Industrial Safety Engineering – Lecture Notes

(For Academic purposes only and not for redistribution)

Contents
1.0 Introduction to safety…………………. ……….…….……………………….2
Terms Used…………..……………….……… …………….………………...……4
Unsafe Acts, Reasons for Accidents……..…………………….…………..……....6
Falls – At ground level: Slip, Trip; From a height…………..….………..…………7
Ladders and Scaffolding………………………………….…….……….…………9
Material Safety Data Sheet (MSDS), Safety Data Sheet (SDS)…….…..…………10
Lockout and Tagout Procedures………………………….….….……....…………11
Safe Material Handling and Storage.…………..……………//….……..…………12
2.0 Fire Safety…..…………………………………………………………...…….18
Introduction …………………………………………..…………….………... …..18
Fire triangle and Fire Tetrahedron..….…………………..………….……………..19
Class A, B, C, D and F fire……..…..………………………………….…..............19
Fire extinguishers ……………………..….……………………………….………20
Fire hazard and analysis and Prevention of fire ..…..……………….………... ….21
Fire protection and loss prevention, steps after occurrence of fire………………..23
Portable fire extinguishers ……………………….…..……………….…..............24
Fire detection, fire alarm and firefighting systems ……………………….………26
Safety sign boards, instruction on portable fire extinguishers…….……….………30
3.0 Mechanical Safety..……………………………..…………………….……….34
Personal Protective Equipment (PPE) …………………………………………….34
Safety Guards………………… …….….………………………………..………...35
Safety while working with machine tools ……..………… ……………………….38
Safety during Welding, Forging and Pressing.………………… ………..………...42
Safety while Handling Material, Compressed Gas Cylinders, Corrosive Substance,...
Portable Mechanical Tools………………………………..……………………….44
4.0 Electrical Safety.…………………………..……………..……………….......47
Introduction to Electrical Safety……..…………………………………………….47
Electric Hazards……………………………………………………………............47
Prevention of electric accidents, PPE used……..…………………………………48
AC and DC current shocks………………..……………………………………….51
Safety precautions against shocks…………………………………………............54
Portable electrical tools……………………..……..………………………………54
Domestic and Industrial Electrical Safety Procedures…..…………………………55
5.0 Chemical Safety…………..………………………………………….………..57
Introduction to Chemical Safety…………… …………………………………...…57
Labelling of Chemicals, Acid Hoods……………………………………..…….…..58
Handling of Acids, Eye Washers and Showers ……………………………….…....59
Hazardous Waste Disposal………………… ………………………………………63
Check List for LPG Installations…………………..……………………..…….…..67
Safety precautions using CNG…………………..…………………………….…....72
Fire prevention safety audit…………………………………………………………74

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 Introduction to Safety
Introduction to Safety

1. Terms used: Accident, Safety, Hazard, Safety Devices, Safety Guard, Security, Precaution,
Caution, Appliances, OSHA, WHO
2. Unsafe Acts, Reasons for Accidents
3. Falls – At ground level: Slip, Trip; From a height
4. Ladders and Scaffolding
5. Material Safety Data Sheet (MSDS), Safety Data Sheet (SDS)
6. Lockout and Tagout Procedures
7. Safe Material Handling and Storage

Bhopal Gas Tragedy

1. The Bhopal gas tragedy, was a chemical accident on the night of 2–3 December 1984 at the
Union Carbide of India Limited (UCIL) Pesticide plant in Bhopal, Madhya Pradesh, India.
The industrial disaster is considered the world’s worst in history.
2. The owner of the factory, UCIL, was majority owned by the Union Carbide Corporation
(UCC), with Indian Government-controlled banks and the Indian public holding a 49.1
percent stake.
3. The UCIL factory was built in 1969 to produce the pesticide Sevin (UCC's brand name
for carbaryl) using methyl isocyanate (MIC) as an intermediate. An MIC production plant was
added to the UCIL site in 1979. The chemical process employed in the Bhopal plant
had methylamine reacting with phosgene to form MIC, which was then reacted with 1-
naphthol to form the final product, carbaryl.
4. In the early 1980s, the demand for pesticides had fallen, but production continued regardless,
leading to an accumulation of stores of unused MIC at the Bhopal site.

Accident as it happened

1. During the late evening hours of 2 December 1984, water was believed to have entered Tank
E610 via a side pipe during attempts to unclog it. The tank still contained the 42 tons of MIC
that had been there since late October.
2. The introduction of water into the tank resulted in a runaway exothermic reaction, which was
accelerated by contaminants, high ambient temperatures and various other factors, such as the
presence of iron from corroding non-stainless steel pipelines.
3. The pressure in tank E610, although initially nominal at 2 psi at 10:30 p.m., it had reached 10
psi by 11 p.m.
4. By 12:40 a.m., the reaction in tank E610 reached a critical state at an alarming speed.
Temperatures in the tank were off the scale, maxed out beyond 25 °C (77 °F), and the pressure
in the tank was indicated at 40 psi (275.8 kPa).
5. One employee witnessed a concrete slab above tank E610 crack as the emergency relief valve
burst open.
6. Pressure in the tank continued to increase to 55 psi (379.2 kPa); this despite the fact that
atmospheric venting of toxic MIC gas had already begun.

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Non functioning of Safety Devices

Direct atmospheric venting should have been prevented or at least partially mitigated by at least
four safety devices which were malfunctioning, not in use, insufficiently sized or otherwise
rendered inoperable:

1. A refrigeration system meant to cool tanks containing liquid MIC, shut down in January 1982,
and whose freon had been removed in June 1984. Since the MIC storage system assumed
refrigeration, its high temperature alarm, set to sound at 11 °C (52 °F) had long since been
disconnected, and tank storage temperatures ranged between 15 °C (59 °F) and 40 °C (104 °F)
2. A flare tower, to burn the MIC gas as it escaped, which had had a connecting pipe removed for
maintenance, and was improperly sized to neutralise a leak of the size produced by tank E610
3. A vent gas scrubber, which had been deactivated at the time and was in 'standby' mode, and
similarly had insufficient caustic soda and power to safely stop a leak of the magnitude
produced
4. A water curtain which could have neutralized the MIC was designed to reach a height of 12 to
15 metres, but the MIC vapour was gushing out at a height of 33 metres above the ground

Accident and Aftermath

1. About 30 tonnes of MIC escaped from the tank into the atmosphere in 45 to 60 minutes. This
would increase to 40 tonnes within two hours.
2. Apart from MIC, based on laboratory simulation conditions, the gas cloud most likely also
contained chloroform, dichloromethane, hydrogen chloride, methylamine, dimethylamine,
trimethylamine, and carbon dioxide , that was either present in the tank or was produced in the
storage tank when MIC, chloroform and water reacted.
3. The gas cloud, composed mainly of materials denser than air, stayed close to the ground and
spread in a southeasterly direction over Bhopal affecting the nearby communities.
4. Over 500,000 people were exposed to Methyl Isocyanate (MIC) gas. The highly toxic
substance made its way into and around the small towns located near the plant. Estimates vary
on the death toll.
 The official immediate death toll was 2,259.
 A government affidavit in 2006 stated that the leak caused 558,125 injuries, including
38,478 temporary partial injuries and approximately 3,900 severely and permanently
disabling injuries.
 Others estimate that 8,000 died within two weeks, and another 8,000 or more have since
died from gas-related diseases.
 2000 bloated animal carcasses had to be disposed.
5. In 1989, UCC paid $470 million (equivalent to $871 million in 2020) to settle litigation
stemming from the disaster.
6. In 1994, UCC sold its stake in UCIL to Eveready Industries India Limited (EIIL), which
subsequently merged with McLeod Russel (India) Ltd.
7. Eveready ended clean-up on the site in 1998, when it terminated its 99-year lease and turned
over control of the site to the state government of Madhya Pradesh.
8. Dow Chemical Company purchased UCC in 2001, seventeen years after the disaster.

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9. On the matter of cleaning up the ongoing contamination in Bhopal, Dow says it is the
responsibility of the Madhya Pradesh government.
10. Dow has ignored six separate summonses to appear in the court’s proceedings in the disaster
claiming that Indian criminal courts have no jurisdiction over it.

Terms Used

Hazard

A condition or physical situation with a potential for an undesirable consequence, such as harm to
life or limb.

A potential condition or set of conditions, either internal and /or external to a system, product,
facility or operation, which, when activated by a stimulus, transforms the hazard into a real
condition, or series of events which culminate in a loss (an accident).

Types of Hazards
1. Safety hazards
2. Biological hazards
3. Physical hazards
4. Ergonomic hazards
5. Chemical hazards
6. Workload hazards

Accident

Accident is that occurrence in a sequence of events that produces unintended injury, death, or
property damage. Accident refers to the event, not the result of the event (see unintentional injury).
An accident is usually a dynamic event (fire, explosion, high energy release, destruction or
separation of parts of the system and so on) since it results from the activation of a hazard and
culminates in a flow of sequential and concurrent events until the system is out of control and a
loss is incurred.

It is an undesired event that results in harm to people and/or damage to property, process or the
environment.

It is also expressed as an unplanned, unwanted, and unexpected event, which because of an unsafe
act or unsafe condition, results in property damage, injury, or death

Safety

A quality system that allows the function under predetermined conditions with an acceptable
minimum accidental loss.
OR
The condition of being free from undergoing or causing hurt, injury or loss.
OR

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Relative protection from adverse consequences.
OR
To put it in a simpler way total safety is freedom from potential harm

Appliance

A device or piece of equipment designed to perform a specific task.

Household appliances: air conditioners, dishwashers, clothes dryers, drying cabinets, freezers,
refrigerators, kitchen stoves, water heaters, washing machines, trash compactors, microwave
ovens, and induction cookers.
Industrial appliances: Material handling equipment – Cranes, Forklifts, Conveyors; Industrial
equipment – Motors, Pumps, Gearboxes, Furnaces, Mills.

Safety appliances: Safety Guards, Safety Devices

Safety Guard

• A guard is a protective device designed to protect workers from harm

• Protective measures consisting of the use of specific technical means, called safeguards
(guards, protective-devices), to protect workers from hazards that cannot be reasonably
removed or sufficiently limited by design
• A guard is a part of machinery specifically used to provide protection by means of a physical
barrier. Other names may be casing, door, or enclosing guard. There are also protective
devices that may be used. The CSA standard Z432 defines six different types of guards:
Adjustable guard
Fixed distance guard
Fixed guard
Interlocked guard
Movable guard
Self-closing guard

Safety Devices

A safety device is a piece of equipment that reduces loss or damage from an accident
Some safety devices are:
1. Height Safety Equipment
2. Safety harnesses, lanyards, and other products to prevent / arrest falls
3. PPE (Personal Protective Equipment)
4. Confined Space Equipment
5. Safety Barriers
6. Permanent Safety Lines
7. Edge Protection Barriers

Caution and Precaution

Care taken to avoid danger or mistakes.

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A measure taken in advance to prevent something dangerous, unpleasant, or inconvenient from
happening.

Security

The state of being free from danger or threat.

Security is protection from, or resilience against, potential harm caused by others, by restraining
the freedom of others to act.

Industrial security describes the protection of production and industrial plants from faults,
whether intentional or unintentional.

The portion of internal security that refers to the protection of industrial installations, resources,
utilities, materials, and classified information essential to protect from loss or damage

OSHA

OSHA – The Occupational Health and Safety Administration

Congress established the agency under the Occupational Safety and Health Act OSH Act, which
President Richard M. Nixon signed into law on December 29, 1970

OSHA's mission is to "assure safe and healthy working conditions for working men and women
by setting and enforcing standards and by providing training, outreach, education and assistance".
The agency is also charged with enforcing a variety of whistleblower statutes and regulations.

OSHA's workplace safety inspections have been shown to reduce injury rates and injury costs
without adverse effects to employment, sales, credit ratings or firm survival.

WHO

The World Health Organization (WHO) is a specialized agency of the United Nations responsible
for international public health. The WHO Constitution states its main objective as "the attainment
by all peoples of the highest possible level of health". Headquartered in Geneva, Switzerland, it
has six regional offices and 150 field offices worldwide.

The WHO was established on 7 April 1948.

The WHO's mandate seeks and includes: working worldwide to promote health, keeping the world
safe, and serve the vulnerable.

Unsafe Acts, Reasons for Accidents

Unsafe Physical/Mechanical/Environmental Condition

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The unsafe condition is a hazardous physical condition or circumstance which could directly
permit the occurrence of an accident

These consist of factors present due to defects in condition, errors in design, faulty planning or
omission of essential safety requirements for maintaining a relatively hazard-free environment.

1. Inadequate mechanical guarding.

2. Defective (i.e. rough, sharp, slippery, decayed, frayed, inferior composition, cracked, leaked)
equipment such as ladders, floors, stairs, vessels, piping, etc.
3. Unsafe design or construction.
4. Hazardous process, operation or arrangement (i.e., unsafe piling, stacking, storage, congested
aisle space, crowding, overloading, violation of desired norms of good housekeeping, etc.)
5. Inadequate or incorrect illumination.
6. Inadequate or incorrect ventilation.
7. Unsafe dress or apparel and PPE (loose clothing, absence of or defective gloves, aprons, shoes,
respirators as required)

Unsafe Personal Acts or Practices

The unsafe act is a violation of an accepted safe procedure which could permit the
occurrence of an accident

The following are the types of human behaviour which lead to injuries and/or accidents. No
attempt has been made to probe the reasons why people behave so. The most common patterns
have been listed below.

1. Working unsafely (i.e., improper lifting, hazardous placement, incorrect mixing of materials,
performing maintenance or repairs on moving machinery, working under suspended loads,
failure to take heed of warning, and any act violating accepted safe practice/procedure).
2. Performing operations without supervisor’s permission, authority or training.
3. Removing safety devices or altering their operation thus making them ineffective.
4. Operating at unsafe speeds.
5. Use of unsafe or improper tools/equipment (i.e., using a chisel with a mushroomed head,
removing chips from cutting m/c by hand and not by brush, etc.).
6. Using tools, equipment, safety gadgets and devices unsafely.
7. Horseplay, teasing, abusing and so forth.
8. Working under the influence of alcohol.
9. Failure to use safe attire or personal protective devices/equipment

Falls – At ground level: Slip, Trip; From a height

Falls and/or Slips on the Same Level: Slipping and tripping

1. Maintenance of adequate and proper norms of good housekeeping is essential in preventing

falls and slips on the same level.

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2. Hazards include obstructions on the floor in the workplace or roads and outside ground. So
also in the aisle, blind corners and intersections.
3. Regular cleaning and the clearing off of loose materials, grease, oil, dirt, sand particles,
chemical and/or water accumulation or other contaminants is a must.
4. Work floors, passageways, aisles and areas around the workplace should be made and
maintained with non-skid material.
5. Use of slip-resistant footwear should be encouraged and enforced.
6. Wet and/or oily floors are hazardous. Oil on the floor, when noticed, should be reported and
wiped off after spreading sawdust.
7. Round-the-clock repair of floor cracks, floor joints, ditches, crumbling edges and other
operating surfaces should add to the smooth manual handling of material and prevent falls on
the same level.
8. The laid down procedure for manual handling should be strictly observed. Under no
circumstances is a material, which is heavier than specified or large in volume or size, which
requires help of others ever be carried by a single individual. This may imbalance him and
cause a fall.
9. Ensure that workplace and surrounding area safety inspections are conducted at specified
intervals by a competent person who can identify slipping and tripping hazards and conditions
that are dangerous.
10. Identify and recognise factors that contribute to slips and falls in a section from information
about housekeeping policies and practices, management style and behaviour and employees
accountability for housekeeping and in effect safety.

Falls from Tall Structures

1. Designers of buildings, such as multi-tiered steel-framed structures should provide anchorage

systems in the overall design of the structure.
2. Designers of tanks should incorporate anchorage points for securing scaffolds, lifelines and toe
boards.
3. Permanent structural members are to be provided across the length and at the apex of the roof
of large industrial activity sheds for anchorage of lifeline.
4. A competent person should evaluate potential tie-off anchorage points and determine if the
available safety equipment (e.g., crawling board or safety belt) can work as designed. If not,
to find what equipment suits the design.
5. A competent person should routinely inspect all protective devices (e.g., guard-rails, lifelines
etc.).
6. Plant/facility owners/operators should identify areas that are hazardous to all and restrict or
prohibit the use of, or access to, these areas
7. The following must be provided with guards and/or fall protection.
1. Roof openings,
2. Floor openings,
3. Skylights,
4. Fragile roof (e.g., A.C. sheet)

Fall Protection Program

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1. Addressing all the aspects of safety and hazards in the planning phase of projects.
2. Identifying all fall hazards at the work-site.
3. Training employees in the recognition and avoidance of unsafe conditions and the regulations
to control or eliminate the hazards applicable to their work environment. Fall-protection
training is recommended to include classroom instruction supplemented by hands-on training
with equipment.
4. A job hazard analysis for each task to be performed.
5. Providing appropriate fall-protection equipment, training workers on its proper use, enforcing
its use under strict supervision and conducting a daily inspection.
6. Conducting scheduled and unscheduled safety inspections of the worksite.
7. Addressing: (a) environmental conditions, (b) multi-lingual differences and (c) alternative
methods/equipment to perform assigned tasks.
8. Establishment of medical and rescue programmes.
9. Encouraging workers to actively participate in workplace safety

Ladders and Scaffolding

Fixed Ladders

A piece of equipment consisting of a series of bars or steps between two upright lengths of wood,
metal, or rope, used for climbing up or down something

1. Should be used at a pitch no greater than 90° from the horizontal, as measured to the rear of
the ladder.
2. Each step or rung should be capable of supporting a single concentrated load of at least 250 lb.
(114 kg) applied in the middle of the step or rung.
3. The rungs or steps of fixed metal ladders should be corrugated, knurled, dimpled, coated with
skid-resistant material.
4. Cages, wells, ladder-safety devices or self-retracting lifelines should be provided to fixed
ladders, where the length of climb the equals or exceeds 24 ft. (8 m)

Climbing Guidelines

1. Wear slip-resistant footwear.

2. Keep the area around the top and bottom of the ladder clear.
3. Wear approved fall-protection equipment where applicable.
4. Never carry large objects while ascending or descending a ladder. Use a hoist or pulley
mechanism to move heavy, large/awkward objects up to the working level or down to the
ground.
5. Keep both hands free for climbing or coming down.
6. Face the ladder and maintain three-point contact (two hands and one foot or one hand two feet
on the ladder) at all times.
7. Do not load ladders beyond the maximum intended load for which they were built, nor beyond
the manufacturer’s rated capacity. Use ladders only for the purpose for which they were
designed

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Industrial Scaffolds

Scaffolds

A scaffold is a temporary raised platform on which workers stand to paint, repair, or build
high parts of a building, structure, chimney etc.

1. The footing or anchorage for scaffolds should be sound, rigid and capable of carrying the
maximum intended load without settling or displacement. Unstable objects, such as barrels,
boxes, loose bricks or concrete blocks, should not be used to support scaffolds or planks.
2. No scaffold should be erected, moved, dismantled or altered except under the supervision of a
competent person.
3. Guard-rails (2 by 4 inches, 42 inches high) and toe-boards (minimum 4 inches in height) should
be installed on all open sides and ends of platforms more than 10 feet above the ground or floor
except on needle-beam scaffolds and floats. Supports should be at intervals not exceeding 8
feet.
4. Scaffolds and their components should be capable of supporting, without failure, at least four
times the maximum intended load.
5. Damaged or weakened accessories such as braces, brackets, trusses, screw legs, ladders etc.
should be immediately repaired or replaced.
6. All scaffold platforms should be tightly planked with scaffold plank grade.
7. A competent person should initially inspect the scaffolding and, at designated intervals, re-
inspect the scaffolding inclusive of components and accessories.
8. Suspension-scaffold rigging should be inspected periodically and the synthetic rope used
should be protected from heat-producing sources.
9. Employees should be trained in using diagonal braces for climbing scaffolds.

Material Safety Data Sheet (MSDS), Safety Data Sheet (SDS)

Material Safety Data Sheet (MSDS)

A material safety data sheet (or MSDS) is a document that provides workers with procedures
for safely handling or working with a particular substance

1. Product Information: Manufacturer's name and contact information, product name, addresses
and emergency phone numbers
2. Hazardous ingredients/identification information
3. Physical data: Melting, boiling and flash points
4. Fire or explosion hazard data
5. Reactivity data: Chemical instability of a product and the substances it may react with
6. Toxicological properties/health effects
7. Preventive measures/precautions for safe handling and use: Storage, protective gear, handling
spills, disposal of the product and associated packaging
8. First aid measures/control measures: Emergency procedures in case of accident and
recognizing symptoms of overexposure
9. Preparation information: Preparation date and person responsible

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Safety Data Sheet (SDS)

The Globally Harmonised System of Classification and labelling of Chemicals contains a

standard specification for Safety Data Sheets. It is a document that lists information relating
to OCCUPATIONAL SAFETY AND HEALTH for the use of various substances and products.

SECTION 1: Identification of the substance/mixture and of the company/undertaking

SECTION 2: Hazards identification
SECTION 3: Composition/information on ingredients
SECTION 4: First aid measures
SECTION 5: Firefighting measures
SECTION 6: Accidental release measure
SECTION 7: Handling and storage
SECTION 8: Exposure controls/personal protection
SECTION 9: Physical and chemical properties
SECTION 10: Stability and reactivity
SECTION 11: Toxicological information
SECTION 12: Ecological information
SECTION 13: Disposal considerations
SECTION 14: Transport information
SECTION 15: Regulatory information
SECTION 16: Other information

Lockout and Tagout Procedures

Lock Out and Tag Out (LOTO)

Lockout: Isolation of a source of hazardous energy, including releasing any residual hazardous
energy that might be present, and securing an isolation point by locking it
The energy-isolating device can be a manually operated disconnect switch, a circuit breaker, a line
valve, or a block

Note: Push buttons, selection switches and other circuit control switches are not considered
energy-isolating devices
The locking device (or lockout device) can be any device that has the ability to secure the energy-
isolating device in a safe position.

Tag out: Placement of danger tag

It is a labelling process that is always used when lockout is required. The process of tagging out a
system involves attaching or using an indicator (usually a standardized label)
Lockout/Tag-out Programmes

Lockout/tag-out programmes should be based on the principle of only one for each lock-the worker
controls.
(Master keys should be reserved and preserved only under managerial control, for emergency or
on misplacement of one under regular use.)

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1. Workers are assigned individual locks operable by only one key for use in securing energy
control devices—breaker panels, control valves, manual override switches etc.
2. Each worker maintains custody of the key for each of his assigned locks.
3. Each lock is labelled with a durable tag, or other means, identifying its owner.
4. When more than one worker is working, each worker issues and deposits the key from and
with the supervisor, who maintains a register ensuring that the worker signs both times and
remains responsible.
5. Verify that all energy sources are de-energised before work begins
6. All de-energised circuits and systems are clearly labelled with durable tags.
7. The worker who opens a lock is the one who locks it after all work has been completed. If the
work is not complete when the shift changes, he signs in the register depositing the key and
the next shift worker signs issue of the key for continuation of the work.
8. Because tags can be easily removed, they are not a substitute for locks. Workers are safest with
a programme that uses both locks and warning tags to prevent systems from being
inadvertently re-energised.

Safe Material Handling and Storage

Material Handling Equipment

1. Hand tools (crow-bar, hook, mallet etc.)

2. Skids, rollers, or other devices for dragging or sliding.
3. Wheelbarrows, hand trucks, and special carrying devices
4. Lift trucks
5. Power trucks and tractors
6. Hoisting apparatus
7. Overhead travelling cranes (E.O.T.)
8. Conveyors
9. Mechanical shovels
10. Elevators and escalators
11. Chutes (gravity or under pressure)
12. Pipelines/pumps for liquids

Manual Material Handling

1. Correct positioning of feet: When lifting a load, space legs apart, with one foot by the side of
the load and in front of the other foot in the direction of movement.
2. Bent knee: For a strong and steady position bend knees and not the back to reach for the load,
as bending the back creates the risk of loss of balance and straining the spine.
3. Straight back: The back needs to be kept straight (not necessarily vertical). It may be inclined
from the hip, as the lifting posture requires.
4. Arms close to the body: The farther the load is to the body, the greater is the strain.
5. Correct grip: The load should be properly grasped using the roots of the fingers and palm
6. Raise head slightly before lifting.
7. Use of body weight: Position the body such that its weight counterbalances the load to be lifted

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EOT Cranes

1. The crane should be centred over the load such that the hoisting ropes are vertical. It should
not be used for angular lifting or pulling a load.
2. The crane should not be overloaded beyond the rated safe working load capacity which should
be prominently marked on the machine.
3. Install limit switches for all three motions, i.e., up–down, longitudinal and transverse or cross
travel should be provided such that power cuts off if movement goes beyond a specified limit.
(A Jib crane may have only an upper and lower limit switch.)
4. Controls should be operated smoothly to avoid abrupt, jerky movements.
5. The hook block should never be lowered below the point where: (a) Less than two full wraps
of rope remain on the hoisting drum; or (b) It is about to touch the floor. The lower limit should
be adjusted accordingly.
6. Brakes should be checked when a near-capacity load is being lifted by actually lifting the load
a few inches and switching off the controls. If the brakes do not apply and the load comes
down, they should be repaired/set/adjusted first before lifting the load again.
7. Personnel in the immediate area should be cleared off when load is being lifted and moved.
8. Before shifting a load it should be lifted high enough to clear all obstructions on the floor.
9. A suspended load should never be left unattended.
10. Limit switches should not be used to stop the hoist under normal operating conditions. These
are emergency devices and are not to be used as operating controls.
11. The upper limit switch should not be bypassed, adjusted or disconnected in order to go higher
than the switch will allow.
12. The upper limit switch should be tested by actuating it at the beginning of the shift. If it is out
of order, the crane must not be used till the limit switch is repaired.
13. The crane should be electrically isolated and the main switch should be locked or tagged and
fuses removed before inspection, repairing, cleaning/lubricating etc. where an accidental start
of the crane may result in a severe accident (refer to ‘Electrical Isolation and Tagging’).
14. When an E.O.T. crane or Goliath crane operates on one linear gantry or rail, safety devices
should be provided which sounds a warning or cuts off the electric supply to crane movement
so that collision between two cranes can be avoided

Forklifts

1. Only trained operators should operate a forklift truck.

2. Before starting the truck at the start of the shift the following equipment must be checked. (a)
Tyres—for cuts, excessive wear, metal embedded in tread and pneumatic pressure. (b)
Brakes—for effectiveness. (c) Leakage (if any) of fuel, hydraulic fluid or engine oil. (d) Horn
and battery connections.
3. Quick and jerky starts, halts, load raising/lowering should be avoided.
4. The front view should be kept reasonably clear. In case a bulky load blocks the front view
completely, the truck should be operated in reverse and the operator should carefully look out
for people and other objects.
5. While travelling, raising or lowering the load should be avoided.
6. While travelling with a load the mast should be tilted backwards and the fork should be kept
low (preferably 6 inches above the ground).

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7. Overloading must not be attempted. The operator should be aware of the safe working load
(SWL) and also the load centre of the truck.
8. While driving the forklift truck on ramps and inclines, the load must face uphill and the path
should be straight.
9. Shut off the ignition while re-fuelling the truck.
10. Traffic rules should be followed by the forklift operator.
11. Forks should be adjusted to match the width of the load or pallet.
12. The mast should be partially tilted backward while raising or lowering the load.
13. Extra care should be taken to maintain the stability of the stack while stacking or de-stacking

Wire Rope Slings

1. Broken wires are a sign indicating the deteriorating condition of a wire rope. Replace it if 10
broken wires are seen on a length of 8 dia. It is very serious if all the broken wires are from the
same strand (rare).
2. Reduction in wire-rope diameter can be due to: (a) excessive localised abrasion, (b) breaking
of core support, (c) corrosion—internal or external, or (d) failure of inner wires. If the reduction
in diameter is about 6% or more, the rope should be discarded.
3. Corrosion: Difficult to detect as it develops inside. As far as possible, wire rope should not be
used in a corrosive environment.
4. Stretch: Some stretch always exists initially due to tightening of wires and strands. If
elongation is more than 5% of the original length (after a proof test) the wire rope should be
replaced.
5. Worn-out wires: Due to friction with sheave drums etc., the outer wire wears out and looks
flatter instead of circular. If wear is excessive and uniform, the wire rope should not be used.
Besides the above, the wire rope should also be checked for flattened strand, bird caging or
bulging, kink, spark damage, protrusions of core, inlaying of strands, inadequate or damaged
splicing, crushes etc.
Chain Slings

1. Stretch and Deformation: If one or a few links are elongated dangerously or twisted badly the
chain should be discarded. If stretch is more than 6% of the original length, the chain sling
should be discarded.
2. Wear: Occurs on the surface subjected to rubbing with another surface. Found at the bearing
surface or inter-link contact and outside barrel. Usually up to 6% wear is allowed in case of
Mild Steel and 8% in case of high tensile steel and alloy steels.
3. Nicks and Grazes: The outer surface of a link (barrel) may get damaged due to foreign objects.
Most of them are found on the straight barrel. This causes stress concentration and should be
removed by filing/grinding/sandering. After this, if the diameter is still under the permissible
limit, the chain can be used or otherwise discarded.
4. Twisting: Severe twisting of one or a few link/s is unacceptable and the slings need to be
discarded. Slight twisting may not require discarding. An overall twist of half a round for the
length of 4 metres is tolerable.
5. Cracks: A crack has a tendency to propagate, hence any chain with a cracked link is not
permissible to be used irrespective of the size of the crack.

14
6. Defects in Hook: If the hook gets opened up by more than 15% and twisted by more than 10%
from the original plane, the use of the same should be discontinued

Gas Cylinder Storage and Transportation

Gas Cylinders Storage

1. Cylinders should be stored in well ventilated spaces or room.

2. Gas cylinders kept in the open should be protected from the sun, rain or contact with corrosive
substances, oil and grease.
3. Areas where gas cylinders are stored should be declared non-smoking zone.
4. If gas cylinders are stored in a closed room, the electric switches should be located outside the
room and electric fittings should preferably be flameproof.
5. Oxygen and acetylene should be stored at least one metre apart from each other.
6. Acetylene cylinders must be stored upright since acetylene is stored in its dissolved form.
7. Never allow gas cylinders to come in contact with electrical apparatus or live wires.
8. Gas cylinders should be kept away from heat sources.
9. Cylinders, their valves, couplings, fittings, regulators, hoses etc., should be kept free from
contamination from oily or greasy substances. (No oil- or grease-based lubricant should be
applied on cylinder valves.)
10. Cylinders should not come in violent contact with each other or with any hard surface.
11. Cylinder should never be dropped.
12. It is illegal to tamper with numbers and markings stamped on cylinders.
13. Valves of empty cylinders should be kept closed and protected by caps.
14. Gas cylinders should never be used as rollers or support, whether full or empty.
15. For transporting cylinders, a suitable handcart should be used. The cart may be provided with
a chain or belt to secure the cylinders so that they cannot fall in case the handcart happens to
go over a bump.
16. If a cylinder has to be transported over a short distance, it can be rolled over its bottom edge
but should never be dragged.
17. A fibre rope sling may be used to lift one cylinder. A chain sling should not be used. If more
than one cylinder has to be lifted, a suitably designed cradle pallet should be used.
18. A lifting magnet or chain sling should never be used to lift a cylinder.
19. Full and empty cylinders should be marked and stacked separately. Empty cylinders can be
marked “Empty” or only “MT” with chalk.
20. While placing a cylinder upright, it should be properly secured to prevent it from falling.
21. The valve of a cylinder is the weakest part, utmost care should be taken at all times to prevent
it from being damaged.
22. When receiving a cylinder, it should be ensured that the valve protection cap is intact.

Corrosive Substances Storage

1. Only trained personnel, aware of the hazards of the corrosive substance, should be allowed to
handle/use it. (Untrained persons should not be deployed to handle/use the corrosive substance.
However, if it is extremely necessary to deploy them, they must be given specific safety
instructions by the supervisor concerned and they must work under strict personal supervision

15
 to ensure that they follow all the safety precautions.) “Today we’re going to talk about fall
protection”
2. Chemical splash goggles, face shields, PVC gloves, rubber/PVC gum boots and rubber/PVC
aprons must be used by everyone handling/using corrosive substance.
3. To dilute acid, it must be slowly added to water while stirring. Never add water to acid or
alkali.
4. In case of accidental contact with a corrosive substance, the affected area must be thoroughly
washed with water for 15–20 minutes.
5. In case of a corrosive substance accidentally splashing into the eyes, they should be thoroughly
washed with water. While washing, the eyes should be kept wide open. Washing should
continue for 15–20 minutes. Washing with plenty of water is very most important and must be
ensured before rushing the injured to medical help.
6. In case of a corrosive substance splashing on the floor, it should be washed with water.
7. Compressed air should not be used in loading, unloading and cleaning/splashing the corrosive
substance

Hydrocarbon Storage

Hydrocarbon Categories

 Flash Point is the temperature at which the liquid gives off sufficient vapour to form a
flammable mixture with air, which would ignite if a source of ignition were introduced.)
 Hydrocarbons (petroleum products) can be classified into three categories.
 Class-A - Flash Point < 23° Celsius
 Class-B - Flash Point >23° but < 65° Celsius
 Class-C - Flash Point >65° but < 95° Celsius
 Safety aspects with regard to storage/handling of hydrocarbons depends on the class of
hydrocarbon.
Class A Storage

1. More than 30 litres of Class-A hydrocarbon should not be stored on the shop floor.
2. Receptacles/carboys in which they are stored should have airtight lids and never be filled full.
About 10% of the container volume should be left unfilled.
3. Storage exceeding 300 litres in carboys, barrels or in bulk needs a permission/licence under
the Petroleum Rules.
4. The storage area should be a non-smoking zone, well ventilated, segregated and electric
switches, lights etc. in the area should be flameproof.
5. Wherever a Class-A hydrocarbon is used, handled or stored, care should be taken to ensure
that no possibility of ignition exists including static electricity.
6. DCP or CO2 fire extinguishers should be available in the area where the Class-A hydrocarbon
is stored/used/handled.
7. If stored in bulk in a tank, the tank should be segregated by fencing, earthed at two places,
should have a vent and should have an inlet pipe going right down to the bottom of the tank.
The vent outlet should be bent so that rain water does not enter the tank and it should be
provided with a muffler. The dip stick and its stopper should be made of non-sparking metal.
The bulk storage facility should be regularly monitored for safety.

16
8. Accumulation of combustible material, e.g., cotton waste, rags, wood etc. in the vicinity of
storage must not be allowed.

Class B and C Storage

1. Storage of more than 5000 litres of Class-B and 25,000 litres of Class-C petroleum requires a
licence under the Petroleum Rules.
2. The storage area should be a non-smoking zone and preferably segregated from the main work
area.
3. The minimum quantity (maximum up to one day consumption) may be stored on the shop floor
or main work area.
4. DCP, CO2 or foam fire extinguishers should be available in the area where the hydrocarbon is
stored/used/handled.
5. If stored in bulk in a tank (surface tank or underground tank), the following precautions must
be taken.
1. The tank should be earthed at least at two places (even underground).
2. The area around the tank should be segregated by fencing and accumulation of combustible
materials in the area must not be allowed.
3. A dyke wall around the tank to contain spillage (if any) is a must.
4. The tank must have a vent and level indicator (electronic indicator, gauge glass or dip
stick). It is advisable not to fill the tank up to its maximum but leave about 5% of its volume
unfilled.
5. The bulk storage facility should be regularly monitored for safety.
6. Barrels/carboys containing Class-B or C hydrocarbons should be stored in specified places
only and not in the general work area/shop floor.

Empty Container Disposal

1. The user should keep the empty containers at a specific place in his shop/department (where
any kind of source of ignition does not exist) and inform the Conservancy Department to
collect the containers.
2. The Conservancy Department shall arrange to collect the empty containers from the
shops/departments, wash and shift them to the specified place in the scrapyard. Before putting
the containers in the scrapyard, they need to be washed with water to ensure that no
hydrocarbon vapour remains in the container.
3. A specified space to keep empty hydrocarbon containers should be allocated, segregated from
rest of the scrap area. Personnel in charge of the scrapyard can ensure that combustible
material, e.g., wood, cotton waste, rags etc. do not accumulate in the vicinity and that
combustible scrap is kept away from the specified area. The area would be declared a non-
smoking zone.
4. While selling the empty containers, the buyer needs to ensure that none of these containers
contain hydrocarbon vapour and if necessary, he/she should wash the containers before
collecting them from the factory

17
 Fire Safety
Fire Safety

1. Introduction
2. Fire triangle and Fire Tetrahedron
3. Class A, B, C, D and F fire
4. Fire extinguishers
5. Fire hazard and analysis and Prevention of fire
6. Fire protection and loss prevention, steps after occurrence of fire
7. Portable fire extinguishers
8. Fire detection, fire alarm and firefighting systems
9. Safety sign boards, instruction on portable fire extinguishers

Introduction

Fire is a rapid burning and oxidation process accompanied by heat, light and poisonous gases / smoke / carbon
dioxide gas due to combustion.

Fire prevention is preventing occurrence of fires by prior actions / precautions and provisions.

Fire protection is the study and practice of mitigating the unwanted effects of potentially destructive fires.

Fire fighting is the action of putting off fire using in order:

 Portable fire extinguishers

 Fire hydrant, hose and nozzle
 Automatic fire extinguishers
 Fire brigade

Importance of industrial fire prevention and protection

Industrial fire prevention and protection ensures the safety of lives and property at the workplace.

1. Prevention of fire hazards

2. Safety of lives
3. Protection of Property
4. Maintain customer trust
5. Maintain employees
6. Protect environment

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Fire Triangle

 The fire triangle or combustion triangle is a simple model for understanding the necessary ingredients
for most fires.
 The triangle illustrates the three elements a fire needs to ignite: heat, fuel and an oxidizing agent (usually
Oxygen). A fire naturally occurs when the elements are present and combined in the right mixture.
 A fire can be prevented or extinguished by removing any one of the elements in the fire triangle. For
example, covering a fire with a fire blanket blocks oxygen and can extinguish a fire.
 In large fires where firefighters are called in, decreasing the amount of oxygen is not usually an option
because there is no effective way to make that happen in an extended area.

Fire Tetrahedron

 The fire tetrahedron represents the addition of a component in the chemical chain reaction, to the three
already present in the fire triangle.
 Once a fire has started, the resulting exothermic chain reaction sustains the fire and allows it to continue
until or unless at least one of the elements of the fire is blocked.
 Foam can be used to deny the fire the oxygen it needs.
 Water can be used to lower the temperature of the fuel below the ignition point or to remove
or disperse the fuel.
 Halon can be used to remove free radicals and create a barrier of inert gas in a direct attack
on the chemical reaction responsible for the fire.

Classes of Fire

According to European / US / Australian / Indian Standards Fires are classified into five / six classes
depending on the combustible material involved.

19
 European US Australian Indian Combustible Material
Standard Standard Standard Standard Involved
IS 15683-
2018
A A A A Solid materials such as
wood, paper or textiles
B B B B Flammable liquids such as
petrol, diesel or oils
C B C C Flammable gases e.g.
hydrogen, ammonia
D D D D Metals e.g. magnesium,
titanium
-- C E -- Live electrical apparatus /
equipment
F K F F Cooking oils such as in
deep-fat fryers

Fire Extinguishers

20
Fire Hazard

Any actions, materials, or conditions that might increase the size or severity of a fire or that might cause
a fire to start are called fire hazards. The hazard might be a fuel that is easy to ignite or a heat source like a
defective appliance.

Common industrial fire hazards include combustible dust, electrical, combustible materials, flammable
liquids, chemical, hot work, equipment, and machinery

Fire Hazard Analysis

A Fire Hazard Analysis (FHA) is a type of engineering analysis that is designed to evaluate the hazards present
and subsequent consequence potential risk of fire present in an environment in both qualitative (descriptive)
and quantitative (numeric) terms.

The FHA considers the severity of hazards in the area by evaluating the total risk of hazards in a given area.

An FHA can be

 hazard-based model is solely concerned with what could happen, regardless of probability.
 risk-based considers the likelihood of a given scenario occurring

Fire Hazard Analysis Steps

1. Selecting a target outcome

2. Determining the scenario(s) of concern that could result in that outcome
3. Selecting an appropriate method(s) for prediction of growth rate of fire effects
4. Calculating the time needed for occupants to move to a safe place
5. Analyzing the impact of exposure of occupants or property to the effects of the fire
6. Examining the uncertainty in the hazard analysis
7. Documentation of the fire hazard analysis process, including the basis for selection of models and input
data

Fire Risk Assessment

Step 1 Identify the fire hazards present at your premises or workplace.

Ignition sources include naked flames, heaters, or other commercial operations.

Sources of energy such as waste materials display materials, textiles, or other products that are
not in stock;
Oxygen sources like air conditioning systems commercial or medical oxygen supplies.

Step 2 Identify the people who’re at risk.

Any person who could be asleep at the premises or workplace.

Those present in large numbers.

21
People who are not familiar with the layout.
People who are exposed to a particular fire risk.
those who suffer from impaired hearing, sight, mobility, or other disabilities;
People who’re working near to fire dangers;
People who work on their own or lone workers, or in isolated or remote zones (e.g., storage
spaces or roofs);
Parents or children with infants;
The old or weak;
Any people who cannot react quickly;
external contractors agencies and the temporary employees.

Step 3 Evaluate & decide if the current fire safety measures are adequate or need any improvement.

Assess The Risk Of Fire

Identify The Potential Consequences Of A Fire
Determine The Risk Rating

Risk of a Potential consequences if a fire was to occur

fire Slight harm Moderate harm Extreme harm
occurring
Low Trivial risk Tolerable risk Moderate risk
Medium Tolerable risk Moderate risk Substantial risk
High Moderate risk Substantial risk Intolerable risk

Determine The Action Level And Timeframe

Risk Level Action required & Timescale

Trivial There is no need to take action, and records should not be kept in detail, although
regular monitoring is recommended.
Tolerable There is no need for significant new controls; However, the situation needs
regular monitoring, and improvements that are not too costly may be considered.
Moderate Efforts should be made to minimize the risk. It is essential to implement risk
reduction measures within a specified time frame and monitor them on an
ongoing basis.
Substantial To reduce the risk, considerable resources may need to be allocated. Unoccupied
buildings should not be occupied until the risk has been reduced. Action should
be taken immediately if the building is occupied.
Intolerable Intolerable: Until the risk is reduced, the area (or building) should not be
occupied.

Step 4 Record the findings, develop an emergency plan, inform, instruct, and train.

Step 5 Conduct reviews regularly.

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Prevention of Fire

Prevention of fires aims at not allowing the conditions: combustible material, air, heat and spark/ignition.

1. Inflammable and explosive materials should be stored separately. Such material should be guarded
against exposure to flames, sparks, hot spots, arcs, flashover etc.
2. Special precautions should be taken while welding, heating, flame cutting, grinding, drying etc.
3. No inflammable material, open flames, smoking, explosive materials are to be permitted near electrical
installations.
4. Special precautions are to be taken during handling and storage of gases and hydro-carbons.
5. Gas cylinders should be leak free.
6. Electrical equipment should not be overloaded.
7. Good housekeeping is necessary. Scrap, waste paper and wood, waste oil etc. should be disposed off.
8. Systems should not ne energized unless fire protection systems are in place.
9. All necessary precautions should be taken during storage, erection, testing, commissioning, operation
and maintenance of equipment to prevent fires.
10. Good preventive maintenance of electrical, mechanical and chemical equipment for eliminating weak
points to prevent fires.

Fire Protection and Loss Prevention

Fire Protection aspects cover Civil works, Plant and Equipment Design, Storage, Installation, Testing,
Commissioning, Operations, Maintenance Activities, Documentation and Human Resource Development.

The following provisions should be made available:

1. No inflammable material should be used in construction. Preferably fire retardant material should be used.
2. Adjacent rooms should be airtight from each other.
3. Fire and smoke should not spread from one room to another but go out of the building.
4. Ventilating and air conditioning ducts should have barriers so that smoke and flames do not get transferred
from one section to the other.
5. Space and approach path should be available for fire fighting personnel and equipment like fire engines
and ladders.
6. Wiring and switchboards should not initiate fires.
7. Fire detection and fighting system should be provided for the plant and equipment.
8. Fire wall barriers should be set up between inflammable material and equipment.
9. Passage, staircase and ladders should be provided for escape of personnel and movement of fire rescue
squad during fire emergencies.
10. All personnel in the plant should receive basic fire fighting training.
11. All local and statutory requirements should be fulfilled.

Steps after occurrence of fire

1. Fire occurs
2. Fire is detected by observer or detection system
3. Alarm is sounded

23
4. Electric power supply and other fuel supplies are switched off
5. Immediate use of portable fire extinguishers and water / sand for extinguishing small fires
6. Automatic fire fighting system gets initiated
7. Fire Brigade is called
8. Persons vacate the place

Portable Fire Extinguishers

Water Extinguishers

Water extinguishers are one of the most cost-effective ways to fight Class A fires, those fuelled by solid
materials such as paper, wood and textiles.

There are four different types of water extinguishers:

 Water jet extinguishers work by spraying a jet of water at the burning materials, cooling them and
preventing re-ignition. They should not be used on live electrical equipment.
 Water spray extinguishers use a very fine spray of water droplets, each droplet is surrounded by air which
is non-conductive.
 Water extinguishers with additives are water extinguishers with foaming chemicals added. The water
loses its natural surface tension meaning that it can soak into the burning materials more effectively.
 Water mist, or fog, extinguishers apply water in the form of mist, or fog, the droplets are much smaller
than those from the water spray extinguisher. The smaller the droplet, the larger its surface area in relation
to its size, the quicker the droplet evaporates which absorbs the heat energy faster. The downside is the
smaller the droplet the less it weighs and therefore the less powerful the cloud of water.

Depending on pressurizing agent there are three types

 Soda Acid – Sulphuric Acid and Sodium Bicarbonate to generate CO2

 Gas Pressure Actuated – CO2
 Constant Air Pressure

All water extinguishers have a red label.

Foam Extinguishers

 Foam fire extinguishers can be used on Class A and B fires.

 Two types:
 The premix foam extinguisher contains a mixture of water and foam concentrate within the
extinguisher. An aerating nozzle is typically used to make foam from the foam solution as
it is discharged.
 The cartridge-type foam extinguisher contains water only in the body of the extinguisher.
At the time of discharge, the water flows through a cartridge containing pellets that make
foam when mixed with the water.
 They are most suited to extinguishing liquid fires such as petrol or diesel and are more versatile than water
jet extinguishers because they can also be used on solids such as wood and paper.

24
 The foam extinguishes liquid fires by sealing the surface of the liquid, preventing flammable vapour
reaching the air and starving the fire of fuel. They are not suitable for use on free flowing liquid fires.
 Foam extinguishers have a cream label.

Powder Extinguishers

 Powder extinguishers are a good multi-purpose fire extinguisher because they can be used on Class A, B
and C fires.
 Two types:
 The stored pressure extinguisher contains a dry chemical agent and pressurizing gas,
usually nitrogen, within the extinguisher.
 The cartridge operated dry chemical extinguisher contains dry chemical agent in the body
of the extinguisher and a separate cartridge of pressurizing gas. When the extinguisher is
needed, its main body is pressurized from this cartridge.
 ABC powder is made up of ammonium or mono-ammonium phosphate mixed with other powders to
improve the flow or add bulk. ABC powder is often referred to as general purpose or multi-purpose
extinguisher powder and is capable to fight class A, B and C fires.
 They can also be used on fires involving electrical equipment however, they do not cool the fire so it can
re-ignite.
 Powder extinguishers can also create a loss of visibility and may create breathing problems.
 They are not generally recommended for use inside buildings unless there is absolutely no alternative.
 Powder extinguishers have a blue label.

Carbon Dioxide (CO2) Extinguishers

 CO2 extinguishers are ideal for places with a lot of electrical equipment such as offices or server rooms
because they are safe to use on fires involving electrical apparatus. Carbon dioxide extinguishers do not
leave any residue, unlike a foam extinguisher.
 They can also be used on Class B fires, those involving flammable liquids such paraffin or petrol.
 CO2 extinguishers work by smothering the fire and cutting off the supply of air.
 Carbon Dioxide Extinguishers (CO2) have a black label.

Wet Chemical Extinguishers

 Wet chemical extinguishers are suitable for use on Class F fires involving cooking oils and fats, such as
lard, olive oil, sunflower oil, maize oil and butter.
 The 'chemical' element of wet chemical fire extinguishers is potassium. Potassium salts are sprayed out
as a fine mist (gently, so as not to spread the burning oil or fat), and these react to create a soapy film on
the surface of the substance on fire.
 They are extremely effective, when used correctly. The wet chemical rapidly knocks the flames out, cools
the burning oil and chemically reacts to form a soap-like solution, sealing the surface and preventing re-
ignition.
 Although they are primarily designed for use on Class F fires, cooking oils and deep fat fryers. They can
also be used on Class A fires (wood, paper and fabrics) and Class B fires (flammable liquids).
 Wet chemical extinguishers have a yellow label.

25
Fire Fighting Instructions

What you should know when using a portable fire extinguisher?

Always:
Be sure that you are trained to use a fire extinguisher before you try to fight a fire.
Know what type and class of material is burning.
Use the correct fire extinguisher type to fight the fire.
Remember, if you feel that you cannot safely extinguish the fire using the portable extinguisher available
and if you have not already done so, pull the fire alarm, evacuate the area, and then call the fire department.

When using an extinguisher, use the PASS system - Pull, Aim, Squeeze, Sweep.
Pull the pin on the extinguisher.
Aim the extinguisher.
Squeeze the trigger or top handle.
Sweep the fire area with the extinguisher's spray until the fire is completely out. For floor fires, sweep from
the edges in. For wall fires, sweep from the bottom up.

Never walk away from a fire, even if you think it is out. The residue may reignite.
Always stand between the escape route and the fire so you can leave safely if the fire grows.
If the fire grows too large, leave the area. Activate the fire alarm to evacuate the area.

Fire Protection System

1. Fire Detection System

2. Fire Alarm System
3. Fire Alarm and Control Panel
4. Fire Fighting System
5. Monitoring System

Fire Detection System

Types of fire detectors

1. Heat Detectors

1. Fixed Temperature Type – Has a fusible bulb which subjected to a specific temperature
shatters releasing compressed air
2. Rate of Rise Type – Detects rate of rise in temperature say 5 degrees C / Min.

2. Smoke Detectors

1. Photoelectric – Contains a source of infrared or ultraviolet light. Two types – Light

sensing / scattering or obscuring / blocking.
2. Ionization – Widely used. Has a radioactive source which causes air to become ionized
and conductive. Smoke makes the air less conductive and raises an alarm when the
conductivity drops below a certain level.

26
3. Flame Detectors

1. Ultraviolet – Detects ultraviolet radiation from flames.

2. Infrared – Uses photoelectric cell sensitive to infrared light. Alarm is given when infrared
light is present for more than 15 secs

Automatic Sprinkler Systems

Automatic sprinkler systems are covered in OSHA regulation 1910.159 and in several NFPA codes. The
primary NFPA code is NFPA 13, “Installation of Sprinkler Systems.”

Types of Automatic Sprinkler Systems

Wet-pipe automatic sprinklers have water provided throughout the piping of the sprinkler system at all times.
The heads on a wet-pipe system are fusible devices that are operated by temperature. Once the engineered
temperature level is reached, the fusible element of the sprinkler head melts and allows water to flow through
the head. Each sprinkler head on the system functions individually.

Dry-pipe systems are sprinkler systems with the piping normally dry. This type of system would typically be
used in an unheated area. The heads and piping are basically the same as in a wet-pipe system, however air
pressure is used to fill the portion of the system piping above the control valve of the sprinkler system. When
a fire occurs, the heat opens the sprinkler head, allowing air to exhaust from the system and water to fill the
piping.

Pre-action systems combine certain aspects of wet-pipe and dry-pipe systems. Wet-pipe systems offer the
advantage of more rapid application of water the moment that the head opens. Dry-pipe systems offer the
advantage of preventing the freezing of piping in unheated areas. The pre-action system combines the dry
piping normally filled with air with some other fire detection method that is tied to the control valve for the
water in the sprinkler system.

During a fire emergency, the detection system will detect the fire more rapidly than the fusible portion of the
sprinkler heads. When the detector is set off by a fire condition, it transmits a signal back to the alarm valve
which will open the valve and allow water to fill the system so that by the time the fire has reached sufficient
magnitude to fuse the element of the sprinkler head, the water is already there. This reduces the delay involved
in the application of water on the dry-pipe system.

Deluge systems are primarily used in high-hazard areas. The piping is very similar to regular sprinkler
systems, except that the heads are open. There is no fusible element. A detection system similar to that used
in a pre-action sprinkler system is used in a deluge system. When this system detects a fire condition, the
sprinkler control value is opened and water will flow from all heads on the system. This is used in high-hazard
areas where fires are liable to spread very rapidly, such as aircraft hangers and paint-spray booths. The problem
with closed heads in these areas is that the fire would be moving too quickly and, by the time they had opened,
the fire would have already passed that area

27
CO2 Installation

 Carbon dioxide systems are available in two primary types: local-application systems and total-flooding
systems.
 They are also available in two primary types of agent supply set ups: high-pressure and low-pressure.
 When applied to a fire, CO2 provides a heavy blanket of gas that reduces the oxygen level to a point
where combustion cannot occur.
 Carbon dioxide systems are typically used on equipment and devices that would have flammable or
combustible liquids in use but which would be severely damaged by the use of dry chemicals. Examples
would be printing presses or metal rolling equipment.
 Carbon dioxide is considerably less expensive than halon.
 Carbon dioxide systems include the following components: storage, activation, and distribution.
 The use of carbon dioxide systems should be avoided in any areas that cannot be quickly evacuated, areas
where pyrophoric materials are used, and areas where reactive metals are used

Halon Installation

 Halon systems are gaseous-agent systems typically used in computer rooms or electronic
control areas.
 Usually they are designed as total-flooding systems. Total flooding systems are systems which
disburse a gas throughout the entire area being protected.
 The agent is stored in cylinders or spheres and is discharged through strategically placed
nozzles.
 These systems are usually activated by smoke detectors on a two-zone system. The two-zone
system requires that a detector in each zone sense smoke before tripping the system. This
arrangement reduces the opportunity for false discharges of the system. In computer rooms,
where many of these systems are installed, smoke detectors will be installed below the raised
floor.
 Halon is an effective agent, with the advantage that it leaves no residue or mess and can be
used to protect delicate equipment such as computers. At proper design concentrations it poses
little risk to personnel in the protected area. The biggest disadvantage is the high cost of the
agent.
 Due to the environmental regulations, these systems are not typically being installed anymore
but are permitted to remain in service at existing installations

Inergen Installation

 Inergen fire suppression is a blend of naturally occurring gases with a blend mix consisting of
Argon 50%,Nitrogen 42% and CO2 8%
 It is a highly effective fire suppression system for extinguishing fire & preventing re-ignition
with no risk to people or damage to equipment.
 The Inergen fire suppression also has no adverse affect on the ozone layer as it is completely
made up of naturally occurring gases and also has a zero global warming potential, and no
atmospheric lifetime
 An Inergen system is certified as a safe and clean fire suppression system for occupied spaces

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 Medically evaluated by leading authorities around the world, the blend of INERT gases
maintains normal blood-oxygen levels, thereby ensuring heart rate & mental performance
remain optimal to ensure a safe escape during or after a fire suppression system discharge.
 Unlike many other suppression systems which need to be located close to the protected area,
Inergen can be stored up to further away, and as it is organic in structure it is not subject to
time use limiting restrictions.
 Inergen gas is clear ensuring a safe and visually un-obscured exit.

Foam Installation

 Foam systems are specialized systems used in areas where flammable-liquid fires are expected.
 Foam systems come in two main varieties: low-expansion foam (expansion ratio < 20) and high
expansion foam (expansion ratio 200 – 1000).
 Low-expansion foam systems can use any of the common varieties of low-expansion foam discussed in
the segment on extinguishing agents. Low-expansion foam may be discharged through a special type of
sprinkler head or through monitor nozzles. These foams may also be made available for manual
application through standpipe systems.
 High-expansion foam systems are speciality systems that apply high-expansion foam. High-expansion
foam is typically applied from a foam generator mounted at roof level. Foam systems are used in high
hazard areas such as aircraft hangars and flammable-liquid storage areas. Foam storage is an additional
component of the system.
 Foam is made by combining a foam concentrate with water. This process is referred to as proportioning
and is typically done either in-line with an eductor, through a process called balance pressure
proportioning, or with an around-the-pump proportioner.

Foams

Synthetic foams

Synthetic foams are based on synthetic surfactants. They provide better flow and spreading over the surface
of hydrocarbon-based liquids, for faster knockdown of flames. They have limited post-fire security and are
toxic groundwater contaminants.

 Aqueous film forming foams (AFFF) are water-based and frequently contain hydrocarbon-based
surfactant such as sodium alkyl sulfate, and fluorosurfactant, such as fluorotelomers, perfluorooctanoic
acid (PFOA), or perfluorooctanesulfonic acid (PFOS).
 Alcohol-resistant aqueous film-forming foams (AR-AFFF) are foams resistant to the action
of alcohols and can form a protective film.
 Fluorine-free foams (FFF, also called F3) are mostly based on hydrocarbon surfactants and is free of any
fluorosurfactant.

Protein foams

Protein foams contain natural proteins as the foaming agents. Unlike synthetic foams, protein foams are bio-
degradable. They flow and spread slower, but provide a foam blanket that is more heat-resistant and more
durable.

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Protein foams include regular protein foam (P), fluoroprotein foam (FP), film-forming fluoroprotein
(FFFP), alcohol-resistant fluoroprotein foam (AR-FP), and alcohol-resistant film-forming fluoroprotein (AR-
FFFP).

DCP Installation

 Dry chemical systems are local-application systems which provide dry chemical agent of any of the
common varieties to a specific hazard such as a dip tank.
 The system is activated by a heat sensor which trips the system and allows the dry chemical to discharge
through strategically placed nozzles.
 Dry chemical systems provide rapid control of flammable-liquid fires, but the chemical can create a
cleanup problem. Areas where delicate equipment is located should generally not be protected with dry
chemical systems.

AP State Disaster Response and Fire Service

Services

Fire Fighting With 175 Fire Stations spreading length and breadth of the state, the department available 24/7
for all types of fire emergencies.

Rescue Services All types of rescue activities like rail road accidents, drowinng incidents, building collapses,
animal rescue attended by department.

Community Safety Various sections of community like women, children, students, hospitals, industries are
made well aware of fire safety and rescue methods by conducting various trainings and awareness programs

Fire prevention Department officials ensure fire prevention measures in various hazardous premises by
issuing NOCs, Notices and conducting inspections.

Standby Arrangements Fire safety stand by arrangements are made at VVIP Programs, meetings, big
festivals at temples, major events in view of public safety. Even private stand by arrangements.

Special Task Force A specially trained team of 15 members placed at every district head quarters to
immediately respond to any emergency with specialized equipment like Hydraulic cutters, spreaders, Etc..

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Fire Safety Sign Colours

Fire Sign Boards

To help prevent fires

Mandatory signs – These signs indicate steps people must take to comply with fire regulations, which are
designed to safeguard occupants. An example of a mandatory sign is a “fire door keep shut” notice.
Prohibition signs – Signs that fall into this category include “No Smoking” notices. These messages outline
a prohibited action that could increase the risk of a fire.
Warning signs – These signs are required to make people aware of the presence of flammable materials. For
example, a store cupboard that contains potentially dangerous liquids.

Type of fire safety Colour of sign Shape of Message Example

sign sign signage
Mandatory signs that Blue with white Circular Fire door keep
indicate things that writing or symbols shut
SHOULD be done

Prohibition signs that Red outline with a Circular No naked

warn outline things white background flames
that SHOULD NOT and a red strike
be done through
Warning signs that Yellow with black Triangular Fire risk
highlight specific fire detail
risks in a building

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To aid in escaping and fighting fires

Safe condition signs – These signs indicate fire escape routes, fire assembly points and first aid equipment to
guide occupants dealing with an emergency and escaping the building.
Fire exit signs – These signs are required in order to highlight the location of fire exits so those escaping the
building quickly know which door to head for.
Fire equipment signs – These notices direct people to the location of fire fighting equipment such as
extinguishers or fire hoses and also fire alarm activation areas. Depending on the layout of your building, this
may not be required if the equipment itself is highly visible.
Supplementary information signs – To provide further instruction, these signs include information such as
a directional arrows or text to expand on neighbouring notices.

Type of fire safety sign Colour of sign Shape of sign Message Example signage

Safe condition and fire Green with white Rectangular Fire exit this way
exit signs that highlight writing and
escape routes symbols
Fire equipment signs Red with white Circular or Fire extinguisher
that direct people to writing and rectangular is located here
extinguishers and hoses symbols

Supplementary Multiple colours, Rectangular Escape route

information signs to including green,
provide additional red or yellow
direction

Fire Escape Plan

1. Imagine various scenarios

1. How do fires breakout
2. What are the risks
3. What if scenarios
2. Establish roles and responsibilities
3. Determine escape routes and nearest exits
4. Create a communication plan
5. Inspect all fire alarm and protection systems regularly
6. Rehearse fire evacuation procedures
7. Follow up and reporting

Fire Safety Codes

BIS has formulated more than 150 standards on fire safety in buildings and firefighting equipment
and systems and important ones are:

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 IS Description
1641 – 1646 Code of practice for fire safety of building
3034 Electrical generating and distributing stations
3079 Cotton textile mills
11457 Part 1 Rubber and plastic
11460 Libraries and archives
13694 Iron and steel industries
13716 Hotels
14435 Educational institutions
2189 Fire detection and alarm systems
2190 First aid fire extinguishers
3844 Internal hydrants and hose reels
8758 Temporary structures and pandals
12349 Fire protection-safety signs
13039 External hydrant systems
15105 Fixed automatic sprinkler fire extinguishing systems
15493 Gaseous fire extinguishing systems
15517 HFC 227ea
15519 Water mist system
15683 Portable fire extinguishers
15811 Long range foam monitors
15908 Fire detection and alarm system

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 Mechanical Safety
Mechanical Safety

1. Personal Protective Equipment (PPE)

2. Safety Guards
3. Safety while working with machine tools like Lathe, Drill Press, Power and Band Saws,
Grinding Machines
4. Safety during Welding, Forging and Pressing
5. Safety while Handling Material, Compressed Gas Cylinders, Corrosive Substance, Portable
Mechanical Tools

Personal Protective Equipment

Personal protective equipment, or PPE, PPE are designed to protect workers from serious
workplace injuries or illnesses resulting from contact with chemical, radiological, physical,
electrical, mechanical, or other workplace hazards. Besides face shields, safety glasses, hard hats,
and safety shoes, protective equipment includes a variety of devices and garments such as goggles,
coveralls, gloves, vests, earplugs, and respirators.

Protection from Head Injuries Hard hats can protect your workers from head impact, penetration
injuries, and electrical injuries such as those caused by falling or flying objects, fixed objects, or
contact with electrical conductors. Also, OSHA regulations require employers to ensure that
workers cover and protect long hair to prevent it from getting caught in machine parts such as belts
and chains.

Protection from Foot and Leg Injuries In addition to foot guards and safety shoes, leggings (e.g.,
leather, aluminized rayon, or other appropriate material) can help prevent injuries by protecting
workers from hazards such as falling or rolling objects, sharp objects, wet and slippery surfaces,
molten metals, hot surfaces, and electrical hazards.

Protection from Eye and Face Injuries Besides spectacles and goggles, personal protective
equipment such as special helmets or shields, spectacles with side shields, and face shields can
protect workers from the hazards of flying fragments, large chips, hot sparks, optical radiation,
splashes from molten metals, as well as objects, particles, sand, dirt, mists, dusts, and glare.

Protection from Hearing Loss Wearing earplugs or earmuffs can help prevent damage to hearing.
Exposure to high noise levels can cause irreversible hearing loss or impairment as well as physical
and psychological stress. Earplugs made from foam, waxed cotton, or fiberglass wool are self-
forming and usually fit well. A professional should fit your workers individually for molded or
preformed earplugs. Clean earplugs regularly, and replace those you cannot clean. (The National
Institute for Occupational Safety and Health (NIOSH) has recommended that all worker exposures
to noise should be controlled below a level equivalent to 85 dBA for eight hours to minimize
occupational noise induced hearing loss)

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Protection from Hand Injuries Workers exposed to harmful substances through skin absorption,
severe cuts or lacerations, severe abrasions, chemical burns, thermal burns, and harmful
temperature extremes will benefit from hand protection.

Protection from Body Injury In some cases workers must shield most or all of their bodies against
hazards in the workplace, such as exposure to heat and radiation as well as hot metals, scalding
liquids, body fluids, hazardous materials or waste, and other hazards. In addition to fire-retardant
wool and fire retardant cotton, materials used in whole-body personal protective equipment include
rubber, leather, synthetics, and plastic.

When to Wear Respiratory Protection When engineering controls are not feasible, workers must
use appropriate respirators to protect against adverse health effects caused by breathing air
contaminated with harmful dusts, fogs, fumes, mists, gases, smokes, sprays, or vapors. Respirators
generally cover the nose and mouth or the entire face or head and help prevent illness and injury.
A proper fit is essential, however, for respirators to be effective. Required respirators must be
NIOSH/BIS-approved and medical evaluation and training must be provided before use.

Safety Guards

Safety Guards – Mechanical Hazards

Mechanical Hazards that can hit, grab or trap an operator are:

 Hazardous Motions—including rotating machine parts, reciprocating motions (sliding parts or

up/down motion), and transverse motions (materials moving in a continuous line).
 Points of Operation—the areas where the machine cuts, shapes, bores or forms the stock being
fed through it.
 Pinch Points and Shear Points—areas where a part of the body can be caught between a moving
part and a stationary object. A wide variety of mechanical motions and actions may present
hazards to the worker.

Safety Guards – Hazardous Motions

Rotary motion is anything that turns in a circle, such as a wheel on a bicycle or car. Rotary motion
can also be described as a type of motion that occurs when a body rotates on its own axis.
Oscillating motion is present in any object that moves from side to side. A clock’s pendulum uses
oscillating motion as it swings from side to side.
Linear motion is an object or body that does not deviate from a straight line of motion. Linear
motion can be known as one-dimensional motion as it travels in a straight line.
Reciprocating motion is something that moves forwards and backwards but stays in the same line.

Safety Guards – Points of Operation

 Cutting
 Punching
 Shearing

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 Bending

Safety Guards – Nip, Pinch, Shear Points

Safety Guards – Common Mechanical Injuries

Fracture: Fracture is the medical term for a broken bone. It can be classified as simple, compound
or complete fracture.
Puncturing/Stabbing: Puncturing results when an object penetrates straight into the body and pulls
straight out, creating a wound in the shape of the penetrating object.
Straining and spraining: A strain results when muscles are overstretched or torn. Strains and
sprains can cause swelling and intense pain.
Impact: Being hit by ejected parts of the machinery or equipment
Friction and abrasion: A section of the skin being rub away by the machine.
Entrapment: Being caught in a moving part of a machine or equipment or plant.
Crushing: Collision of plant with a person can result to crushing.
Shear: Can be two moving parts (sharp or otherwise) moving across one another.
High pressure injection: This is an injury caused by high-pressure injection of oil, grease, diesel
fuel, gasoline, solvents, water, or even air, into the body.
Cut: Severing of a human body part by a cutting motion e.g. amputation

Safety Guards – Principles of Mechanical Guarding

1. Experience has shown that if the various types of mechanical motion are clearly understood,
the dangerous parts of any machinery can be identified and such parts or combination of parts
of machinery which contribute to dangers should be guarded.
2. The guard shall effectively eliminate dangers from parts of machinery in motion and work in
process. Effective guarding is an essential factor in efficiency and productivity. The correct
elimination of dangerous conditions enables machinery operators to work with speed and
efficiency.
3. No allowance should be made on the assumption of carefulness by workers in avoiding
accidents from machinery in motion.
4. Intrinsic safety should be a basic feature of machinery design and installation. Where the
design features do not safeguard dangerous parts, provision should be made to facilitate
appropriate guarding.

Safety Guards – Definition

Physical barrier, designed as part of the machine, to provide protection

A guard may act either alone, in which case it is only effective when “closed” (for a movable
guard) or “securely held in place” (for a fixed guard), or in conjunction with an interlocking device
with or without guard locking, in which case protection is ensured whatever the position of the
guard.

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Depending on its construction, a guard may be described as, for example, casing, shield, cover,
screen, door, enclosing guard.
ISO 14120:2015

Safety Guards

Fixed Guard
Guard affixed in such a manner (for example, by screws, nuts, and welding) that it can only be
opened or removed by the use of tools or by destruction of the means by which the guard is affixed

Interlocked Guard
Guard associated with an interlocking device so that, together with the control system of the
machine, the following functions are performed — the hazardous machine functions “covered” by
the guard cannot operate until the guard is closed;
 if the guard is opened while hazardous machine functions are operating, a stop command is
given;
 when the guard is closed, the hazardous machine functions “covered” by the guard can operate
(the closure of the guard does not, by itself, start the hazardous machine functions)

Adjustable Guard
Guard which is adjustable as a whole or which incorporates adjustable part(s)

Self-Adjusting Guard
Movable guard operated by a machine element (e.g. moving table) or by the work piece or a part
of the machining jig, so that it allows the work piece (and the jig) to pass and then automatically
returns (by means of gravity, a spring, other external power, etc.) to the closed position as soon
as the work piece has vacated the opening through which it has been allowed to pass

Safety Devices

Presence Sensing Devices

Photoelectric (optical) – Uses a system of light sources and controls which can interrupt the
machine's operating cycle. Radiofrequency (capacitance) – Uses a radio beam that is part of the
machine control circuit. – When the capacitance field is broken, the machine will stop or will not
activate.

Pullback Devices
Pullback devices utilize a series of cables attached to the operator's hands, wrists, and/or arms –
This type of device is primarily used on machines with stroking action – When the slide/ram is up
between cycles, the operator is allowed access to the point of operation

Two Hand Trips

This device requires concurrent application of both the operator’s control buttons to activate the
machine cycle, after which the hands are free. – Must be far enough away to prevent intentional
contact.

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Gates
Provide a barrier which is synchronized with the operating cycle of the machine in order to prevent
entry to the danger area during the hazardous part of the cycle

Safety while working with machine tools like Lathe, Drill Press, Power and Band Saws,
Grinding Machines

Lathe

A lathe is a machine tool that rotates a work piece about an axis of rotation to perform various
operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with
tools that are applied to the work piece to create an object with symmetry about that axis.

Lathe Safety Tips

1. Never wear long sleeves, gloves or any jewelry and always tie your hair back.
2. Keep ALL rags away from the machine while it is in motion.
3. ALWAYS remove the chuck key from chuck immediately after using
4. Make sure that the chuck or faceplate is ALWAYS fully tightened onto the spindle.
5. Make sure your part is securely tightened in the chuck or collet.
6. Always check that the chuck or collet will clear the tool post before you start.
7. Move the tool bit, tool post and/or tailstock a safe distance from the chuck or collet when
inserting or removing your work piece.
8. Don’t run the machine faster than the proper cutting speed.
9. In setting up the tool holder, place it to the left side of the compound slide to prevent the
compound slide from running into the chuck or spindle attachments.
10. Always clamp the tool bit as short as possible in the tool holder to prevent it from breaking or
chattering.
11. Always make sure that the tool bit is sharp, at the correct height and has the proper clearance.
12. Filing on work revolving in the lathe is only done with permission and supervision
13. If work is turned between centers, make sure that the proper adjustments are made between
centers and that the tailstock is locked in place.
14. Do not grasp or touch chips or turnings with your fingers. It is safer to turn off the lathe before
clearing chips with a brush or soft air blasts.
15. Set the tool bit on the centerline of work to prevent work from climbing over tool or cutting
above center and dragging.
16. Don’t cut work completely through when turning between centers.
17. Turn chuck or face plate through by hand before turning on the power to be sure there is no
binding or clearance problems.
18. Stop the machine before taking ANY measurements.
19. Leave the entire machine CLEANER than when you found it

Milling Machine

Milling machine shapes metal and other solid materials. A cutter rotates about the spindle axis and
table to which the work-piece is affixed. In contrast to drilling, where the drill is moved exclusively

38
along its axis, milling involves movement of the rotating cutter sideways as well as ‘in and out’.
The cutter and work-piece move relative to each other, generating a tool path along which material
is removed. Milling machines may be manually operated, mechanically automated, or digitally
automated via computer numerical control.

Milling Machine Requirements and Safeguards

1. Milling machines must be in good condition and properly lubricated with all moving chains
and gears guarded at all times.
2. As with all other machinery, guards are required for all moving parts and the point of
operation.
3. An adjustable chip shield must be in place whenever cutting is taking place
Milling Machine

Milling Machine Training and PPE

You must receive specific training and personal protective equipment (PPE) before working with
a milling machine. Training must include instruction from an experienced user on how to operate
a band saw, review of the SOP, and the proper use of guards and PPE. Operators must always wear
safety glasses and slip-resistant shoes. Never wear loose clothing or other articles that dangle and
could catch on the cutter.

Milling Machine Safety Tips

1. Keep area around machine clear of debris; wipe up any oil on the floor.
2. Clean and dry the table before setting up.
3. Secure any holding devices (e.g., vise, angle plate, dividing head, or tail stock).
4. Select the right kind of cutter for the job.
5. Check to make sure that the machine is turned off before inserting the cutter.
6. Make sure that the arbor, cutter, and collars are clean before mounting them in the spindle.
7. Handle sharp cutters with a rag.
8. Securely set the work piece in the vise with a rubber hammer or mallet.
9. Be certain that the holding device clears the arbor and the over-arm supports.
10. Select the proper cutting speed, rpm, and rate of feed for the job.
11. Disengage the control handles when using automatic feeds.
12. Keep hands away from the revolving cutter at all times.
13. Never touch the metal chips with your fingers. Clear chips away from the cutter with a brush.
After cutting is finished, vacuum or sweep debris rather than blowing with an air hose.
14. Release any automatic feeds after the job is complete.
15. Clean and wipe the machine when finished

Drill Press

A drill press is a machine that is used to drill holes of various sizes in wood, metal, and other
materials. Usually mounted or bolted to the floor or work bench, it consists of a base, column,
table, spindle, and drill head, which is usually driven by an electric motor. The head has a set of

39
turning handles that move the spindle and chuck vertically. The table can also be adjusted vertically
and is usually moved by a rack and pinion.

Drill Press Drill Press Requirements and Safeguards

1. Drill presses be guarded at all times when in use, secured to the floor or bench, and be in good
working condition.
2. Guards are required for all moving parts, including the point of operation where the work is
performed, at all power transmission components, and at all other moving parts of the machine.
3. The adjustable debris guard must always be adjusted and in place before attempting any type
of cut

Drill Press Training and PPE

1. You must receive specific training and PPE before working with a drill press. Training must
include instruction from an experienced user on how to operate a drill press, review of the SOP,
and the proper use of guards and PPE.
2. At a minimum, you must always wear safety glasses when operating a drill press. Face shields
are recommended for added protection whenever feasible

Drill Press Safety Tips

1. Select round, hex, or triangular shank bits.

2. Secure bits and remove chuck before turning on machine.
3. Work at speed appropriate for bit size and material.
4. Position work to avoid drilling into table.
5. Clamp work to table.
6. Feed bit evenly into work piece.
7. Back out of deep holes.
8. Clear off chips with brush after turning off machine.
9. Never hold work piece by hand

Band Saw

Band saws have blades made of continuous bands of metal with teeth along one edge, and are used
to cut a variety of materials, including wood and metal. Work pieces are fed into the cutting edge
of the blade on vertical machines powered by electric motors. The metal band blade rides on two
wheels rotating in the same plane. Band sawing produces uniform cutting as a result of an evenly
distributed tooth load. Band saws can be used to produce straight cuts and are also particularly
useful for cutting irregular or curved shapes.

Requirements and Safeguards

1. All band saws must be secured to the floor or bench, and have blade tension control devices
with indicators.
2. As with other machinery, all moving parts and the point of operation must be guarded.

40
3. The entire saw blade must be enclosed or guarded, except for the working portion of the blade
between the bottom of the guide rolls and the table. Adjust the blade guard as close as possible
to the table without interfering with movement of the stock.
4. An adjustable secondary debris guard must also be in place.
5. Push sticks or push shoes are recommended to keep fingers and hands away from moving
blades.

Band Saw Training and PPE

You must receive specific training and personal protective equipment (PPE) before working with
a band saw. Training must include instruction from an experienced user on how to operate a band
saw, review of the SOP, and the proper use of guards and PPE. Operators must wear safety glasses.
If the material being sawed chips severely, use a face shield in addition to safety glasses. Slip-
resistant footwear is also essential. As with any power saw, do not wear gloves, ties, dangling
jewelry, long sleeves, or loose-fitting clothing.

Band Saw Safety Tips

1. Clear tools, debris, and unnecessary materials off table.

2. Verify location of on/off switch and emergency power disconnect.
3. Check blade for tightness.
4. Adjust the blade guard as close as possible to the table without interfering with movement of
the stock.
5. Adjust the travel guard down so that the blade will travel within the angle or channel.
6. Operate at manufacturer’s recommended speed.
7. Cut only those materials recommended for use with the machine.
8. Do not force material into the blade.
9. Unplug power cord before changing blade or servicing.
10. Lock power disconnect in “off” position when changing the blade or servicing the saw.
11. Test the saw after disconnecting power and before beginning service.

Bench or Pedestal Grinder

A grinder uses an abrasive wheel to grind objects that need to be shaped or repaired. It is often
used to remove metal from a work piece, sharpen tools, and clean parts. It consists of a power
driven grinding wheel and a tool rest used to guide and feed work-pieces onto the wheel.

Grinder Requirements and Safeguards

1. All grinders must be mounted to floors or benches.

2. The tool rest must be adjusted within one-eighth inch of the grinding wheel.
3. Adjustable tongue (spark) guards should be within one-fourth inch from the wheel.
4. Side guards must cover the spindle, nut and flange, and at least 75% of the wheel.
5. Safety glass shields must be clear to allow the user to see the wheel.
6. As with all other machinery, guards are required for all moving parts and at the point of
operation. Side guards must cover the spindle, nut, flange, and 75% of the wheel. In addition,

41
 each stone or wire brush must have an adjustable, clear debris shield (also known as an eye
shield).
7. If metal grinding operations are going to take place, a hot work permit must be obtained
Grinding Machine

Grinder Training and PPE

You must receive specific training and personal protective equipment (PPE) before working with
a band saw. Training must include instruction from an experienced user on how to operate a
grinder, review of the SOP, and the proper use of guards and PPE. Operators should wear full-face
protection and ear protection, and should wear leather gloves and a leather apron.

Bench and Pedestal Grinder Safety Tips

1. Stand to the side of the grinder when starting the electric motor.
2. Use the correct wheel for the material you are grinding, polishing, or buffing.
3. Adjust the tool rest as close as possible to the grinding wheel without touching it. It must have
a gap of between one-sixteenth and one-eighth inches.
4. Keep the face of the abrasive wheel square. Use a dressing tool to remove some of the abrasive
compound to square the wheel.
5. Never grind on the side of the wheel. This can cause the wheel to shatter.
6. Avoid overheating metal when grinding. If the metal becomes too hot and is allowed to cool
too slowly, it may become soft. If it is cooled too quickly (quenched), it may become brittle.
7. Dip the metal into the water pot attached to the bottom of the grinder as you shape it to keep it
from getting too hot.
8. If your grinder does not have a water pot, place a container of water near the grinder to cool
the piece you are grinding

Safety during Welding, Forging and Pressing

Welding

1. The Welding SOPs must be read and understood. Then the Welding BUST (Basic Use and
Safety Test) must be passed before you are allowed to use the welding equipment.
2. Utilize all protective equipment and clothing. Do not weld with any part of the body uncovered,
the arc light will cause burns similar to severe sunburn.
3. Welders, assistants, and anyone else in the welding area shall wear glasses or shields of
recommended shades during welding operations.
4. Abide by any other safety measures required for each particular type of welding.
5. Inspect all welding equipment to be used, prior to each use, for possible damage.
6. Always strap tanks to a welding cart or a fixed object. Never allow a gas cylinder to be free
standing. Replace the safety cap on all cylinders when not in use.
7. When doing any kind of TIG/ARC/MIG welding, make sure work and/or work table is
properly grounded.
Welding
8. Do not weld in or near a wet area or with wet gloves/hands.

42
9. Be alert to possible fire hazards. Move the object to be welded to a safe location, or, remove
all flammable materials from the work area.
10. Never weld in the same area where degreasing or other cleaning operations are performed.
11. Never cut or weld any container that has held explosive or flammable materials.
12. Do not weld on painted, galvanized or greasy, oily metals. Not only can the fumes be toxic,
but the welds will not be satisfactory and will fail in use.
13. Never weld inside drums or enclosed spaces without adequate ventilation, or, the use of airline
respirators or self-contained breathing apparatus.
14. Check the ventilation system before starting to weld and periodically thereafter to insure
adequate performance. Welding fumes should not be allowed to get into the rest of the shop
working areas.
15. Allow for proper ventilation when brazing or soldering. The fluxes are acidic and toxic.
16. Keep suitable fire extinguishing equipment nearby and know how to operate it.
17. Shut off the cylinder valves when the job is completed, release pressure from the regulators by
opening the torch valves momentarily and back out regulator adjusting valves. Never leave the
torch unattended with pressure in the hoses.

Forging

1. One must have the thorough knowledge of the working of the forging machine before
operating it.
2. During machine forging, always observe the safety rules prescribed for each machine.
3. Always wear proper clothes, foot-wears and goggles.
4. No person should be allowed to stand in line with the flying objects.
5. Proper safety guards should be provided on all revolving parts.
6. Always keep the working space clean.
7. The anvil should always be free from moisture and grease while in use.
8. Always avoid the use of damaged hammers.
9. The handle of the hammer should always be tightly fitted in the head of the hammer.
10. Always use the proper tongs according to the type of work.
11. Head of the chisel should be free from burrs and should never be allowed to spread.
12. Never strike a hardened surface with a hardened tool.
13. Always put out the fire in the forge before leaving the forge shop.

Hydraulic Press

Personal Protective Gear Is a Must

There’s no question that personal protective equipment is an absolute must when spending time
on the machine or factory floor. Proper attire is also necessary, since loose or baggy clothing could
get caught in machinery like a press, which can lead to injury.

Gear that should be worn includes:

1. Company uniform or suitable, form-fitting outfit

2. Protective vests

43
3. Gloves or arm covers
4. Face masks
5. Hearing protection
6. Helmets or head coverings
7. Sturdy, close-toed work boots

Pre-operational safety checks

1. Ensure you are familiar with the operation of the hydraulic press.
2. Check for any hydraulic fluid leaks.
3. The press table must be clean and steel weights are flat and secure on press table.
4. Any forming die or cutting die must be inspected for safe use i.e. no cracks.
5. Ensure safety glasses or goggles are available and are worn by all persons in the vicinity.
6. Any test piece, project or material (work piece) to be pressed must be of an appropriate
thickness and safe to use on this equipment.
7. Faulty equipment must not be used. Immediately report suspect machinery.
Hydraulic Press

Operational safety checks

1. Place your test piece, project or material (work piece) securely on the press table.
2. Ensure the pressure valve is closed before operation.
3. Use the press handle, in a pumping action, to slowly lower the press hammer.
4. Use your shoulder muscles when operating – NOT your lower back.
5. Keep hands and fingers away from all clamping and moving parts.
6. Carefully and accurate alignment the press hammer face with the work piece for even force to
be applied.
7. Once the press hammer makes contact with the work piece, closely watch the PSI gauge and
note the pressure applied.
8. Once the work piece is pressed sufficiently, release the hammer pressure at the release valve.
9. DO NOT apply excessive force with the press.

Safety while Handling Material, Compressed Gas Cylinders, Corrosive Substance, Portable
Mechanical Tools

Hand Tools

Hand tools are manually powered tools such as pliers, screwdrivers, hammers, hand saws, and
wrenches. While not powered by an external source, hand tools can be dangerous if improperly
handled or used to perform the wrong task.

Hand Tool Safety Tips

1. Never use a tool for something other than for what it was intended. Common examples of
misuse include using a wrench for a hammer or using a screwdriver as a crowbar.
2. Don’t use extender or “cheater” bars to increase leverage or force on wrenches.

44
3. Keep hand tools in good working condition and always inspect them before using.
4. Keep knife and saw blades sharpened.
5. Direct blades away from other workers in the work area.
6. Replace wrenches when jaws are worn and begin to slip.
7. Replace tools with splintered handles, cracked blades, or any other defect.
8. Use tools for their intended use only.

Pneumatic Tools

Pneumatic tools are powered by compressed air. Common types of these air powered hand tools
include nail guns, stapling guns, grinders, drills, riveting guns, and jackhammers.

Safety Guidelines for Pneumatic Tools

1. Before you begin a job, make sure that pneumatic tools are fastened securely to their air hoses
to prevent them from becoming disconnected while in use.
2. Wear safety glasses or a face shield and, where necessary, safety shoes or boots and hearing
protection.
3. Make sure air hoses do not present a tripping hazard.
4. Never point a compressed air gun at another person.
5. Use the recommended air pressure for the task.
6. Post warning signs where pneumatic tools are used. Set up screens or shields in areas where
nearby workers may be exposed to flying fragments, chips, dust, and excessive noise.
7. Ensure that the compressed air supplied to the tool is clean and dry. Dust, moisture, and
corrosive fumes can damage a tool. An in-line regulator filter and lubricator increases tool life.
8. Keep tools clean and lubricated, and maintain them according to the manufacturers’
instructions.
9. Do not attempt to catch falling machinery or power tools.
10. Support heavy tools with a counter-balance when possible

Hydraulic Tools

Hydraulic tools are powered by a hydraulic pump which can be hand, foot, or engine powered, or
even built into the tool itself. Hydraulic tools generate, control, and transmit power by the use of
pressurized liquids. Examples of hydraulic tools include jacks, presses, and impact wrenches.
Hydraulic power tools present various hazards, including trip hazards or slipping hazards from oil
leaks.

Safety Guidelines for Hydraulic Tools

1. Never exceed the load limit marked on the tool.

2. Always use a hydraulic jack on a firm and level surface.
3. Visually inspect all hydraulic tools at least once every six months.
4. Visually inspect all jacks used outside the shop before they go out and when they return.
5. Immediately inspect any hydraulic tool when subjected to an abnormal load, pressure, or
shock.

45
6. Always use leather gloves, safety shoes, and face, eye and ear protection.
7. Consider using impact-resistant gloves.

Liquid Fuel Tools

Liquid fuel-powered tools are usually powered by gasoline. Examples of liquid fuel tools include
chain saws, lawn mowers, concrete saws, and pressure washers.

Safety Guidelines for Liquid Fuel Tools

1. Shut and cool down the engine before refilling a fuel tank.
2. Always transport fuel in approved flammable liquid containers.
3. Have fire extinguishers available when working.
4. Always wear foot, eye, face, head, and ear protection when required
5. The most serious hazards presented by these tools are dangerous exhaust fumes and vapors
that can burn or explode. Proper ventilation, careful handling of fuel, and attention to fire safety
can help reduce these hazards.

46
 Electrical Safety
Electrical Safety

1. Introduction to Electrical Safety

2. Electrical Hazards
3. Prevention of electric accidents, PPE used
4. AC and DC current shocks
5. Safety precautions against shocks
6. Portable electrical tools
7. Domestic and Industrial Electrical Safety Procedures

Introduction
1. Electricity is an ubiquitous energy agent to which many workers in different occupations and
industries are exposed daily.
2. Many workers know that the principal danger from electricity is that of electrocution, but few
really understand just how minute a quantity of electrical energy is required for electrocution.
3. The number of people who believe that normal household current is not lethal or that power
lines are insulated and do not pose a hazard is alarming.
4. In reality, the current drawn by a tiny 7.5 watt, 120-volt lamp, passed from hand to hand or
hand to foot across the chest is sufficient to cause electrocution.
5. Electrocutions may result from contact with an object as seemingly innocuous as a broken light
bulb or as lethal as an overhead power-line, and have affected workers.
6. The first electrical fatality was recorded in France in 1879 when a stage carpenter was killed
by an alternating current of 250 volts

Dangers from Electricity

1. Electric Shocks resulting in burns, injury and deaths

2. Electric Flashovers resulting in death, fires and damages
3. Electric Faults resulting in arcing, explosions and fires
4. Explosions in electrical equipment resulting in damage to installations and deaths
5. Fire Hazards resulting in destruction, loss of life, and release of smoke, dust and gases which
spread quickly over large areas
6. Pollution by thermal power plants

Electrical Hazards

Hazardous Effects of Electrical Energy

1. Electrical injuries consist of four main types—electrocution (fatal), electric shock, burns and
falls caused as a result of contact with electrical energy.
2. Electrocution results when a human is exposed to a lethal amount of electrical energy.
3. Electrical injuries may occur in various ways—direct contact with electrical energy, injuries
that occur when electricity arcs to a victim at ground potential (supplying an alternative path),

47
 to flash burns from the heat generated by an electrical arc, and flame burns from the ignition
of clothing or other combustible, non-electrical materials.
4. The extent of injuries received depends on the current’s magnitude (measured in Amps), the
pathway of the current through the body, and the duration of current flow through the body
(event). The resulting damage to the human body and the available emergency medical
treatment ultimately determine the outcome of the energy exchange (post-event).
5. Direct contact and arcing injuries produce similar effects. Arcing to the skin can cause burns
at the point of contact with electrical energy, heating at the point of contact by a high-resistance
contact or higher voltage currents. Contact with a source of electrical energy can cause external
as well as internal burns.
6. Exposure to higher voltages will normally result in burns at the sites where the electrical
current enters and exits the human body. High voltage contact burns may display only small
superficial injury; however, the danger of these deep burns destroying subcutaneous tissue
exists.
7. Additionally, internal blood vessels may clot, nerves in the area of the contact point may be
damaged, and muscle contractions may cause skeletal fractures either directly or in association
with falls from elevation.
8. It is also possible to have a low-voltage electrocution without visible marks to the body of the
victim. Flash burns and flame burns are actually thermal burns. In these situations, electrical
current does not flow through the victim and injuries are often confined to the skin.
9. Contact with electrical current could cause a muscular contraction or a startle reaction that
could be hazardous if it leads to a fall from elevation (ladder, aerial bucket, etc.) or contact
with dangerous equipment
10. For death to occur, the human body must become part of an active electrical circuit having a
current capable of over-stimulating the nervous system or causing damage to internal organs.

Prevention of electrical accidents, PPE used

Prevention of Electrical Accidents

1. The employee should be properly trained and qualified for the job
2. Identify the electric shock and arc flash hazards, as well as others that may be present.
3. Use the right tools for the job.
4. Isolate equipment from energy sources.
5. Test every circuit and every conductor every time before you touch it.
6. Work on electrical equipment and conductors only when de-energized.
7. Lock out/tag out and ground before working on equipment.
8. Treat de-energized electrical equipment and conductors as energized until lockout/tagout, test,
and ground procedures are implemented.
9. Use non-conductive ladders to keep from being shocked at large heights. This can help prevent
falls, as well.
10. Wear protective clothing and equipment and use insulated tools in areas where there are
possible electrical hazards.

48
 Elements of Electrical Safety Program

1. All workers should receive hazard awareness training so that they will be able to identify
existing and potential hazards present in their workplaces and relate to the potential seriousness
of the injuries associated with each hazard.
2. Based on an analysis of these data, to reduce occupational electrocutions, employers can:
1. Develop and implement a comprehensive safety program in compliance with existing
regulations and revise existing programs to thoroughly address the area of electrical safety
in the workplace.
2. Provide all workers with adequate training in the control of the hazards associated with
electrical energy in their workplace.
3. Provide additional specialised electrical safety training to those workers working with or
around exposed components of electric circuits. This training should include, but not be
limited to, training in basic electrical theory, proper safe-work procedures, hazard
awareness and identification, proper use of PPE, proper lockout/tag-out procedures, first
aid including CPR and proper rescue procedures. Provisions should be made for periodic
retraining as necessary.
4. Develop and implement procedures to control hazardous electrical energy, which include
lockout and tag-out procedures and ensure that workers follow these procedures.
5. Provide those workers who work directly with electrical energy with testing or detection
equipment that will ensure their safety during performance of their assigned tasks.
3. Ensure compliance with the National Electrical Code and the National Electrical Safety Code

PPE Used

Insulating Hand Gloves Classification

49
Electrical Helmets and Eye Protection

Class G/A (General Hard Hats)

Class G hard hats are general use hard hats and are the most commonly found hard hats available.
They do provide some protection against electricity, but only up to 2200 volts. The primary use
for this class of hard hat is to protect against impact hazards.

Class E/B (Electrical Hard Hats)

Class E hard hats are approved for use in areas where exposure to electrical hazards is a possibility.
To qualify as a class E electrical hard hat, one must provide the wearer with dielectric protection
of as much as 20,000 volts.

Class C (Conductive Hard Hats)

Class C hard hats are not intended to provide any protection against electrical hazards. Instead,
conductive hard hats are designed just to protect from impact hazards. In most cases, a class C
hard hat will have built-in vents to help keep the wearer cool, which is why they are commonly
found in hot factories or construction yards.

Eye protection is required whenever there is danger of injury to the eyes or face from electric arcs
or flashes or from flying objects resulting from electrical explosion. If using face shield for arc
flash protection be sure to check the Minimum ATPV rating (in cal/cm²)

Insulating Footwear

Electrical shock resistant (EH) footwear is manufactured with non-conductive electrical shock
resistant soles and heals.

It must be capable of withstanding the application of 14,000 volts at 60 hertz for one minute with
no current flow or leakage current in excess of 3.0 milliamperes, under dry conditions.

Dielectric insulating boots provide protection against accidental contact with live electrical
equipment, cables or conductors reducing the electrocution risk.

(Cd) conductive properties

(EH) electrical hazard
(Mt) metatarsal resistance rating,
(PR) puncture resistance
(SD) static dissipative properties.
Insulated Tools

50
Arc Flash Hazard PPEs

AC and DC Current Shocks

Electric Shocks

Electric Shock is the sudden stimulation of the nervous system of the human body by the flow of
electric current through a part of the body. Shocks are caused by direct contact with a live
conductor or a flashover.

Primary Shock is a shock of such magnitude as to produce direct physiological harm. Results are
Fibrillation (irregular heart beat), respiratory tetanus (continuous contraction of muscle)

Secondary Shock is a shock of such magnitude such that it does not produce direct physiological
harm. Results in annoyance, involuntary muscle reaction, alarm, aversion, loss of balance due to
involuntary muscle reaction

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AC and DC Shocks

AC Shocks (4 wire 3 phase AC)

1. Person standing on earth and touching one phase conductor
2. Person standing on earth and touching two phase conductors
3. Person insulated from ground but touching two points of same phase conductor at different
voltage
4. Person touching charged conductor already disconnected from supply circuit due to
capacitive discharge currents through body

DC Shocks (3 wire bipolar DC)

1. A person standing on ground and touching a pole conductor

2. A person insulated from ground and touching two pole conductors

AC and DC Current Shocks

Alternating Current

1. Alternating current, depends mainly on the frequency, in fact the low frequency alternating
current is more dangerous than the high-frequency alternating and direct current of the same
voltage.
2. The low frequency alternating current produces extended muscle contraction –
Tetanus. Tetanus is the condition where muscles involuntarily contract due to the passage of
external electric current through the body. When involuntary contraction of muscles controlling
the fingers causes a victim to be unable to let go of an energized conductor, the victim is said
to be frozen on the circuit.
3. AC is more likely to cause a victim’s heart to fibrillate, which is a more dangerous condition
for the victim after the shocking current has been halted.

Direct Current

1. Direct current is most likely to cause a single convulsive contraction, which often forces the
victim away from the current’s source.
2. Direct current (DC) is more likely to cause muscle tetanus, making DC more likely to “freeze”
a victim in a shock scenario.

Effects of Electrical Shock

Electrical Injuries Internal organs are mainly affected by electrical burns. The burns of this kind
may appear slightly or they doesn´t show on the skin at all. They are caused by the heat
generated from the body’s resistance to the current passing through it. These cases are more
dangerous than external injuries.

52
Internal burns are devastating and often have serious consequences: scarring, amputation, loss
of function, loss of sensation and even death. For example, if a lot of tissue is destroyed, the large
amount of waste generated can cause serious kidney or blood circulation disorders.

Cardiac effects are among the most serious and among the most common electrical injuries. The
issue is that the heart's central anatomical location in the chest and it is more commonly affected
than other internal organs because the electric current usually follows the path of least resistance
in the body along blood vessels and nerves, directing the current towards the heart.

Arrhytmias: Exposure to high voltage current is more likely to cause cardiac asystole, but even
low voltage alternating current can cause cardiac arrest by ventricular fibrillation. The mechanism
behind induced cardiac arrhytmias is predicted to be initial damage to heart muscle and subsequent
scar formation leading to abnormal electrical activation of the heart.

Bradycardia: Injuries can result from interference with the normal conduction system The sino-
atrial and atrio-ventricular nodes responsible for impulse generation and propagation within the
heart may be more susceptible to damage by electrical injury than other cardiac cells.

Heart muscle injury: Chest pain may be absent and injury may manifest only as non-specific
electrocardiographic changes, increased levels of myocardial proteins in the blood-troponin from
damaged tissue. Occasionally, mostly after high voltage accidents, myocardial infarction can be
caused by occlusion of coronary arteries by blood clots or spasm.

The Blood Vessels: The walls of blood vessels through which a current has passed long enough to
cause necrotic change become brittle and friable. The inner endothelial lining of the vessel
undergoes changes and parietal thrombi are attached to the intima.

Neurologial: Damage to nerve tissue may cause loss of consciousness, impaired recall, spinal cord
injury, paralysis, or loss of sensations in limbs. Electricity may pass through the spinal cord
transversely, obliquely or longitudinally, resulting in many different cord syndromes. Permanent
defects may remain, of which syndromes from loss of anterior horn cells are common. Peripheral
nerves likewise may be transiently paralyzed or more permanently damaged by heat-effects from
passage of current or by outright burns.

Neurophsychological problems are often underappreciated, but post-traumatic stress disorder,

depression and chronic neuropathic pain have been reported.

The eye: The changes observed on the eyes are usually late complications of electrical injuries.

Musculoskeletal system: In some cases the electric arc burns a deep hole in the bone, and the
meninges and the brain, too, may be affected, in other cases of less severe types of accidents, the
bone is often exposed by the destruction of the soft tissues. Bone fractures. Direct muscle damage
and also compartment syndrome.

53
Safety precautions against shocks

1. Bodies / structures must be earthed

2. Conductors should be insulated / enclosed / not-accessible
3. Person should keep clear distance from high voltage conductors
4. Person should wear safety insulating shoes and safety insulating hand gloves
5. Live line working should be avoided
6. Conductor should be touched only after making dead and discharged

Portable Electrical Tools

Electrical Hazards

1. When bare live conductors are exposed and come in contact with damaged enclosure.
2. Insulation failures causing leakage of current make the metal works live if the equipment is
not earthed properly.
3. If the earth wire is detached from the plug terminal because of loose or ineffective cord grip
and comes in contact with the live terminal, the metal work of the apparatus can become live.
4. Metal work becoming live as a result of wrong electrical connections.
5. Damaged flexible cables used with the apparatus.
6. Badly made joints in flexible cables which lose their insulation or pull apart when strained.
7. Servicing tools without disconnecting them from the power supply.
8. Unauthorised repairs carried out by the operator or his associates.
9. Electrical leakage in damp or wet location increases the electrical shock hazard. Perspiration
on the workman will lower his body resistance and hence permit a higher current through the
body increasing the resulting injury. Usually, the operator is unable to release his grip on the
electrical tool and gets a shock increasing the severity of the injury.
Portable Electrical Tools

Mechanical Hazards

1. Particles flying from grinding wheels or drills can fall in operator’s eyes. This can sometimes
blind the person.
2. While working at heights with portable electrical tools, the chances of the tool falling and
injuring people standing below or the operators themselves falling from a height are high.
3. The equipment connecting the electrical cable with the power supply, if left on the floor, may
cause up passers-to trip, causing nasty injuries.

Fire Hazards

1. The heat and sparks generated from the tools can at times ignite combustible material nearby.
2. Work with portable tools should not be carried out in areas where hazardous gases are likely
to be present. This is because the sparks and heat generated by the tools could cause an
explosion and fire.

54
3. Overloading and short circuits in the electrical supply system of the portable electrical tools
can give rise to heat and sparks resulting in fire when combustible materials are present in the
vicinity.

Key Safety Measures for Power Tools

1. Select the right tools for the right job.

2. Train the worker to use tool correctly.
3. Keep tools in good condition.
4. Store tools in a safe place.
5. Ensure use of proper personal protective equipment.
6. Earth tools properly.
7. Use double insulated tools.
8. Use safety guards provided on tools.

Domestic and Industrial Electrical Safety Procedures

Domestic Safety Procedures

1. Before carrying out any repair work, switch of mains, take out fuse-holders and keep with
you till completion of work
2. Use shock-proof appliances
3. Use correct fuse wires
4. Miniature circuit breakers are preferred
5. Use good quality copper wiring
6. Replace worn out wiring
7. Do not allow water leakage / seepage in walls near or over switch boards
8. Replace defective switches immediately
9. Ensure healthy earthing system
10. Provide secure earthing to appliances via 3 pin plug socket
11. Use insulated tools and stand on dry wooden stool while working on electrical wires
Domestic Safety Procedures
12. Electrical outlets in bathroom should be away from shower or sink
13. Electrical outlets in kitchen should not be above the stoves
14. Care should be taken to see that the insulation does not get damaged accidentally or thermally
15. Care should be taken not to overload wiring by connecting appliances to lighting circuits or
connecting several appliances through multi plug sockets

Industrial Safety Procedures

1. Procedures and paper work to be strictly followed: Permit to work, Access to work, Entry
Passes, Materials gate passes
2. Use safety PPEs
3. Electricians should be well trained
4. Take work permit before start of work from authorized person and return to same person after
completion of work

55
5. Isolation of the part from live parts during the period of installation, testing and maintenance
6. Danger and safety notices should be placed at work spot
7. Switches should be locked to avoid switching by a third person
8. Work equipment and conductors should be isolated and then earthed by means of earthing
connections from all ends / incomers / outgoers. Open a circuit by opening circuit breaker,
opening isolator and closing earthing switch in sequence. Closing should be in reverse order.
9. Switching on should be done only after completion of work, and cancellation of work permit
by authorized person.
10. Keep barriers around section under maintenance
11. Be familiar with the circuit and auxiliary supply circuits
12. First aid kit should be available

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 Chemical Safety and other safety checks

Chemical Safety and Other Safety Checks

1. Introduction to Chemical Safety

2. Labelling of Chemicals, Acid Hoods
3. Handling of Acids, Eye Washers and Showers
4. Hazardous Waste Disposal
5. Check List for LPG Installations
6. Safety precautions using CNG
7. Fire prevention safety audit

Introduction

1. Chemicals are part of our daily life. All living and inanimate matter is made up of chemicals
and virtually every manufactured product involves the use of chemicals. Many chemicals can,
when properly used, significantly contribute to the improvement of our quality of life, health
and well-being. But other chemicals are highly hazardous and can negatively affect our health
and environment when improperly managed.
2. The production and use of chemicals continues to grow worldwide, particularly in developing
countries. This is likely to result in greater negative effect on health if sound chemicals
management is not ensured. Multi sectoral action is urgently needed to protect human health
from the harmful effects of improperly managed chemicals.
3. Chemical Safety is achieved by undertaking all activities involving chemicals in such a way as
to ensure the safety of human health and the environment. It covers all chemicals, natural and
manufactured, and the full range of exposure situations from the natural presence of chemicals
in the environment to their extraction or synthesis, industrial production, transport use and
disposal.
4. Chemical safety has many scientific and technical components. Among these are toxicology,
ecotoxicology and the process of chemical risk assessment which requires a detailed
knowledge of exposure and of biological effects.

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Labelling of Chemicals, Acid Hoods

Labelling of Chemicals

Chemical / Acid Fume Hood

The purpose of a chemical fume hood is to prevent the release of hazardous substances into the
general laboratory space by controlling and then exhausting hazardous and/or odorous
chemicals.

A fume hood is a ventilated enclosure in which gases, vapors and fumes are captured and removed
from the work area. An exhaust fan situated on the top of the laboratory building pulls air and
airborne contaminants through connected ductwork and exhausts them to the atmosphere.

Flammable solvents, corrosive acids, corrosive bases, combustible or potentially explosive

concentrations of gases, irritating vapors or dust, asphyxiating gases, or open sources of volatile
radionuclides are all examples of materials that must be used inside of a fume hood.

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Handling of Acids, Eye Washers and Showers

Commonly used Acids in Laboratories

Purchase of Acids

 Purchase dilute acids whenever possible. Dilute acid solutions are safer and easier to handle,
use and store than concentrated acids. They will also save valuable prep time.
 Purchase small quantities of acids to help keep your acid fresh and to make storage and
handling safer and easier. It is easier to clean up a 100 mL acid spill than a 2.5 L one.
 Always purchase concentrated acids in PVC-coated glass bottles. PVC-coated bottles will not
shatter and spill acid when dropped. The PVC creates a plastic envelope around the bottle that
greatly reduces spills and breakage. The PVC coating may discolor over time, especially when
exposed to hydrochloric acid fumes. This discoloration does not affect the PVC coating or the
quality of the acid inside the bottle.

Storage of Acids

 Store all acids in a dedicated corrosives or acid cabinet. The best acid cabinets are built with
wood because metal cabinets will quickly corrode from acid fumes. Wood cabinets will provide
years of safe and durable acid storage. The cabinet should be located in a locked chemical
storeroom. If not, the cabinet must be secured with a lock.
 Storing acids and bases together in one corrosive cabinet is acceptable. However, the bottles
may become covered with ammonium chloride from the hydrochloric acid and ammonia
fumes. The cabinet and bottles should be washed with TSP or other strong cleaner to remove
the white film.
 Label all prepared acid solutions before storing them with at least the name of the acid, its
concentration, a hazard warning or how the acid can hurt you and the date prepared on the
label.
 Always keep the appropriate color-coded acid bottle cap on the concentrated acid bottle. Never
use these caps on other bottles. Color-coded bottle caps provide an extra safety measure to
identify concentrated acids if the label is removed or destroyed. If an acid bottle cap becomes
cracked or discolored, always replace the cap with the proper color-coded cap. The following
colors are used on all concentrated acid bottles sold in the United States.
 Acetic Acid—Brown
 Phosphoric Acid—White

59
  Hydrochloric Acid—Blue
 Sulfuric Acid—Yellow
 Nitric Acid—Red
 Ammonium Hydroxide—Green
 Concentrated hydrochloric acid fumes continously and cannot be stored without releasing
hydrochloric acid fumes. These fumes are responsible for most of the corrosion damage in your
chemical storeroom. Storing hydrochloric acid in a wood acid cabinet is a must. Hydrochloric
acid fumes will quickly corrode metal cabinets.
 Nitric acid is a strong oxidizing agent. Concentrated nitric acid must be stored in a separate
liquid-tight compartment within an acid cabinet (e.g., SE8071). If nitric acid is mixed with a
flammable organic compound, such as acetic acid, the heat from the oxidation and
neutralization reactions is enough to ignite the flammable material. Nitric acid also slowly
destroys its red plastic bottle cap. Always replace with a new red cap. Nitric acid may also turn
yellow over time because of the release of nitrogen dioxide on exposure to light. The yellow
color does not affect the product’s usefulness in the school laboratory.
 Glacial acetic acid is a flammable liquid. It should be stored in an acid cabinet, but in a location
that is isolated from possible contact with nitric acid. Glacial acetic acid freezes at 16.6 °C; the
material may crystallize in a cool storeroom. If this occurs, allow the bottle to warm up to
ambient (25 °C) temperature.
 Concentrated sulfuric acid is a strong dehydrating agent. Because of its strong ability to remove
water, it reacts violently with many organic materials such as sugar, wood and paper. If sulfuric
acid has turned brown, it has probably been contaminated with an organic material and its
purity should be in question.
 Concentrated phosphoric acid has a melting point close to ambient temperature and may also
crystallize in a cool storeroom. Phosphoric acid is hygroscopic and will absorb water over time.
Keep tightly sealed.

Transporting Acids

 Secondary containment is critical to prevent major spills or accidents when transporting acids.
Use PVC-coated acid bottles or unbreakable bottle carriers (e.g., AP4379).
 A good habit is to check the acid bottle for cracks before touching or picking it up. Also check
for spilled acid on the handle or bottle.
 Always carry 2.5-L acid bottles with one hand underneath the bottle and the other hand around
the neck or finger hole. This keeps the bottle closer to your body and decreases the risk of
hitting a sharp object, like a desk corner and breaking the bottle.
 Plastic or rubber safety bottle carriers (AP4379 or SE201) should be used whenever acids are
transported from one laboratory to another or from the storeroom to a laboratory.
 If a cart is used to transport hazardous chemicals, such as acids, place compatible chemicals
inside an unbreakable secondary containment vessel, such as a plastic tote. The cart should be
equipped with guardrails to prevent plastic totes or bottles from sliding off the cart.

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Preparing an Acid Solution

 Add the appropriate amount of acid to about 2 /3 of the required amount of distilled or
deionized water.
 Always add acid to water! Never add water to concentrated acids. The acid may splatter and
generate acidic steam.
 Always use borosilicate glassware.
 Stir to mix the solution.
 Once the solution has cooled to ambient temperature, dilute the solution to the proper volume
with water.
 Use a volumetric flask for extra precision.
 When diluting sulfuric acid, place the borosilicate beaker or flask in an ice bath. The heat of
dilution of sulfuric acid is very high and may melt plastic containers or crack non-borosilicate
glassware.

Using and Dispensing Acids

 Always review the Safety Data Sheet (SDS) before using any hazardous material in the
laboratory.
 Students should dispense acids from smaller bottles to limit spills and fumes.
 Use lab mats and or plastic trays when dispensing acids to contain acid spills and drips.
 Dispense acids, especially hydrochloric, nitric and acetic acids, in an operating fume hood.
 During lab, set the acid bottle in a central dispensing location and have students bring a
graduated cylinder or test tube to the dispensing area. This will help to minimize spills and
accidents as well as limiting the amount of acid being transported back to the lab bench.
 Instruct students to only remove the amount of acid needed for the experiment from the reagent
bottle. Chemicals are never added back to the reagent bottle.
 Have acid spill clean-up materials readily available whenever acids are used.
 Acids are corrosive and will eat through most fabrics, resulting in small holes in clothing. This
process does not occur instantly but rather over several hours and may not become apparent
until the clothes are washed. Always wear a chemical resistant apron or laboratory coat when
working with acids.

PPEs

 Nitrile rubber gloves are acid-resistant and are the best choice to use when handling
concentrated acids. However, any plastic or vinyl glove will provide some protection against
the occasional splash, small spill and splatter that may occur when using or dispensing acids.
 Operating eyewashes must be available in any classroom or laboratory where acids or acid
solutions are used. An approved eyewash must treat both eyes and provide clean potable water
for at least 15–20 minutes.
 Chemical splash goggles must be worn whenever acids or acid solutions are used. Safety
glasses are not adequate protection.
 Good ventilation should be available whenever hydrochloric, nitric or acetic acids are used.
 Spill control materials (sand, absorbent and neutralizer) must be available whenever acids or
acid solutions are used.

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First Aid

 Always seek professional medical attention upon exposure to any hazardous chemical,
especially concentrated acids.
 The best first aid for any chemical exposure to body tissue or eyes is immediate dilution with
water.
 If an acid is splashed in the eyes, use an eyewash to irrigate the eyes for at least 15–20 minutes.
Make sure the eyelids are held open to properly irrigate them. Ask the victim to look up, down
and sideways to better reach all parts of the eye.
 If an acid is splashed onto bare skin, rinse with water for at least 15–20 minutes.
 If an acid is splashed onto clothing, consider removing the clothing immediately before the
acid soaks through the clothing and reacts with the skin. If an acid splashes onto your skin and
clothing, immediately begin rinsing the affected areas with water (safety shower is ideal) and
then begin to remove affected clothing. Modesty must take a back seat to the potential chemical
burns that can occur.
 If acid is ingested, the primary goal is to dilute the acid in the stomach and prevent further
injury caused by vomiting. If the victim is conscious, immediately have the victim rinse their
mouth out with water. Have the victim drink one or two cups of water or milk. Gastric antacids
such as milk of magnesia or aluminum hydroxide can also be given. Do not induce vomiting,
do not try to neutralize the acid with a strong base, and do not give the victim any sodium
bicarbonate or any carbonated drinks. Call a poison control center or hospital emergency room
and follow their directions.

Eye Wash, Shower and Drench Hose

Necessity of Eye or Body Wash

The first 10 to 15 seconds after exposure to a hazardous substance, especially a corrosive

substance, are critical. Delaying treatment, even for a few seconds, may cause serious injury.

Emergency showers and eyewash stations provide on-the-spot decontamination. They allow
workers to flush away hazardous substances that can cause injury.

Accidental chemical exposures can still occur even with good engineering controls and safety
precautions. As a result, it is essential to look beyond the use of goggles, face shields, and
procedures for using personal protective equipment. Emergency showers and eyewash stations are
a necessary backup to minimize the effects of accident exposure to chemicals.

Emergency showers can also be used effectively in extinguishing clothing fires or for flushing
contaminants off clothing.

The ANSI standard defines "flushing fluid" as any of potable (drinking) water, preserved water,
preserved buffered saline solution or other medically acceptable solutions. Local laws may apply
in some cases. This document will use the term "water" to mean any of these acceptable flushing
fluids unless otherwise specified.

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How to Wash

ANSI Z358.1-2014 does not specify how long the affected body part should be rinsed. It does
specify that the equipment installed according to the standard be capable of providing flushing
liquid for a minimum of 15 minutes.

However, other references recommend a minimum 20-minute flushing period if the nature of the
contaminant is not known. The flushing or rinsing time can be modified if the identity and
properties of the chemical are known. For example:

1. 5-minutes for non-irritants or mild irritants,

2. 15-20 minutes for moderate to severe irritants and chemicals that cause acute toxicity if
absorbed through the skin,
3. 30 minutes for most corrosives, and
4. 60 minutes for strong alkalis (e.g., sodium, potassium or calcium hydroxide).
In all cases, if irritation persists, repeat the flushing procedure. It is important to get medical
attention as soon as possible after first aid has been given. A physician familiar with procedures
for treating chemical contamination of the eyes and body should be consulted.

Hazardous Waste

 Any waste or combination of wastes which pose a substantial present or potential hazard to
human health or living organisms because such wastes are non-degradable or persistent in
nature or because they can be biologically magnified, or because they can be lethal, or because
they may otherwise cause or tend to cause detrimental cumulative effects.
 Also, a waste or combination of wastes of a solid, liquid, contained gaseous, or semisolid form
which may cause, or contribute to, an increase in mortality or an increase in serious irreversible,
or incapacitating reversible illness, taking into account the toxicity of such waste, its
persistence and degradability in nature, its potential for accumulation or concentration in
tissue, and other factors that may otherwise cause or contribute to adverse acute or chronic
effects on the health of persons or other organisms.
 Classes (Schedule II of Hazardous and Other Wastes (Management and Transboundary
Movement) Rules, 2016)
 Class A: Based on leachable concentration limits [Toxicity Characteristic Leaching
Procedure (TCLP) or Soluble Threshold Limit Concentration (STLC)]
 Class B: Based on Total Threshold Limit Concentration (TTLC)
 Class C : Based on hazardous Characteristics

Class A

Up to A79

1. The testing method for list of constituents at A1 to A61 in Class-A, shall be based on Toxicity
Characteristic Leaching Procedure (TCLP) and for extraction of leachable constituents,
USEPA Test Method 1311 shall be used.

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2. The testing method for list of constituents at A62 to A79 in Class- A, shall be based on Soluble
Threshold Limit Concentration (STLC) and Waste Extraction Test (WET) Procedure given in
Appendix II of section 66261 of Title 22 of California Code regulation (CCR) shall be used.
3. In case of ammonia (A10), cyanide (A11) and chromium VI (A64), extractions shall be
conducted using distilled water in place of the leaching media specified in the TCLP/STLC
procedures.
4. A summary of above specified leaching/extraction procedures is included in manual for
characterization and analysis of hazardous waste published by Central Pollution Control Board
and in case the method is not covered in the said manual, suitable reference method may be
adopted for the measurement.

A list of hazardous waste elements as per Class A up to A 20 is given under:

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Class B

A list of hazardous waste elements as per Class B is given under:

In case of asbestos, the specified concentration limits apply only if the substances are in a friable,
powdered or finely divided state.

Class C
List of Hazardous Substance Characteristics – Class C

Code Characteristic Description

H1 Explosive An explosive substance or waste is a solid or liquid
substance or waste (or mixture of substances or wastes)
which is in itself capable by chemical reaction of
producing gas at such a temperature and pressure and at
such a speed as to cause damage to the surrounding
H3 Flammable Liquids The word “flammable” has the same meaning as
“inflammable”. Flammable liquids are liquids, or
mixtures of liquids, or liquids containing solids in
solution or suspension (for example, paints, varnishes,
lacquers, etc. but not including substances or wastes
otherwise classified on account of their dangerous
characteristics) which give off a flammable vapour at
temperatures of not more than 60.5ºC, closed-cup test, or
not more than 65.6ºC, open-cup test. (Since the results of
open-cups tests and of closed-cup tests are not strictly
comparable and even individual results by the same test
are often variable, regulations varying from the above
figures to make allowance for such differences would be
within the spirit of this definition).
H4.1 Flammable Solids Solids, or waste solids, other than those classed as
explosives, which under conditions encountered in
transport are readily combustible, or may cause or
contribute to fire through friction.

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H4.2 Substances or Substances or wastes which are liable to spontaneous
wastes liable to heating under normal conditions encountered in
spontaneous transport, or to heating up on contact with air, and being
combustion then liable to catch fire.
H4.3 Substances or Substances or wastes which, by interaction with water,
wastes which, in are liable to become spontaneously flammable or to give
contact with water off flammable gases in dangerous quantities.
emit flammable
gases
H5.1 Oxidizing Substances or wastes which, while in themselves not
necessarily combustible, may, generally by yielding
oxygen cause, or contribute to, the combustion or other
materials.
H5.2 Organic Peroxides Organic substances or wastes which contain the bivalent-
o-o-structure are thermally unstable substances which
may undergo exothermic self-accelerating decomposition
H6.1 Poisons (acute) Substances or wastes liable either to cause death or
serious injury or to harm human health if swallowed or
inhaled or by skin contact.
H6.2 Infectious Substances or wastes containing viable micro-organisms
substances or their toxins which are known or suspected to cause
disease in animals or humans.
H8 Corrosives Substances or wastes which, by chemical action, will
cause severe damage when in contact with living tissue,
or, in the case of leakage, will materially damage, or
even destroy, other goods or the means of transport; they
may also cause other hazards
H10 Liberation of toxic Substances or wastes which, by interaction with air or
gases in contact water, are liable to give off toxic gases in dangerous
with air or water quantities
H11 Toxic (delayed or Substances or wastes which, if they are inhaled or
chronic) ingested or if they penetrate the skin, may involve
delayed or chronic effects, including carcinogenicity).
H12 Eco-toxic Substances or wastes which if released, present or may
present immediate or delayed adverse impacts to the
environment by means of bioaccumulation or toxic
effects upon biotic systems or both
H13 Capable by any means, after disposal, of yielding another
material, e.g., leachate, which possesses any of the
characteristics listed above

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Essential Elements of a Hazardous Waste Disposal Program

1. Identification of hazardous waste generation – Identifying hazardous waste generating

industries
2. Data collection – Identifying hazardous waste generation sources
3. Waste characterization – Hazardous waste characteristics are to obtained
4. Quantification of hazardous waste – To be quantified based on individual characteristics
5. Identification of sites for disposal – identifying areas for treatment, storage and disposal
6. Conducting environmental impact assessment – To be conducted at identified site
7. Implementing Treatment, Storage and Disposal Facility program – Program to be
implemented at final site chosen

Hazardous Waste Disposal Methods

1. Treating Hazardous Waste

 Chemical treatment – e.g., neutralization, precipitation, ion exchange, reduction, or
oxidation;
 Thermal treatment – e.g., incineration;
 Biological treatment – e.g., landfarming; and
 Physical treatment – e.g., solidification, flotation, sedimentation, evaporation, or
filtration.
2. Underground Disposal
3. Landfill Disposal
4. Ocean Dumping
5. Recycling
 Reclaiming – Regeneration or processing to recover a useful product
 Reuse/use – Substituting it for another product or using it as an industrial ingredient
 Burning to recover energy – Burning for fuel
 Disposal through use – Placement of waste on the land.

Check List for LPG Installations

Liquified Petroleum Gas

1. Liquefied petroleum gas (LPG or LP gas) is a fuel gas which contains a flammable mixture
of hydrocarbon gases, specifically propane, propylene, butylene, isobutane and n-butane.
2. LPG is used as a fuel gas in heating appliances, cooking equipment, and vehicles.
3. It is increasingly used as an aerosol propellant and a refrigerant [R50 (methane), R290
(propane), R600 (butane), R600a (isobutane), R1270 (propylene)], replacing
chlorofluorocarbons in an effort to reduce damage to the ozone layer.
4. When specifically used as a vehicle fuel, it is often referred to as autogas or even just as gas.
5. LPG is prepared by refining petroleum or "wet" natural gas, and is almost entirely derived
from fossil fuel sources, being manufactured during the refining of petroleum (crude oil), or
extracted from petroleum or natural gas streams as they emerge from the ground.
6. It was first produced in 1910 by Walter O. Snelling, and the first commercial products appeared
in 1912.

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7. It currently provides about 3% of all energy consumed, and burns relatively cleanly with
no soot and very few sulfur emissions. As it is a gas, it does not pose ground or water
pollution hazards, but it can cause air pollution.

Safety Inspection Checklist for LP Gas Installations – Abbreviations Used

Abbreviation Description
SMPV (U) Rules Static and Mobile Pressure Vessels (Unfired) Rules, 1985.
P.A. Petroleum Act, 1934.
P.R. Petroleum Rules, 1976.
I.S.I. Indian Standard.
F.A. Factories Act, 1948.
M.F.R. Maharashtra Factories Rules, 1963.
M.S.I.H.C. Manufacture, Storage & Import of Hazardous Chemicals.
M.H.C.M. Major Hazard Control Manual, International Labour Organisation (ILO),
Geneva.
NSS-RPS No Standard Specified—Required for Safety Purpose
Safety Inspection Checklist for LP Gas Installations – Aspects

1. Location and Spacing

2. Mechanical Integrity
3. Fittings
4. Piping
5. Underground Piping
6. Hydrostatic Relief Valve
7. Flexible Connections
8. Fire Precaution
9. Loading and Unloading Facilities
10. Maintenance and Examination
11. Operational Procedure
12. Training

Mechanical Integrity

S. No. Inspection Criteria Specified Standard

1 Vessels are designed, constructed, tested & SMPV (U) Rule 12 & IS-2825
certified to appropriate standards
2 Maximum safe operating pressure is 14.5 kgs SMPV (U) Rule 16 & as per
(210 psi.) design standard
3 Minimum safe operating pressure is 480 SMPV (U) Rule 16 & as per
absolute (7 psi) design standard
4 Vessels are marked with minimum safe SMPV (U) Rule 16
operating pressure

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 5 Safe operating limit of pressure, temperature at
unloading
6 Are certified by competent person after SMPV (U) Rule 33
installation of the vessel and before filling it
7 Periodic examinations are done by competent SMPV (U) Rule 19
person in accordance with the prescribed codes
8 Maximum permissible fill (contents) and SMPV (U) Rule 33
maximum permissible load on supports is
included in the documentation

Fire Precaution

S. Inspection Criteria Specified

No. Standard
1 Electrical equipment installed near LPG vessels etc. meet the required SMPV (U)
standards & separation distance Rule 31, IS-
2148 & 2206
2 Plant design and layout take care of water supplies, fire protection, fire NSS-RPS
fighting equipment means of access for fire brigade appliances,
protection of fire brigade personnel
3 There is an arrangement to ensure an early call out to the fire brigade NSS-RPS
in the event of fire
4 There is adequate supply of water for protection to use in emergency TAC Rule

5 On-site hydrants and fixed monitors are designed so that water flow TAC Rule
can be controlled from safe position
6 There is adequate drainage to deal with water used for fire protection NSS-RPS
and fire fighting purposes
7 Water sealed interceptors are filled where necessary, to prevent LPG NSS-RPS
entering from drain and sewer
8 The storage vessels are provided with fixed fully automatic water TAC Rule
spray system capable of detecting a fire therein the vessel and
operating without manual intervention
9 Fire detecting systems do not depend upon sensing of excessive NSS-RPS
vessel pressure
10 For manually operated water, spray there is continuous supervision TAC Rule

11 Manual operation point of water sprinkler is situated at safe place NSS-RPS

12 Fixed water spray system is fitted to bulk vessels at cylinder filling NSS-RPS
installations and to rail loading and unloading gantries

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 13 LPG installations are provided with portable fire fighting equipment F.A-71-B

14 People in the premises where LPG is stored have received adequate F.A. 7-A(C)
instructions with training to unable them to under stand the fire
protection and action to be taken in the event of fire or leakage of
LPG

Maintenance and Examination

S. Inspection Criteria Specified Standard

No.
1 The installation is maintained to acceptable standards by SMPV (U) Rule-19 & F.A.-31
a competent person of appropriate discipline with the & M.F.R.-65
objective of:
a) maintaining the established safe operating
limits,
b) taking care of the features affecting the
integrity of the installation or ability to take
emergency measures
2 Maintenance has been prepared which includes M.S.I.H.C. Rule (As per the
protective devices and instruments and the format properties of chemical)
containing the details which reflect the need of particular
installation.
3 Suitable records are kept so that all maintenance schemes As per ISO procedure
are properly monitored
4 All significant deterioration, defect, repairs of SMPV (U) Rule-12
replacement is recorded
5 Vessels are examined at the intervals as required by SMPV (U) Rule-19 & F.A.-31
Factories Act & M.F.R.-65
6 Examinations of pressure vessel include support SMPV (U) Rule-23
structure, holding down arrangement and foundation
7 Examination reports specify: SMPV (U) Rule-19 & F.A.-
a) The maximum safe operating pressure. 31 & M.F.R.-65
b) The minimum safe operating pressure.
c) The minimum safe operating temperature.
d) The maximum permissible load.
e) The date, when it is due (or, Due date) for the next
examination
8 Repairs and modification undertaken are to a standard, SMPV (U) Rule-12
equal to the original design and construction code

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Operational Procedure

S. Inspection Criteria Specified Standard

No.
1 Written operation procedures are prepared, which clearly M.S.I.H.C. Rule & On Site
define the action or the function required of the involved Emergency Plan (Schedule
11)
2 Written operation procedures cover both normal and M.S.I.H.C. Rule 4(2), NSS-
emergency operation and regularly review and modify if RPS
required
3 The procedure is readily available to the people on site M.S.I.H.C. Rule & On Site
including contractors entering or working at the site Emergency Plan (Schedule
11)
4 Written operating procedure includes — SMPV (U) Rule-30
a) The transfer of LPG to or from the installation MHC Manual, ILO
b) The transfer of LPG at other sites when the delivery SMPV (U) Rule-12
tankers operate from the site SMPV (U) Rule-31
c) Permit to work system M.S.I.H.C. Rule 13(4)
d) Plant maintenance and modification
e) Including maintenance of electrical equipment
including the flameproof one
f) Emergency procedures
5 Any deviation from the written procedures should only NSS-RPS
be undertaken with the written authority of the
appropriate responsible person at the site
6 Daily checklist of safety and fire hazard about the NSS-RPS
installation and its accessories pipelines maintained by
the user dept
7 Mock drill for LPG handling M.S.I.H.C. Rule 13(4)

8 Safety audit conducted M.S.I.H.C. Rule 10(4)

Training

S. No. Inspection Criteria Specified Standard

1 Employees concerned with LPG are familiar As per F.A. 41B & M.S.I.H.C. Rule
with its properties and hazards (On Site Emergency Plan)
2 Employees are instructed about normal operation As per F.A. 41B & M.S.I.H.C. Rule
including loading and unloading procedures and (On Site Emergency Plan)
emergency shutdown
3 Training is a continuous commitment and As per F.A.7-A(C) & On Site
includes refresher courses appropriately. Emergency Plan

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 4 Emergency procedures are practised regularly As per F.A. & M.S.I.H.C. Rule
13(4)

Natural Gas – Methane

1. Natural gas (Methane with small quantities of ethane, propane, butane, and pentane) is widely
used as fuel for domestic heating and industrial processes.
2. When natural gas is burned, it produces 45 percent less carbon dioxide than coal, 30 percent
less than oil and 15 percent less than wood
3. It is easily transported through pipelines and costs about the same or slightly less than gasoline.
4. Vehicles converted for the fitment of Compressed Natural Gas (CNG) emit low levels of
toxic—and ozone—forming hydrocarbons.
5. But CNG must be stored under pressure in heavy tanks and the cost of accommodating these
tanks has to be considered.
6. There are significant trade-offs for CNG vehicles with regard to emission, vehicle power,
efficiency and range.
7. However natural gas is already used in some fleet vehicles and appears to have a bright future
as a motor vehicle fuel.
8. Natural gas was found in America in 1626 by French explorers who noticed that the Native
Americans were igniting gases that seeped from Lake Erie. More than 100 years later in 1785,
Britain became the first country to commercialize the use of natural gas, using it to fuel
lighthouses and streetlights

Safety Aspects of Piped Natural Gas Supply for Domestic Use

Natural Gas (NG) is a clean, versatile fuel in most of the major cities catering to domestic and
commercial applications.

1. It is a mixture of hydrocarbons consisting of approximately 80 to 90% methane in gaseous

form. It is colourless, odourless, non-toxic, flammable and lighter than air.
2. Natural gas has the narrowest flammability range in the event of leakage and hence is a safer
fuel in comparison to other competitive domestic fuels. The combustible mixture of NG and
air does not ignite, if the mixture is leaner than 5% and richer than 15% of the air-fuel ratio
required for ignition. Thus it is one of the safest fuels in the world.
3. A large quantity of LPG is stored in liquefied form at high pressure in a cylinder, so that the
fuel can last long over a period of 20 to 30 days with its user. This is a risk that the user takes
in the event of any explosion causing damage to life and property.
4. With piped NG this possibility is remote as the pipeline inside the user’s premises contains
only limited quantity of NG and that too at a much lesser pressure, i.e., 21 mbr. Moreover the
user has the provision to switch off the appliance valve inside the kitchen and the main valve
outside the kitchen premises, which will fully cut off the gas supply.
5. NG is lighter than air as compared to LPG which is heavier than air. This property of NG
minimises the risk of accidents. In the event of leakage it will mix with atmospheric air and
disperse. Whereas LPG, being heavier than air, does get trapped in the enclosures at floor level
and thus remains a potent explosive mixture.

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6. A piped NG connection has an in-built safety system which ensures trapping of the regulator
in case a leak occurs more than the specified range already set.
7. Moreover, NG is non-corrosive, non-carcinogenic and eco-friendly in nature.

Safety Aspects of Compressed Natural Gas for Vehicular Use

Check your cylinder and kit certificate

1. The workshop issues a safety certificate after the kit fitment that the conversion kit has been
in safe and proper manner.
2. The dealer issues a certificate stating the details of cylinder make and number and re-testing
date.

Use only approved CNG kits

1. Use only CNG kits approved by the Automobile Research Association of India (ARAI),
Pune, Vehicle Research and Development (VRDE), Ahmednagar or India Institute of
Petroleum (IIP), Dehradun.
2. Install your CNG kits at a workshop authorised by kit supplier or manufacturer.
3. Install CNG cylinders approved only by Chief Controller of Explosives.
4. CNG cylinders are required to be tested and certified for use after every five years.
Do not try to source the kit components separately

1. Do not make the CNG kit yourself as non-compatibility of components could be unsafe.
2. Usage of spurious cylinders is an offence.
3. Ensure your CNG conversion is authorised by the Regional Transport Authority.

CNG vehicles may be parked, serviced and repaired inside garages provided following
conditions are observed

1. There should be no leaks in the fuel system.

2. These vehicles should not be parked within 6 m of any source of ignition or fire
3. Cylinder shut-off valve and service valves should be closed and CNG fuel in the service line
exhausted by running the engine or depressurising the line in a well-ventilated area.
4. In case of vehicles undergoing repairs involving any hot work (i.e., welding, gas cutting or
any type of heat application to any part) within 1.5 m of the cylinder, the cylinder should be
removed first.
Safety Aspects of Compressed Natural Gas for Vehicular Use

Periodical inspection, testing schedule of CNG equipment and components

1. After initial conversion, the vehicle may have to be brought to the workshop for tuning on gas
after 1,000 to 1,500 km as diaphragms and other parts require this much usage before settling
down.
2. As specified under the law by the Chief Controller of Explosives, the CNG cylinder must be
hydraulically tested and certified by an authorised ‘testing shop’ once in every five years.

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3. In addition, the vehicle user is required to take the vehicle for annual inspection to a ‘CNG
Conversion Workshop’, and obtain a certificate from the workshop that the CNG system,
which has been installed, is satisfactory. It is necessary to produce this certificate at the time
of CNG filling.

Dos and Don’ts

1. In case of an accident, get the vehicle thoroughly checked at an authorised workshop and obtain
a fresh certificate.
2. Don’t smoke or bring any source of flame near any of the components through which CNG is
passing.
3. Don’t park the vehicle in a non-ventilated area.
4. Handle all the valves and parts with due care. Any mishandling may flatten the CNG piping.
5. Do not install an LPG, propane or any other cylinder in the place of CNG cylinder. It is not
only illegal but also unsafe.
6. For emergency handling of any CNG leak, users must be aware of the location and operation
of the cylinder valve, master shut-off valve and the burst disc in the CNG system. (Study the
system and ask your mechanic to educate the user to identify these parts.)

Fire Prevention Safety Audit

Fire Prevention Safety Audit – Fire Equipment

1. Ensure that no storage of material or equipment has been kept or scattered in such a way that
it blocks the access to the following, which should always remain clean, clear and free of all
obstructions:
a) Fire hose cabinet.
b) Fire extinguishers.
c) The standpipe system.
d) The sprinkler system and sprinkler heads. (Nothing should be kept hanging from the
sprinkler system. There must be a minimum of 18 inch clearance under each of the sprinkler
heads.)
e) Fire alarm devices (i.e., pull stations).
f) Fire alarm panel/fire enunciator panel.
2. Are the exit lights operating and positioned properly?
3. Ensure that there is no junk of unnecessary fire equipment in the area, obstructing the passage
to the required equipment.

Fire Prevention Safety Audit – Egress Route

1. Is the corridor, passageway, aisle etc., through which rescue and fire-fighting crew walk or run
in emergency, clean and clear of obstructions? Is the corridor clear of combustible or
flammable materials?
2. Are the fire doors clear of obstructions? Do the fire doors close properly, as and when required?
3. Are the following kept and maintained wide open and clear of obstructions?
a) Exit-doors

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 b) Egress route
c) Staircases
d) Fire-exit-lanes.

Fire Prevention Safety Audit – Fire Hazards and Housekeeping

Fire Hazards

1. Is the flammable storage cupboard being used for flammable storage?

2. Is there a breach in the walls or ceiling?
3. Are there any fire hazards due to electrical wiring? Are there proper outlets installed in areas
where flammable materials or vapours may be present?

Housekeeping

1. Are the areas clean, clear and tidy?

2. Is the storage of flammable and/or combustible materials proper?

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