.

95
12. Oil the machine while it is in motion.
13. Change/remove the tool.
14. Do not operate the machine if the insulation of the machine lamp is damaged.
15. Don't Feed the job too fast.
16. Operator should not take unsafe posture.
17. Operator should not make unsafe position by climbing on the machine.
18. Don't allow the chip to become long spiral type.
19. Operator should not touch the job when it is hot.
20. Don't use more than one cutter at a time except where unavoidable.
21. Don't use compressed air to blow chips, cuttings or shavings from machine.

Important precautions to be followed by operator when machine is running:

TURNING:
Do's :

1. Use transparent chip shield to protect against flying chips and splash of cutting
fluids.
2. Inspect the tailstock of spinning lathe frequently to prevent loosening.

MILLING:
Do's :

1. Operator should ensure that the job does not strike the cutter while reversing the
table.
2. Operator should draw the job back to a safe distance from the cutter for loading
and unloading.
3. Dress the cutter properly before fitting it in the machine.
4. The rotating cutter should be properly guarded.

Don'ts :
1. Don't use machine power for tightening the arbor nut.
2. Don't clean or touch the cutter while it is in motion or by naked hand.
3. Do not wear gloves, rings, muffler or loose clothing while at work.
4. Do not use hands for removing swarf.

BORING/DRILLING:
Do's :
1. Use a plastic shield, wire mesh guard or other barrier in drilling machine to
prevent contact with the spindle.
2. Before the boring bar is inserted into spindle, the operator should make certain
that the spindle's hole and the bar are cleaned and free from risk.
3. While deburring on drilled holes never hold the job in your hands and apply
pressure against revolving drill bits.

96
4. Do not use dull drills.
5. Do not raise or lower the boring mills head without loosening the clamps on the
column.
6. Never work on a drilling machine without clamping the job rigidly.
7. Never apply excessive pressure on the drill bit as it may break.

PLANING:
Do's :
1. Careful loading / unloading of heavy jobs should be done.
2. Always check the limit switches of both ends of the bed before loading.
3. Job should be clamped atleast at four places on the bed.
4. Install guards on the revolving parts of the Planers.

Don'ts :
1. Job should not overhang on the bed of the machine.
2. Don! t allow any obstruction in the path of the bed.

COLD SAW/HACK SAW:

Do's :
1. Always operate the machine with coolant at cutting point.
2. Ensure that the teeth of the saw segments are not blunt and in right direction.
3. Ensure that the segments are securely riveted with the saw body.

Don'ts :
1. Do not operate the cold saw machine below the prescribed pressure.
2. Don't operate the machine at higher than specified speed.
3. Don't allow the cut pieces to cause injury.

DEEP HOLE BORING:

Do's :
1. Operator should apply barrier cream on hands before starting the work.
2. Job/ Barrel should be loaded with due care on machine to avoid the damage to
machine.
3. After loading the job/ barrel operator should fix the chuck guard in its place.
4. Area around the machine should be swept frequently by saw dust so that the
floor does not ' become slippery.
5. Chip collector should be placed just below the oil discharge pipe of the machine.

Don'ts :
1. Don't allow spillage of oil from the bored job/barrel.
2. Don't allow jamming of oil drams by chips:
3. Don't allow spillage of oil/Chips from the chips while transporting the chip
collector.
4. Don't allow the chip collector to be over loaded.

97
 CNC SAFETY
1. Know Your Machine

Though an operator is not expected to be a machine designer to work with CNC

equipment yet it is important that he knows that how the CNC Machine Tool is
constructed. At least knowing about the following points is essential:

(A) About Construction:

1. What is the machine's maximum RPM?

2. How many spindle ranges does the machine have and what are the cut-off points
for each range?
3. What is the tool taper?
4. What is the maximum size of tool that can be used?
5. What are the spindle and axes drives' motor ratings?
6. How many axes are available?
7. What is the maximum travel distance in each axis?
8. What are the software limits positive and negative of each axis?
9. How many tools can the machine hold?
10. What way construction does the machine incorporate usually squire ways,
dovetail, and/or linear bearing ways?
11. What is the machine's rapid rate i.e. fastest traverse rate?
12. What is the machine's fastest cutting feed rate?
13. What are the specifications of various oils (Hydraulic, Lubricating and Coolant)
used?
14. What is the required air/hydraulic pressure for pneumatic/hydraulic system?
15. What are the accessories available with machine?
16. What are the safety devices installed on machine and how these devices work?

(B) About Performance Specification:

1. What is the motion direction of each axis motion ?

2. What is the reference value and direction for each axis?
3. What 'G' and 'M' codes are available?
4. How many tool offsets/zero offsets are available?
5. How to define offsets?
6. How many 'R' parameters are available?
7. What are the programming modes?
8. What programming formats are available?
9. What types of interpolations are available?
10. What are the compensations available?
11. How to define compensations?
12. How to interpret alarm?

98
2. Do's and Don'ts in operation of CNC machines:

(A) In Workshop:

Do's :

1. Read instructions of machine tool builder carefully.

2. Know where the incoming power supply distribution box is installed, Learn to
operate main switch.
3. Always wear an apron.
4. Wear good strong safety shoes.
5. Wear helmets wherever required.
6. When learning how to use a machine, ask questions, especially if you do not fully
understand.
7. Always put the guard or safety hoods in position when working on a machine.
8. Keep hands away from moving/rotating machinery.
9. Use hand tools carefully, keeping both hands behind the cutting edge.
10. Maintain good housekeeping in workshop, as it helps in preventing accidents.
11. Make use of TPS Tools like 5 'S to improve house keeping.
12. Report any damage to machines/ equipment or any abnormal condition
immediately as this "could cause an accident.

Don'ts :

1. Do not run in the workshop.

2. Don't wear loose clothing such as ties, muffler while working on machine.
3. Do not use a machine, if you have not been shown how to operate it safely.

(B) Routine Checks:

1. Clean the chips daily, leave the machine neat and clean for next shift or day's
work.
2. Check on daily basis for levels of Hydraulic, Lubrication and Coolant oils- if low-
get it topped up.
3. Check for required air pressure/hydraulic pressure.
4. For new users, it is a good practice to put the machine in warming up mode for
first 10 minutes every day. A warming up program may be used for this purpose.
5. Know the monthly, half yearly and yearly preventive maintenance requirements,
make sure that machine is handed over for preventive maintenance as per
schedule.
6. Know the 'quality' instruction before attempting to use any CNC equipment.
7. Occasionally, look into the electrical cabinet of CNC Machine, report any
abnormal condition for rectification.
8. Remember, Common Sense applies to the use of all machines including CNC
machines.

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3. Do's and Don'ts in Normal Mode of Operation of CNC Machines:

Do's :

1. Honour safeguard put on work area and tool magazine/ station,

2. Always jog the machine to safe limits before performing reference/ homing.
3. Do careful chip removal; this must not result in personal injury due to the chips or
moving parts of the machine.
4. Put the guard in position to prevent any personal injury due to flying chips.
5. Take care to prevent any injury due to flying work-pieces or parts thereof, flying
work-piece clamping fixture and flying tools or parts thereof. For example, this
can occur due to:

5.1 Inadequate clamping or tightening

5.2 Inadmissible cutting force
5.3 Inadmissible rotation speed
5.4 Work-piece breakage
5.5 Defective clamping fixtures
5.6 Material defects
5.7 Collision with the work-piece or a machine parts
5.8 Collision with the tool or machine parts
5.9 Selection of wrong tool/ grinding wheel
5.10 Entering a wrong offset
5.11 Power failure

Don'ts :

1. Don't approach or step into the danger zones during automatic movements.
2. Do not approach into the danger zones of moving chip conveyors.
3. Do not approach into drive systems.

4. Do's and Don'ts in Special Modes of Operation of CNC Machines:

Do's :

1. While changing job, clamp the job in such a way that no part of the body can be
trapped between closing clamping fixtures and work-piece.
2. Take special care when power-operated clamping means are used.
3. Make sure that no finger can be trapped, while advancing tail stock sleeve tip or
putting a tool in holder/spindle.
4. During job or tool change process, make sure that no one issues a starting
command to spindles, axes, sleeves, turret heads, and tool magazine or chip
conveyors.

100
5. On completion of work-piece change or tool change, put back the safety guards
in position before issuing automatic command.
6. Manipulation of job either manually or with tools must be carried out carefully.
7. After manual entry of part program, double check the program entered for
possible typing errors.
8. Always use the right offset valves, if not aware, ask the supervisor/ programmer.
9. Keep the offset values written in book for current job.
10. To prevent hitting of work-piece or tool with machine tool, consider software limits
carefully in. assigning offset values.
11. Take due consideration for taking all axes to safe position by program, while
calling an automated tool change command.
12. Always record any change incorporated in part program.
13. Always use correct spindle speed and cutting speed according to material and
dimension of job.
14. During maintenance or troubleshooting, machine must be prevented from
starting.
15. Personal injury resulting from a machine part splintering off or dropping must be
prevented.
16. Handle fluid or gaseous media carefully.
17. If movements are required with the safety guards removed (during set-up,
production fault correction, trouble shooting etc.), these movements must be
done in close control and supervision.

Don'ts :

1. Never manipulate work-piece with rotating grinding wheel.

2. Never step into other moving machine parts from the tool loading station.
3. Don'ts perform dimension check or set up measurement, while any part of the
machine is moving, take special care with CNC Grinding Machines.
4. Movement of the machine must be prevented, while manipulation of a defective
part is being carried out.
5. Never tend to touch live parts of the machine.
6. Never exceed designed parameters for spindle rpm, cutting feed and axes
movements.

101
 SAFETY IN GRINDING
Do's :

1. Always wear authorized PPE's..

2. Select grinding wheel carefully.
3. Grinding should be done only from the periphery of the wheel and not from the
sides.
4. Run the wheel for a minute before applying to the job.
5. Coolant should be applied on the job during grinding.
6. Hold the job firmly on pedestal grinders.
7. Always maintain correct distance between work rest and grinding wheel.
8. Always use wheel washer.
9. Prevent brushing of wheels or disk by avoiding vibration and excessive speed.
10. Make sure that spindles mounted are of correct size and do not loosen as it
revolves due to thread cut in those.
11. Ensure that all moving parts are adequately guarded.
12. Ensure that all controls are well within the reach of the operator.
13. Before grinding, machine should always be run with a wet wheel & without
coolant for some time.
14. Always test the grinding wheel for visible cracks before taking for use. Replace in
case of cracks.
15. The gap between the wheel and tool rest should be 2.5 to 3.0 mm.

Don'ts :

1. Don't allow the wheel to run at more than the specified speed.
2. Don't apply too heavy cuts to the wheel.
3. Don't stand at the side of the grinding machine to avoid sparks.
4. Coolant should not be applied on stationary wheel.
5. Don't touch the running wheel to determine the smoothness/ condition.
6. Don't move the job too fast on the grinding wheel.
7. Don't grind too high above the center of the wheel.
8. Don't force a wheel into a machine or alter the size of mounting wheel.
9. Don't jam work into wheel.
10. Don't stand directly in front of a grinding wheel when a grinder is started.
11. Don't grind materials for which the wheel is not designed.
12. Don't use a wheel that has been dropped.
13. Don't tighten the mounted nut excessively.
14. Don't adjust the tool rest of the grinding wheel when it is in motion.

102
 SAFETY IN PRESS OPERATION

Do's :

1. Two dangerous portions such as the point of operation and power transmission
shall be guarded.
2. Make sure that working space is cleared of all stock containers tools and other
items.
3. Raise the ram slowly by hand on light press and by jogging or inching under
power on large presses and make sure that the die does not foul in the slide.
4. Block the ram in its higher position .If power was used shut off the power and
lock out the switch.
5. Check the die to make sure that it does not contain any chips, tool or parts and
that it is in good operating order.
6. Check all the bolts and clamps to see that they are tight and the dies are
securely fastened in the press.
7. Foot pedal needs some shielding so that the operator's foot can not accidentally
turn the machine on. As far as possible, press should be operable by both hands.
8. Any malfunctioning of the press shall be reported to the concerned maintenance
group.
9. All authorized PPE's should be used.
10. Power presses shall be examined by competent person at least once in a year.
11. Keep the press clean and lubricate the moving parts.
12. Switch off electricity/ main switch after completion of work on press machine.

Don'ts :

1. Don't bypass the safety devices provided in the press.

2. Don't make any adjustment without shutting off the power and blocking of the
ram.
3. Don't operate the machine in case of abnormal sound.
4. Do not talk or divert your attention while working on press machine.
5. Do not work with overconfidence.
6. Do not ignore the instructions given by the manufacturer.

103
 SAFETY IN HANDLING OF GAS CYLINDERS

Serious accidents may result from the misuse, abuse or mishandling of compressed gas
cylinders. Observance of the following rules will help control hazards in the handling of
compressed gas Cylinders.

Do's :

1. When doubt about handling of compressed gas cylinders or its contents, consult
superiors.
2. Protect cylinders from cuts or abrasions.
3. When empty cylinders are to be returned to stores mark them "EMPTY" with
chalk.
4. Cylinders should be rolled on their bottom edge but never be dragged for shifting
from one place to other place.
5. Keep cylinders particularly Acetylene in upright position. .
6. Keep the metal cap in its place to protect valve assy.
7. Make sure the threads on the regulator correspond to those on the cylinder valve
outlet.
8. Open cylinder valve slowly with a cylinder key.
9. Use a cylinder of compressed gas with pressure reducing regulator.
10. Use regulators and pressure gauges only with gases for which they are
designed.
11. Before a regulator is removed from a cylinder valve close it and release the gas
from the regulator.

Don'ts :

1. Do not remove or change numbers or marks stamped on cylinders.

2. Do not lift compressed gas cylinders with an electromagnet.
3. Do not drop cylinders or let them strike each other violently.
4. Do not use cylinders for rollers, supports or any purpose other than to contain
gas.
5. Do not tamper with safety devices/ valves of the cylinder.
6. Do not force connections that do not fit.
7. Do not attempt to repair or alter cylinder valves or attachments
8. Do not permit sparks, molten metal, electrical currents, excessive heat or flames
in contact with cylinder or attachments.
9. Never use oil or grease as a lubricant on valves.

104
 SAFETY IN WELDING

GENERAL POINTS:

1. Remove flammable materials from the work place before starting welding
operations.
2. Fire extinguishers should be provided at work place & they should be checked
periodically.
3. While working in confined place, welding machine should be fixed from outside &
arrange adequate ventilation.
4. Welding should be done by authorized person only.
5. Protection equipments like leather aprons, leather hand gloves, nose mask,
safety shoes & hand shields should be used.
6. Welding set should be checked periodically and replace bad parts & fittings.

ARC WELDING/ CUTTING:

Do's :
1. Welding transformer/ generator should be connected through protective devices
like switch, fuse starters and LCD's.
2. Insulation of cables from welding generator/ machine should be proper.
3. During working in confined space cable should be covered with dry boards.
4. Welding cable should be of proper size sufficient to carry load and return current.
5. Welding transformer/ generator should be periodically checked for Di-electric
strength-of oil/ JR values.
6. Electrode holder should be at least 3Q-50mm away from, the job while welding
otherwise holder will get damage.
7. Electrode pieces should be stored in a pot and warning symbol must be
displayed.
8. After completion of work detach machine from power source and keep electrode
holder at safe place.

1. Electrical connections at terminal boards should not be exposed.

2. No insulation cuts, broken wires, joints or loose connections should be allowed &
should be replaced if found so.
3. Earth or member structure should never be used for the return path of the
welding circuit.
4. Do not change the electrodes with bare hands or wet gloves.
5. Do not work without Welding enclosures at the work place.

105
WELDING/CUTTING (OXY-ACETYLENE):

Do's :

1. Use red colored tube for acetylene and black tube for oxygen. Both tubes should
be of equal size.
2. Clean the valve seat of the cylinder before fitting the regulator.
3. Use flash back arrestor on each regulator.
4. Use non return valve on the tubes.
5. Open the cylinder valve slowly to avoid damage to the regulator.
6. The pressure of the acetylene gas should not exceed 9 psi.
7. Always use lighter to light the torch.
8. Always extinguish the flame before changing the gas cylinder.
9. Always purge the regulator after welding and then close it.
10. Use proper welding/ cutting nozzle.
11. Keep hoses properly so that nobody falls.

Don'ts :

1. Do not allow dust on the nozzle of the gas torch.

2. Do not use regulator/ rubber pipe/cylinders where leakage is detected. Replace
bad fitting immediately.
3. Do not use grease or oil on the joints of the gas tube.
4. Do not use copper fittings for acetylene gas.
5. Do not remove the keys of the cylinder valve.
6. Do not leave the gas supply open even during small breaks in work.
7. Do not use match stick, hot metal or welding arc for lighting the torch.
8. Do not stand near regulator while opening cylinder valve so that accident can be
avoided in case regulator explodes.

106
 SAFETY IN PAINTING
Do's :

1. Check leakage in pressure line & pressure vessels.

2. Use authorized PPE's such as safety aprons, safety shoes, nose mask, rubber
gloves while doing painting operation.
3. Keep spray gun at sufficient distance while doing painting work.
4. Fill paint in pressure vessels after filtering only.
5. Avoid spread of splashing of paint at work place. If paint falls somewhere then
clean it immediately.
6. Ensure cleaning of exhaust ducting line of painting booth at fixed intervals.
7. Ensure earthing of electric baking furnace.
8. Store paint at work place according to the requirement only.
9. Remove empty boxes of paint from the work place as soon as work is over.
10. Follow radioactive safety while painting with right shining paint.
11. Wash hands, nails & face thoroughly after completion of work and before eating.

Don'ts :

1. Do not start painting work without switching on exhaust system.

2. Do not perform painting work without wearing authorized PPE's.
3. Do not horse play at work place.
4. Do not carry out spray painting work without proper air pressure.
5. Do not smoke at work place and put 'No Smoking' board.
6. Do not open door of baking furnace without switching off power.
7. Do not use untested pressure vessels in spray painting work.
8. Do not use pressure vessels without safety valve.

107
 SAFETY IN WOOD WORKING
Do's :

1. Before starting any machine (circular saw machine, bend saw machine) check for
availability of all guards on machine & also their positions.
2. Adjust circular saw & bend saw blade guard according to the job.
3. Wear authorized PPE's (Safety shoes, Safety goggles, Aprons) while working on
saw machine.
4. Put" No Smoking" board in wood working work place.
5. While working on circular saw machine, push end point of wood with the help of
push rod.
6. Always clean saw dust of machine or machine itself after shutting off the machine
only.
7. Maintain the level of housekeeping at work place.
8. Always deploy trained persons only on saw machine.
9. Always use sharp blade on saw machine.
10. While working exhaust system installed at work place should be on.

Don'ts :

1. Do not bring hand near blade of the running machine.

2. Do not wear loose clothes while working on saw machine.
3. Do not smoke at wood working work place.
4. Do not try to clean saw dust from running machine.
5. Do not use blunt blade on saw machine.
6. Do not switch off the exhaust system while working.
7. Never work in haste or in tension on saw machine.
8. Do not horse play.
9. Do not avoid the precautions/ instructions given by the manufacturer while
running machine.

108
 ELECTRICAL SAFETY

Electricity is a versatile energy but it has to be safely used. Failure to take precautions
against electrical hazards may result in injuries or property damage or both. Control of
electrical hazard is neither difficult nor very expensive but ignoring them may lead to
serious accidents.

Do's :

1. Always carry out the work in accordance with IE Rules 1956 and OFB Standing
Instructions on Electrical Safety.
2. Ensure that all the control switches are opened and locked in OFF position and
or fuses withdrawn before commencing work on any electrical equipment or
installation.
3. Only qualified persons should undertake electrical repair.
4. Treat all circuit as live unless ensured after testing to be dead.
5. Ensure that extension cord is free from cuts, damaged insulation, kinks or joints
etc.
6. Check that the pins of the sockets are not loose. Confirm colour coding used for
the wiring in making connection is correct.
7. Ensure easy access to put off the supply.
8. Use switches which clearly indicate ON or OFF and are of appropriate
amperage.
9. Frequently check the values of electrical parameters like voltage and amperage
and ensure that they are appropriate.
10. Get the equipments, circuit breakers etc checked periodically by competent
persons.
11. Use work permit in areas of inflammable atmosphere.
12. Identify electrical hazards and report them immediately.
13. In case of short circuit or fire, put off the main switch immediately.
14. Know first aid procedures.
15. In case of injury7, give the victim artificial respiration and call for a doctor.
16. In case of burn injury, hold the affected part of the body under water.
17. Always check all equipments before use.
18. Use only non-conductive material ladder. In case of aluminium ladder use with
bottom shoe & earth it.
19. While working on electrical line put signboards near the switches like "DANGER,
CAUTION and MEN ON LINE".
20. Machines/Portable equipments with exposed metal parts should be properly and
effectively grounded. Double earth is to be provided in three phase devices and
single earth in one phase devices.
21. IR & ER test to be conducted regularly and recorded.
22. Laying of cables should be done as per IS specifications.
23. Internal wiring should be fixed in such a way that the functional insulation does
not come into contact with external parts.

109
Don'ts :
1. Do not ignore the maintenance instructions of the manufacturer when carrying
out repairs on any equipment.
2. Do not have any unsafe temporary connections, naked joints/ wiring.
3. Do not work wet on electrical equipments.
4. Do not use trial and error methods with electrical circuits.
5. Fuses are saviors, don't tamper with them, Don't replace a blown fuse unless the
fault is detected and rectified.
6. Don't just operate any switch unless you know the consequences,
7. Do not overload an electrical point.
8. Do not use water for extinguishing electrical fire. Use dry sand, C02 or DCP
extinguisher.
9. Don't crowd things near electrical main switches.
10. In case of lightening, Don't stand besides or rest against tall structures.
11. Don't take shortcuts. Follow safe procedures.
12. Don't start work without authorized PPE's.
13. Avoid cable crossing pedestrian routes.
14. Rubber mats should not have curling edges and should be securely fixed.
15. Do not crowd around the victim. He needs fresh air.
16. Do not abuse electrical cords.
17. Do not ignore broken or missing switch covers.
18. Never use REWIRABLE fuses in place of HRC fuses.
19. Don't wear metal objects while working on live lines such as rings, key, watch,
chain or flammable articles like celluloid cap.
20. Telephone and electrical cables should not be laid down together.
21. Do not use inferior quality electrical items. Use only IS certified items.

110
 CHEMICAL SAFETY

Remember that chemicals in any form can be safely used if their physical, chemical
and hazardous properties are fully understood and the necessary precautions observed

Do's :

1. For production doing chemical reaction personnel should receive appropriate

warning or notices advising the explosion risk involved and must be carefully
controlled.
2. Ensure that the place where explosives are handled stored and explosives
vapors exist must be free from ignitions sources.
3. Immediately inform the fire brigade in case of fire.
4. Know the use of different types of fire extinguishers. For Chemical fire use
CFo2, DCP or foam extinguishers.
5. Store inflammable materials in its assigned place
6. Have complete knowledge of toxic chemicals and its antidotes.
7. Being highly reactive, oxidizing chemicals should be kept separated
8. Protect skin and body parts while dealing with oxidizing agents.
9. In case of contamination with oxidizing agents wash the exposed area thoroghly
with running water / eye shower.
10. Ensure that each container is labeled with correct name of the chemicals
contained in it.
11. Know the significance of different properties of the chemicals contained in it.
12. Decontaminate the empty containers thoroughly after use.
13. Use authorized PPE's.
14. In chemical god owns, MSDS should be displayed for all chemicals.

Don'ts :

1. Don' t mishandle or mismanage explosives

2. Do not wear clothes soaked with oil and solvent.
3. Do not smoke in prohibited areas. Do not obstruct the path leading to fire
extinguisher or emergency doors wherever provided.
4. Don't use water on an electrical fire or oil fire.
5. Avoid spillage of inflammable liquids. Store 6n sand beds
6. Do not keep toxic chemicals in accessible areas.
7. Do not store oxidizing agents near reducing agents to avoid explosion and fire.
8. Do not throw cotton waste soaked with inflammable liquids /solvents/ chemicals
in drains or room corners.
9. Do not store inflammable materials near any electrical switch boards.
10. Do not handle the container if you are not sure about its content.
11. Do not taste or inhale any chemical.
12. Do not use chemicals which have no labels.
13. Do not eat without washing hands and face.

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 SAFETY IN ELECTROPLATING

1. GENERAL POINTS:

Do's :
1.1 Use authorized PPE's such as rubber gloves, rubber boots, appropriate
respirator, eye shield.
1.2 Before starting the work, check that fans & condensers are on.
1.3 Use rubber gloves and nose mask while handling cyanide solution.
1.4 Ensure periodical medical examination of employees engaged in
hazardous operations once in six months.
1.5 MSDS should be displayed prominently.

Don'ts :

1.1 Do not eat near work place.

1.2 Do not smell dry compounds.

2. Pre Cleaning:
Do's:

2.1 Remove oil, grease & loose dirt from surface to be plated.

3. Tank Clean out:

Do's :

3.1 Allow degreaser to cool to near room temperature before proceeding

further.
3.2 Drain solvent from tank in to proper-labelled and sealed container.
3.3 Open clean out doors and allow degreaser to air out. Ventilating air will
speed their process.
3.4 Wear a supplied air respirator if cleaning requires working inside
degreaser tank.
3.5 Have a second worker similarly equipped to be stationed outside the tank
to help in emergency.
3.6 Ensure that the second worker is able to communicate by voice or visual
signals with the worker inside the tank.

4. Degreasing:
Do's :

4.1 Ensure work is dry before removing it from tank.

4.2 To promote quick drying leave the parts in the vapour zone until solvent
condensation ceases.
4.3 Use covers when degreaser is not in use.

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 4.4 Don't overload degreaser.
4.5 Don't substitute one solvent for another unless specified.
4.6 Don't enter an operating degreaser to perform repair work.
4.7 Don't raise & lower parts in to the degreaser so rapidly that splashing
occurs.

5. Pre-Soak Tank recharging:

Do's :

5.1 Fill tank 2/3full with cold water.

5.2 Add chemical slowly to the tank.
5.3 Provide forced air to agitate for complete mixing.
5.4 Fill remaining tank with cold water & again provide air agitation for
complete mixing.

6. ELECTRO CLEANING:
Do's :

6.1 Ensure tight sealing and correct labelling of barrels storing unused alkali.
6.2 Store alkali drums in a dry area or off the floor on a platform.

Don'ts :

6.1 Don't mix soda powder, flakes or pellets with any acid solution.
6.2 Don't breath dry chemicals when recharging alkaline bath.
6.3 Don't store alkali next to acid.
6.4 Don't allow Excessive amount of foam on the surface of the solutions in
the tanks.

7. Pickling & Plating :

Do's :

7.1 Always add acid to water,

7.2 Stir solution while adding acid.
7.3 Properly dip the components in the tank solution.
7.4 Ensure that no acid/ alkali drop outside from components.
7.5 Ensure that the various types of effluents are properly canalized and
treated/ neutralized and under no circumstances pollute water and soil.
7.6 Use cyanide carefully and there should be knowledge about its antidote

Don'ts :
7.1 Do not allow untrained persons to work in plating shop.
7.2 Don't store carboys near the alkali powder & cyanide salt; do not handle
cyanide with bare hand.
7.3 Avoid skin contact especially in case of copper and cyanide plating.
7.4 Do not try to smell dry salts.

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 GENERAL SAFETY IN CLOTHING

General Points:

Do's :

1. Keep/ fix fire extinguishers/ equipments at right places as per requirement and
ensure their upkeep.
2. House keeping and upkeep should be of high level in section and factory, so that at
the time of the fire slips & falls can be avoided.
3. Earmark separate place for smoking in the factory. Display No Smoking board in
non smoking zone and it should be observed strictly.
4. All sections should have proper lighting & ventilation.
5. While working, use authorised PPE's such as safety goggles, nose masks,
respirators, aprons, Ear muffs, barrier cream (To avoid powder sticking with
mattresses in Ordnance-equipment factory).
6. Portable electrical tools should be earthed properly.
7. Use Caviler gloves only for using bend knife cutter.
8. Ensure that cotton dust does not affect environment and health of workman.
9. Economically comfortable chairs should be provided to tailors.

Don'ts :

1. Do not store flammable materials in excess of requirement in clothing sections.

2. Clothes should not be stored near electrical switch panels and fire extinguishers.
3. Do not work by wearing ear rings, loose clothes, tie or muffler.
4. Cotton dust should not exceed 0.2 mg / cubic meter.
5. Do not run machine without needle guard.

SAFETY IN GARMENT SHOP

Do's :

1. Keep hand finger at safe distance from moving needle.

2. Put cloth pieces in bag only.

Don'ts :

1. Do not keep measuring scale, tape & pattern on machine.

2. Do not compromise for Safety.
3. Do not put belt on pulley of moving machine.
4. Do not put oil in moving machine or clean it.
5. Do not check job without stopping the machine. '

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 SAFETY IN CUTTING SHOP

Do's :

1. The operator of hand machine should check his machine properly and should
adjust height of lay according to safety guard.
2. Clean the machine with cloth so that there is no dust.
3. The operator of bend knife machine should clean his machine. Get the machine
repaired immediately in case of any fault.

Don'ts :

1. Check knife by running the machine after cleaning it and do not work without
sharpening the knife.

SAFETY IN SOCKS MANUFACTURE

Do's :

1. Clean the machine properly before starting the work and put oil in machine.
2. Stop the machine immediately in case of breaking of needle in machine or any
other fault.
3. Check socks properly after manufacture. Contact Mistry in case of any defect in
socks.
4. Put socks on linking machine carefully so that points do not hurt the fingers.
5. Carry/ move the material carefully to avoid fall.
6. While carrying manufactured material to packing & dispatch, fix it properly so that
material does not fall on the way.
7. Clean your work place and near by places.
8. Put manufactured & un-manufactured material to specified places.
9. Use time properly.
10. Follow security/ safety rules.
11. Be careful in each work every time.

Don'ts :
1. Do not operate the machine incase of any fault in it.
2. Do not over load the vehicle while bringing material from store or carrying further
to P&D. Also do not forget to fix rope.
3. Do not carry out any electrical work your self.
4. Do not make dirty your work place & its nearby places.
5. Do not spit here & there inside or out side the section after chewing Pan /Masala.
6. Do not keep manufactured or un-manufactured material without order.
7. Do not waste time while in work.
8. Do not work un-carefully.
9. While removing pressed socks from machine & pattern, be careful so that hands
do not burn.

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 SAFETY IN BLANKET MANUFACTURE

Do's :

1. Work attentively.
2. Do not allow any employee to come nearby when looms are moving.
3. Keep body parts at distance from shuttle way when looms are moving.
4. Do not tamper with electrical arrangements.
5. In case of fault in looms, set it repaired only by person authorized by Incharge.
6. Use PPE's where sound is very fatal.
7. Stand in centre of loom.
8. Exhaust provided in building should always be kept running.

Don'ts :

1. Do not tamper with moving looms.

2. Do not allow any body part to come in the way of moving loom, since there are
chances of accident incase shuttle flies.
3. Unauthorised person should not be allowed to repair electrical fault in motor or
fuse.
4. Do not stand or allow any other person to stand by the side of loom.
5. Smoking is prohibited at workplace.

SAFETY PRECAUTION TO BE OBSERVED FOR STOPPING THE SHUTTLE FLY :

1. Wear beam thread on beam with proper tension.

2. Loom operator should set the beam, so that there is equal tension in all threads.
3. Wire Hild setting should be such that shuttle can move without any obstruction in
the shed.
4. Ensure correct alignment of shuttle box at both ends.
5. Check the Patiya so that there is no obstruction on its surface.
6. Do not use damaged pickers, replace them immediately.

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 SAFETY IN DURRY MANUFACTURE

Do's :

1. Ensure good house keeping and always used authorised PPE's while working at
machine.
2. Keep the personal belongings/ tools etc. at proper place.
3. Always use spittoon for spiting.
4. Clean the machine regularly and use proper oil, coolant etc.
5. Only trained person should be allowed to work on this machine.
6. Always concentrate on the work & start work timely.
7. Follow correct procedure to ensure quality of products being produced.
8. Observe safety precautions regularly.
9. Keep the stretcher and first aid box at an easily accessible place and in good
condition.

Don'ts:

1. Do not talk when working on a machine.

2. Do not over look or by pass safety precautions/ rules.
3. Do not disorder the material at workplace.
4. Do not waste time.
5. Do not spill slippery chemical/ liquid on the floor.
6. Do not spit on the shop floor.
7. Do not operate the loom without safety guard.
8. Do not obstruct the path of fire extinguishers & only trained persons should use it
when ever needed.

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