safetyinmechmaintenance-150925033622-lva1-app6891.pdf

Prepared By
A.Prasad roshan
prasadroshan1982@gmail.com
Prepared By
A.Prasad roshan
prasadroshan1982@gmail.com

What is safety ?
Protecting your self and
others
Safety is the absence of
injury,
Procedures intended to prevent
injury
Freedom from danger, risk, or injury
Safety First, Last and Always

 Clean work area
 Tools would be clean
 Proper tools for opening /closing
 All equipment safety guards installed
 Equipment and power tools properly
grounded
For All Job ,Safety First!

Safety awareness is important on the job
to stay away you from hurting or
killing someone else
Safety awareness
Safety awareness saves lives

0
LOSS
FAILURE
DEFECT
DOUBT
ACCIDENT
BREAKDOWN
Safety is no accident

What is an accident in industrial
establishment ?
The FACTORIES ACT,1948, defines
accident as, "an occurrence (act of something
happening) in an industrial establishment
causing bodily injury to a person which makes
him unfit to resume his duties in the next 48
hours”

 Falling
 Inhaling
 Electrical Contact
 Exposure to Heat or Cold
 Striking Against
 Getting Hit
 Getting Caught in
 Exposure to Fire
Think Safety

 OPERATING WITHOUT AUTHORITY
 FAILURE TO SECURE OR STORE MATERIALS PROPERLY
 FAILURE TO SIGNAL OR ADVISE
 OPERATING AT UNSAFE SPEEDS
 CAUGHT IN OR BETWEEN
 CONTACT WITH
 STRUCK BY
 FALL FROM OR ONTO
 SLIP OR TRIP
 WHAT IF?

9
 Lack of training for personnel
 Hazardous arrangement of tools,
machines, equipment, supplies, etc.
 Improper illumination
 Unsafe ventilation

10
 sources of MOTION
 sources of EXTREME temperatures
 types of chemical exposures
 sources of harmful dust
 sources of light radiation
 sources of falling objects
 sources of sharp objects
 sources or rolling or pinching objects
 layout of workplace and location of co
workers
 any electrical hazards

11
Equipment worn by an
employee that is designed to
prevent injury or illness from
a specific hazard.

It's better to correct an unsafe friend than to bury one

 Eye protection comes in many forms, such as safety glasses,
goggles, face shields, and welding protection.
 Your supervisor will select the proper eye protection for the
hazard, but the most important thing is for you to wear it
when provided.
 Don’t wear old or loose-fitting clothing that can get caught in
moving machinery.
 Wear serviceable leather top shoes. Athletic shoes don’t
offer foot protection
 Be aware that long hair and jewelry can get caught in
moving machinery.
 When handling rough or sharp parts, wear the proper gloves
for your hands.

Neoprene
Polyvinyl
Alcohol
(PVC)
Wire mesh
Polyvinyl
Chloride (PVC)
Nitrile
Natural
Rubber
Leather
Kevlar Welding
Cotton
Anti-vibration

Glove Uses
Cotton Light duty material handling and cleanup work
Leather Equipment handling, general construction, heavy cleanup,
welding, moderately hot or cold material handling
Shock absorbing Operating rotary hammers and other vibrating equipment
Kevlar or Wire mesh Work with sheet metal, glass, or heavy cutting
These gloves Do Not provide puncture protection
Rubber, nitrile,
neoprene, PVC, PVA
and other synthetics
Chemical gloves must be chosen for the specific chemical
being used
Insulated Extreme high and low temperatures
Which Glove is Best?

 Do not use a power tool until you
understand it thoroughly and it has been
demonstrated by the instructor.
 Use guards on power tools
 Always keep fingers away from the moving
cutting edges
 Keep the floor around the work area clean

HAND OPERATED TOOLS
Tools must be
guarded
When you gamble with safety you bet your life

 When using screwdrivers, place the object on a
flat surface or in a Don’t hold it in your
hand!
 Don’t use screwdrivers as chisels or pry bars
 Use the correct size driver for the screw
 Don’t use screwdrivers with chipped tips

 Use safety knives whenever
possible
 Keep knife blades sharp
 Cut away from your body
 Do not use knife blades as
screwdrivers
 Avoid working on the same
object when a co-worker is
using a knife
Safety Knives

 Never use a hammer with a broken, cracked, or
loose handle
 Use the correct hammer for the job
 Don’t strike a hammer face with another hammer

 Use moderate pressure on hack saws to prevent
blade failure
 Spray saw blades lightly with lubricant prior to use
 Keep blades sharp

 When possible use a safety chisel
 Don’t use chisels with mushroomed heads
 Use the correct chisel for the job
 Don’t use chisels as lever open bars
Safety chisel

 Use the correct sized wrench for the job
 Don’t use pliers with worn grooves
 Don’t use pliers over-tight bolts and nuts

 Use high-temperature
gloves to handle hot or
cold parts and
equipment

Never dispose of used razor blades, broken glass, or other
sharp objects in regular trash cans! Keep a metal can
specifically for disposal of sharp objects.

 Disconnect power tools when not in use and before
changing bits, blades, and other accessories
 Wear anti-vibration gloves when using power tools that
vibrate excessively
 Never remove guards!
 Ground power tools unless double insulated
 Don’t wear gloves if they can get caught on
 rotating parts
 Secure work in a or on a bench - Don’t hold it in
your hand!

28
The spindle speed of the machine shall be checked before
mounting of the wheel to be certain that it does not exceed the
maximum operating speed marked on the wheel.
Max RPM

 Unplug or Lockout tools before changing blades
 Keep tools sharp
 Never remove guards
 Use a drill press vise when drilling – Don’t hold
parts with your hands!
Drill press vise

30
Abrasive wheels shall be
used only on machine
provided with safety
guards.
Portable abrasive
wheels

 Don’t wear gloves when operating bench grinders
 Never remove guards!
 Maintain proper clearances on tool rests and tongue guards
 Use vice grips when grinding small parts
Maintain tool rest
within
1/8” of the wheel
Maintain tongue guard
within
¼” of the wheel
Don’t use grinders on aluminum unless the wheel is
specifically intended for use with aluminum!
Bench Grinders

Immediately before mounting, all wheels shall be closely
inspected and sounded by the user
Ring test

 Remove jewelry before
using power tools or
working on machines
No pain know safety

34
“FATAL FACT”
Employee killed when struck in head by a nail fired
from a powder actuated tool. Tool operator was
attempting to anchor a plywood.

35
“FATAL FACT”
Employees performing remodeling operations building a wall.
Operator was attempting to anchor plywood to a 2”x 4” stud. The nail
penetrated the stud and struck the victim. One worker killed when
struck by a nail from a powder-actuated tool.

• Use tag lines
• Wear leather gloves
• Never place your hand on top of the load or between the
load and a fixed object
• Inspect hooks and chain slings before use

 Don’t operate a machine until:
 Receiving proper instruction
 You fully understand how to use it
 You have permission
 Always wear eye protection
 Know and understand all the manufacturers’
safety rules

The best way to prevent back injuries is to develop
habits that reduce the strain placed on the back. There
are some basic things you can do to help.
Avoid Lifting and Bending Whenever You Can!
Place objects up off the floor. If you can set
Something down on a table or other elevated
surface instead of on the floor, do it so you won't
have to reach down to pick it up again.
Raise / lower shelves. The best zone for lifting is
between your shoulders and your waist. Put heavier
objects on shelves at waist level, lighter objects on
lower or higher shelves.

 Take a balanced stance with your feet
about a shoulder-width apart. one foot can
be behind the object and the other next to
it.
 Squat down to lift the object, but keep
your heels off the floor. Get as close to
the object as you can. Keep your back
straight.
 Use your palms (not just your fingers) to
get a secure grip on the load. Make sure
you'll be able to maintain a hold on the
object without switching your grip later.

 Lift gradually (without jerking) using your leg, abdominal and buttock
muscles and keeping the load as close to you as possible. Keep your chin
tucked in so as to keep a relatively straight back and neck line.
 Once you're standing, change directions by
pointing your feet in the direction you want
to go and turning your whole body. Avoid
twisting at your waist while carrying a load.
 By following these lifting guidelines and by
practicing good body/back management,
you can prevent back injuries on the job and
at home.

Don’t forget the most common
causes of back injury
 Bending
 Twisting
 Heavy Lifting
Stay safe, someone at home is waiting for you

Confined Space Entry
Confined Space Entry
Definitions:
The entrant is the person who enters a confined space.
The attendant is the person who stays with the entrant
outside the confined space, and is responsible for assisting
the entrant in exiting the confined space, and calling for
emergency assistance when required.
The safety representative is the qualified person who
evaluates the hazards, prescribes required equipment
and precautions and issues the Confined Space Entry Permit.

CONFINED SPACE ENTRY -
CONFINED SPACE ENTRY -
HAZARDS
HAZARDS
Both animal and plant life
require oxygen to live. One of the
primary hazards of entering
confined spaces is oxygen
deficiency.
When oxygen is present in
concentrations less than 19.5%
the atmosphere is said to be
oxygen deficient.
O2
O2

CONFINED SPACE ENTRY - HAZARDS
Oxygen in concentrations
greater than 23% is too
oxygen rich and can cause
combustible materials to
ignite very quickly.

Oxygen deficiency can be caused by several
processes:
Consumption: oxygen is used up by the person who is in the
confined space and turned into carbon
dioxide.
Displacement: denser materials push the oxygen out of
the occupied space.
Reaction: oxygen is reacted with other materials
to make other compounds.

CONFINED SPACE ENTRY
The entry of a confined space begins with a
Confined Space Entry Permit.
Confined Space Entry Permit
Location and Description of Confined Space:
Reason for Entry:
Permit Issued to (Name of Company/Organization):
Location and Description of Confined Space:
Reason for Entry:
Permit Issued to (Name of Company/Organization):
The permit system requires
that a qualified safety
representative visit the
work location and evaluate
the conditions under which
entry will be made.

Each process hazard to which
the entrant may be exposed,
adjacent operations or processes,
and scheduled activity
are reviewed. For each hazard
identified, countermeasures
are detailed on the Confined
Space Entry Permit.

The safety representative
tests the space for
hazardous concentrations
of known harmful
substances, such as
hydrogen sulfide,
carbon monoxide, and
flammable liquid or gas.
The concentration
of oxygen is measured
at the same time.

If concentrations of
materials are found to
be at harmful levels,
the confined space
must be ventilated to
remove them before
entry.
??
??
??
Fresh Air
Fresh outside
air is blown into
the space to dilute
and remove
contaminants, and
supply oxygen.
Fresh outside
air is blown into
the space to dilute
and remove
contaminants, and
supply oxygen.
O2
O2
O2
O2

Means of emergency rescue
must be readily available
to the confined space
entry attendant for
emergency
extrication of
entrants.

A means must be provided
for both safe normal entry
or exit , and emergency
disconnection. Tripods with hoist,
lifeline, and full body harness
are often used for emergency
extrication. Ladders may be
used for ordinary entry and
exit.

o
Danger
Do not use!
o
Danger
Do not use!
Requirements
Ground Fault Interruption yes no
Lockout of Hazardous
Energy Sources yes no
Requirements
Ground Fault Interruption yes no
Lockout of Hazardous
Energy Sources yes no
Required countermeasures also
include prevention of electrical
shock hazards due to loss of
earth ground for portable tools.
GFCI’s are required for portable
electric tooling.
There may also be a need to
lockout and tag equipment both
in the confined space and on
adjacent equipment and processes.

Entrants must leave the
confined space when the
monitor alarm is activated.
It is the attendant’s
responsibility to see that
the entrant leaves the
space during an alarm.
Entrants must leave the
confined space when the
monitor alarm is activated.
It is the attendant’s
responsibility to see that
the entrant leaves the
space during an alarm.
CO
CO2
O2
Entrants must constantly monitor
the confined space for toxic gases,
oxygen, and combustible gases.
Entrants will be issued a personal
monitor to wear
for this
purpose.

The attendant should
attempt to remove the
entrant from the confined
space using tripods, hoist, and
lifelines.
Attendants are NOT
TO ENTER CONFINED
SPACES.
Only properly equipped
and trained emergency rescue
personnel may enter confined
spaces to make rescues.
The attendant should
attempt to remove the
entrant from the confined
space using tripods, hoist, and
lifelines.
Attendants are NOT
TO ENTER CONFINED
SPACES.
Only properly equipped
and trained emergency rescue
personnel may enter confined
spaces to make rescues.

CONFINED SPACE ENTRY - SUMMARY
CONFINED SPACE ENTRY - SUMMARY
Confined space entry hazards can include:
- the presence of toxic substances
- insufficient oxygen, or too much oxygen
- presence of combustible gases and liquids
- process or equipment related hazards.
- conditions changing from nonhazardous
to hazardous.

11 - 59
 Should be worn
 Also behind hood to prevent severe arc
flash reaching eyes
 Can Absorb more than 99.9%
harmful ultraviolet rays
 Worn by others who work with
welders
 Light in weight, well ventilated, and
comfortable
 Lenses have light tint (Not dark!)
and tented side shields
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
© RobCrandall/The Image Works

11 - 60
 Gloves to protect hands
 Made of leather or some other type of fire-resistant material
 Leather capes, sleeves, shoulder
garments with removable
aprons
 Split-type apron if sitting down
 No place to collect hot particles
 High-top shoes
 Leggings and spats
Department of Labor

 100% cotton or wool
 Thick enough to prevent
injurious ultraviolet rays
from penetrating to skin
 Long sleeves
 Shirts buttoned to neck
 Shirttails tucked
 pants long enough to cover
top of leather boots Miller Electric Mfg. Co.

11 - 62

With out safety shoes , doing plasma
cutting

Safety check list for welding
1) Check that the power source functions correctly,
2) you are familiar with its operation.
3) Ensure that gas cylinders are properly secured,
4). Acetylene and oxygen regulators shall be fitted with
flashback arrestors.
5) Protect cylinders against heat and mechanical damage.
6)The valve opening of the acetylene cylinder shall point
away from other compressed gas cylinders,
7) Hoses shall be in good condition, without leaks or damage,
and with correct color coding for the gas.
8) Use correct hose connectors and hose clamps.
9) Pieces of pipe and twisted wire must never be used
10) Keep your welding equipment well maintained. Never use
defective welding cables.

65
 Inspection
 Frequent
 Daily, monthly
 Hooks, rope, crane operation
 Periodic
 At least annually
 Complete inspection - wear, damage,
deterioration, operation
 slings
 Testing
 Records

66
 Contact with energized power lines
(45% of accidents)
 De-energize overhead lines
 Maintain minimum distance
 10 feet distance for 50 kv
 Over 50 kv, add 4 inches per 10 kv
 Use proximity alarms
 Warn when energized line is near
 “No fatalities” in 25 years, according
to mfg.
 Warning signs
 I-15 construction was a good example
Sigalarm®

67
 Proper outrigger use
 Level
 Fully extended
 Stable base
 Use cribbing to
distribute the load

68
Floor-mounted
jib crane
Floor-mounted
jib crane
Wall-mounted jib crane

 The crane is the most
common type of equipment
which most often contacts
overhead power lines.
 When contact happens, the
rigger or ground worker is
most often electrocuted
(90% of time)

EFCOG Electrical Improvement Project

 Power hoist
 Usually electric
operated
 Tower cranes

Practical Exercise
1. Tuck your thumbs into the palms of your
hands
2. Now tie your shoes
It’s not so easy is it?

 Hand injuries can be associated with working
with machinery or equipment
 The materials being used or the job process
might be hazardous
 Hand tools or powered hand tools may be
faulty or improperly used
Stay safe, someone at home is waiting for you

The most common causes of hand injuries are:
 Carelessness
 Lack of awareness
 dullness
 pay no attention for safety procedures
 interruption

To avoid hand injuries:
 Know the hazards and dangers in the job to be done
 Be aware of pinch points
 Be aware of hot areas
 Be aware of rotating or moving surfaces
 Automated machinery may be controlled by remote
control, or delayed timing devices that cause the machine
to start automatically
 Loose clothing and jewelry may be caught up in moving
machinery
 Never remove machine safeguards or operate machinery
with safeguards removed

77
 Rigging: The hardware
and equipment used to
safely attach a load to a
lifting device
Wire rope

78
 Always use rigging to connect the load to the
hook
 Materials
 Wire rope
 Fabric
 Chain
 Slings
 Straight (regular)
 Choker
 Basket
 Double, triple, etc.

 Know the weight of the load
 Know the center of gravity of the load.
 Make load attachment above the center of gravity of the load.
 Know the rated capacity of slings and hardware.
Rules for Rigging Safety

Sl no DIAMETER OF
SLIG in inch
SWL
1 ¼ 300kg
2 3/8 800kg
3 1/2 1.0ton
4 5/8 2.0ton
5 3/4 3.0ton
6 1 5.0ton
7 1 1/4 8.0ton
SWL of various diameter of
slings

LOAD
L
H
Load ÷ Number of legs) X (L ÷ H) = Load each sling leg
Load each sling leg

Example
Example
Load = 120,000 pounds
Load = 120,000 pounds
4 load legs ÷ 120,000 equals
4 load legs ÷ 120,000 equals
30,000 pounds each leg if
30,000 pounds each leg if
vertical hitch
vertical hitch
Sling legs are 20 feet
Sling legs are 20 feet
Height from top of load to
Height from top of load to
lifting device is 15 feet
lifting device is 15 feet
20 ÷ 15 = 1.33
20 ÷ 15 = 1.33
Load on each leg is 1.33 x
Load on each leg is 1.33 x
30,000 = 40,000 pounds
30,000 = 40,000 pounds
20'
15'
120,000 lb.

Center of Gravity
Center of Gravity
A load is stable when:
A load is stable when:
– The hook is directly above the center of gravity of the
The hook is directly above the center of gravity of the
load
load
Estimate the center of gravity
Estimate the center of gravity
Lift the load just enough to clear the ground
Lift the load just enough to clear the ground
If the hook is not over the center of gravity the hook
If the hook is not over the center of gravity the hook
will travel to the center of gravity
will travel to the center of gravity
CG?

Hooks are designed to apply
the load at the bottom of the
saddle.
LOAD

Shackles and hooks
Manufacturers’ identification
Never weld on hooks or shackles
Working safety latch on hooks
Recommended Not Recommended Recommended
Screw Pin Anchor Shackle
Round Pin Anchor Shackle
Bolt Type Anchor Shackle

Never replace a shackle
pin with a bolt.
The load will bend the
bolt.

Bad Good
Avoid eccentric
loads.
Good
Bad
Proper chocking of
shackles.

Check wear
Check cracks,
bending and
twisting
Check wear and
straightness
Pin always seated
Check opening
width

 Slips and falls injure more people than any
other type of accident.
 Pay attention to hazards such as wet or slippery
floors and old carpet or tile.
 Eliminate hazards when detected.
 Never run at work.
 Use only authorized walkways or passageway,
especially in warehouses or around machinery.
 Always hold onto the handrail when walking
up or down stairs.
 Use fall protection when working in an elevated
area.

 Don’t take chances. If you can’t extinguish the fire
safely, leave the fire fighting to the professionals.
 Learn where fire extinguishers at your facility are
located and make sure you know how to operate
them. If time permits, extinguish the fire safely.
 Know where emergency exists are located and make
sure that they aren’t blocked.
 In the event of a fire, personal safety is the greatest
concern. Activate the nearest pull alarm to alert
everyone else and notify your supervisor.

 Never use electrical tools near water.
 Use Ground Fault Circuit Interrupters (GFCI)
around water source.
 Report damaged switches, plugs, cords,
receptacles, tools and other electrical hazards to
your supervisor immediately.

05/21/99 7
Eliminate confusion
Know proper work practices for chemical
materials you use
Use unbreakable secondary containers
Store chemicals properly
Dispose of waste and excess chemicals in a
timely manner

 Some can be seen
 Some can be smelled
 Some can be tasted
 Most can be felt (e.g. burning
sensation, choking)
 All can be detected by
appropriate instruments
DANGER
TOXIC
CHEMICALS

Can not be seen
Can not be smelled
Can not be tasted
Can not be felt
Can be rapidly detected by
instruments!

05/21/99 28
Know the properties of all the hazardous materials you
handle
Prevent spills
If a potentially hazardous spill occurs, protect people first,
evacuate & ask for help
Call Engineering for EMERGENCY spill/fire assistance
Call Safety for information and non-emergency assistance
You are responsible for reporting or cleaning up spills of
materials you use

Scrap lumber, waste material, and rubbish
Removed from the immediate work area as the work
progresses.
Disposal of waste material or debris by burning
All solvent waste, oily rags, and flammable liquids
Kept in fire resistant covered containers until removed from
worksite
Disposal of waste materials

 If you are injured on the job, you
must report the injury to your
supervisor immediately.
 Even if you don’t need medical
treatment, report all accidents, near
misses and injuries to your
supervisor when they occur.

 Keep your work
area clean & clear
 Notify your inst. if
anything breaks
or malfunctions
 Get first aid
treatment for
every injury

Be About
Be About
job Safety
job Safety
Smart
Thank
you

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