Practical PDIS 102

GNFC-PDIS (102-Safety Engineering-1)
Practical file
PDIS-102-Safety Engineering-1
Name of Student: - Chauhan Rutvikkumar Mahendrabhi

Enrollment Number: - 19304722007.
This is to certify that, Mr. Chauhan Rutvikkumar Mahendrabhai.

(Enrolment Number- 19304722007), completed His Practical work in
Safety Engineering-1(PDIS-102) from GNFC, Bharuch had submitted.
This work has been carried out under my supervision and is to my
satisfaction.
Internal Guide
Shri P S Keshwani Sir
Date :- Sign:-
Post Diploma in Industrial Safety 1

Index
Practical No. Name of Practical Page No. Sign
1 To Study about safety aspect during material handling 3 to 14
2 To study about Illumination & workplace visibility 16 to 24
3 To study about Heat stress with respect to Work 25 to 47

Place Safety
4 To study about fire hazards and their control measures 48 to 59
5 To study about Electrical hazards & Its Safety 60 to 72
6 To study Effective ventilation for safe work place 73 to 77
7 To study about machine guarding 78 to 93
8 To study about Noise and Vibration 94 to 106
9 107 to 115
To study about Plant Safety Layout
10 To study about Good Housekeeping and 5S 116 to 124
11 To Study about safety at work Place 125 to 131
12 To Study about Transportation of Chemicals 133 to 144

Practical No:- 1
Aim: - To Study about safety aspect during material handling.
1. Introduction to Material Handling Equipment (MHE)

Material handling equipment (MHE) is mechanical equipment used for the movement, storage,
control, and protection of materials, goods and products throughout the process of manufacturing,
distribution, consumption, and disposal. The different types of equipment can be classified into four
major categories: transport equipment, positioning equipment, unit load formation equipment, and storage
equipment.
 Material handling is nothing but the loading, moving and unloading of any material
 Material handling is the preparation, placing and positioning of materials to facilitate their
movement or storage
 In many industries, handling of materials, articles, equipment etc. becomes a main source of
accident
Figure 1:-Material Handling Equipment

1.1 Types of Material Handling Equipment’s
1. Manual
Manual Material Handling Equipment can be defined as the human powered and manipulated
equipment that enables the control, protection, storage and movement of materials not only throughout a
company’s value-added processes, but it’s entire supply chain.
To avoid unsafe acts & other hazards like, slipping, falling, striking etc. in manual handling, it is
substituted by more and more powered or mechanical handling. It reduces such hazards and manpower,
and increases productivity

Figure 2: -Manual-Material Handling Equipment
2. Powered or Mechanical
This type of equipment is used to move goods and material from one location to another such as
between a storage area and a loading dock. These include both external and internal machinery.
Internal-these can include a conveyor belt, forklift truck, or hoist that is used to move materials.
This category may travel from an assembly line to a packing or storage room or between production
areas.External-these include shipping containers or commercial trucks, which are used to move goods to
retail outlets and stores.
Figure 3: - Powered or Mechanical -Material Handling Equipment

1.2 Hazards of manual and material handling are due to
Manual Handling Mechanical Handling

Carrying excessive load Wrong selection of equipment
Lifting improperly Design defect
Unsafe gripping or placing Overloading of equipment
Struck by falling or slipping Wrong position of material
Person falling or slipping Working at excessive speed
Unsafe handling of trolleys Lack of space for operation
Failure to use PPEs. Poor maintenance
1.3 Accident can be avoided if safety professionals should study,

 Possibility of eliminating or reducing manual handling or its defects
 Possibility of mechanical handling
 In what ways injury possible?
 Handling hooks, pallet trucks, trolleys – to make the job safer
 Protective equipment or clothing to help prevent injuries
 Need of good training and supervision to workers
2. Legal Requirements
2.1 Manual Handling – As per FA, 1948
Section 34: Excessive weights. –
(1) No person shall be employed in any factory to lift, carry or move any load so heavy as to be likely to
cause him injury.
(2) The State Government may make rules prescribing the maximum weights which may be lifted,
carried or moved by adult men, adult women, adolescents and children employed in factories or in
any class or description of factories or in carrying or any specified process.
2.2 Manual Handling – As per GFR, 1963
Rule Prescribed Under Sub Sec. (2) of Sec.
34
Rule 34. Excessive Weights: -
(1) No woman or young person shall unaided by another person, lift, carry or move by hand or on head,
any material, article, tool or appliance exceeding the maximum limit in weight set out in the
following schedule: -
(2) No woman or young person shall engage, in conjunction with others in lifting, carrying or moving by
hand or on head, any material article, tool or appliance if the weight thereof exceed the lowest weight

fixed by the Schedule to sub-rule(l) for any of the persons engaged, multiplied by the number of the
persons engaged.
Schedule I
Persons Max. weights of goods

Adult female 50 Kilograms
Adolescent male 29.5 Kilograms
Adolescent female 20.4 Kilograms
Male child 15.9 Kilograms
Female child 13.6 Kilograms
2.3 Mechanical Handling – As per FA, 1948

Section 28. Hoists and lifts. –
(1) In every factory-
(a) every hoist and lift shall be-
(i) of good mechanical construction, sound material and adequate strength;
(ii) properly maintained, and shall be thoroughly examined by a competent person at least once
in every period of six months, and register shall be kept containing the prescribed particulars of
very such examination;
(b) every hoist way and lift way shall be sufficiently protected by an enclosure fitted with gates, and
the hoist or lift and every such enclosure shall be so constructed as to prevent any person or thing
from being trapped between any part of the hoist or lift and any fixed structure or moving part;
(c) the maximum safe working load shall be plainly marked on every hoist or lift, and no load
greater than such load shall be carried thereon;
(d) the cage of every hoist or lift used for carrying persons shall be fitted with a gate on each side
from which access is afforded to a landing:
(e) every gate referred to in clause (b) or clause (d) shall be fitted with interlocking or other efficient
device to secure that the gate cannot be opened except when the cage is at the landing and that
the cage cannot be moved unless the gate is closed.
(2) The following additional requirement shall apply to hoists and lifts used for carrying persons and
installed or reconstructed in a factory after the commencement of this Act, namely: -
(a) where the cage is supported by rope or chain, there shall be at least two ropes of chains
separately connected with the cage and balance weight, and each rope or chain with its
attachments shall be capable of carrying the whole weight of the cage together with its maximum
load;
(b) efficient devices shall be provided and maintained capable of supporting the cage together with
its maximum load in the event of breakage of the ropes, chains or attachments; (c) an efficient
automatic device shall be provided and maintained to prevent the cage from over-running.

(3) The Chief Inspector may permit the continued, use of a hoist of lift installed in a factory before the
commencement of this Act which does not fully comply with the provisions of sub-section (1) upon
such/conditions for ensuring safely as he may think fit to impose.
(4) The State Government may, if in respect of any class or description of hoist or lift, it is of opinion
that it would be unreasonable to enforce any requirement of sub-sections (1) and (2), by order direct
that such requirement shall not apply to such class or description of hoist or lift.
[Explanation: For the purposes of this section, no lifting machine or appliance shall be deemed to
be hoist or lift unless it has a platform or cage, the direction or movement of which is restricted by a
guide or guides.
2.4 Mechanical Handling – As per GFR 1963

Rules Prescribed Under Sub-Sec (1) of Sec.28
Rule 58. Exemption of Certain hoist and lifts:-
A register shall be maintained to record particulars of examination of hoists or lifts and shall give
particulars as shown in Form No.9
Rules Prescribed Under Sub-Sec (4) of Sec.28
Rule 59. Exemption of Certain hoists and lifts
In pursuance of the provisions of sub-sec. (4) of sec.28, in respect of any class of description of
hoists or lifts specified in the first column of the following schedule, the requirements of the section 28
specified in the second column of the said schedule and set opposite to that class of description of hoists
or lift shall not apply.
Schedule
Class 1 or description of hoist or lift Requirement II which shall not apply

Hoists or lifts mainly used for raising materials for Sub-sec. (1) (b) in so far as it requires a gate at
charging blast furnaces or lime the bottom landing, sub-sec. (1) (d); sub-sec.
(1)(e)
Hoists not connected with mechanical Power and
Sub-sec. (1) (b) in so far as it requires the hoist
which are not used for carrying persons
way or lift ways enclosure to be so constructed
to prevent any person or thing from being
trapped between any part of the hoist or lift and
any foxed structure: or moving part sub-sec.
2.5 Mechanical Handling – As per FA, 1948

Section 29 Lifting machines, chains, ropes and lifting tackles. –

(1) In any factory the following provisions shall be complied with in respect of every lifting machine
(other than a hoist and lift) and every chain, rope and lifting tackle for the purpose of raising or
lowering persons, goods or materials:—
(a) all parts, including the working gear, whether fixed or movable, of every lifting machine and
every chain, rope or lifting tackle shall be
(i) of good construction, sound material and adequate strength and free from defects;
(ii) properly maintained; and
(iii) thoroughly examined by a competent person at least once in every period of twelve
months, or at such intervals as the Chief Inspector may specify in writing; and a register
shall be kept containing the prescribed particulars of every such examination;
(b) no lifting machine and no chain, rope or lifting tackle shall, except for the purpose of test be
loaded beyond the safe working load which shall be plainly marked thereon together with an
identification mark and duly entered in the prescribed register; and where this is not practicable,
a table showing the safe working loads of every kind and size of lifting machine or chain, rope or
lifting ankle in use shall be displayed in prominent positions on the premises;
(c) while any person is employed or working on or near the wheel track of a travelling crane in any
place where he would be liable to be struck by the crane, effective measures shall be taken to
ensure that the crane does not approach within '[six metres] of that place.
(2) The State Government may make rules in respect of any lifting machine or any chain, rope or lifting
tackle used in factories-
(a) prescribing further requirements to be complied with in addition to those set out in this section;
(b) providing for exemption from compliance with all or any of the requirements of this
section,where in its opinion, such compliance is unnecessary or impracticable.
(3) For the purposes of this section a lifting machine or a chain, rope or lifting tackle shall be deemed to
have been thoroughly examined if a visual examination supplemented, if necessary, by other means
and by the dismantling of parts of the gear, has been carried out as carefully as the conditions permit
in order to arrive at a reliable conclusion as to the safely of the parts examined.
Explanation: In this section. -
(a) "lifting machine" means a crane, crab, winch, teagle, pulley block, gin wheel, transporter or
runway:
(b) "lifting tackle" means any chain sling, rope sling, hook, shackle, swivel, coupling, socket, clamp,
tray or similar appliance, whether fixed or movable, used in connection with the raising or lowering
of persons, or loads by use of lifting machines.
2.6 Mechanical Handling – As per GFR, 1963

Rules Prescribed Under Sub-Section (1) of Section 29
Rule 60. Lifting machines, chains, ropes and lifting tackles: -

(1) No lifting machine and no chain, rope or lifting tackle except a fibre rope or fibre sling shall be taken
in use in any factory, for the first time therein unless it has been tested and all parts have thoroughly
examined by a competent person and certificate of such test and examination specifying the same
working load or loads and signed by the Person making the test and examination has been obtained
and is kept available for inspection.
(2) A register in Form 10 containing the particulars, therein specified shall be kept for every examination
made under sub-rule (1). The register shall be readily available for inspection.
(3) (a) Every jib-crane so constructed that the safe working load may be varied by the raising or lowering
of the jib, shall have attached thereto either an automatic indicator of safe working loads an automatic
jib angle indicator and a table indicating the safe working loads at corresponding indication ofthe jib
or corresponding radii of the load.
(b) A table showing the safe working load of every kind and size of chain, rope or lifting tackle in
use. and in the case of a multiple sling, the safe working loads at different angles of the legs, shall be
posted in the store room or place, where or in which the chains, ropes or lifting tackles are kept in
prominent positions on the premises and no rope, chain or lifting tackle not shown in the table shall
be used in a factory unless in the case of lifting tackle, the safe working load thereof, or in the case of
a multiple ng, the safe working load at different angles of the legs, is plainly marked upon it.
(4) All rails on which a travelling crane moves and every track on which the carriage of a transporter
runway moves, shall be of proper size and adequate strength and have an even running surface. try
such rail or track shall be properly laid and maintained and shall be adequately supported.
(5) All chains and lifting tackle, except a rope sling, shall unless they have been subjected to such other
heat treatment as may be approved by the State Government, be effectively annealed under the
supervision of a competent person at the following intervals, namely: -
i. All chains, slings, range hooks, shackles/and swivels used in connection with molten metal or
molten slag or when they are made on 12.7 millimetres bar or smaller, at least once in every six
months.
ii. All other chains, rings, hooks, shackles, and swivels in general use at least once in everytwelve
months:
Provided that chains and lifting not frequent use shall subject to the approval necessary
andparticular of such annealing shall be entered in a register in Form 10.
(6) Nothing in sub-rule (5) shall apply to the following classes of chains and lifting tackle namely
I. Chains made of malleable cast iron,
II. Plate link chains.
III. Chains, rings, hooks, shackles and swivels made of steel or of any non-ferrous metal.
IV. Pitched chains, working on sprocket or pocketed wheels.
V. Rings, hooks, shackles and swivels permanently attached to pitched chains, pulleys
block or weighing machines.
VI. Hooks and swivels having screw threader parts or ball bearing or other case-hardened
parts.
VII. Socket shackles secured to wire ropes by white metal capping,
VIII. Bordeau connections.

IX. Any chain or lifting tackle which has been subjected to the heat treatment known as
"normalising" instead of annealing. Such chains and lifting tackle shall be thoroughly
examined by a competent person at least once in every twelve months, and particulars
of such examination shall be entered in the register in Form 10
(7) All lifting machines, chains, ropes and lifting tackle except a fibre rope or fibre sling, which have
been lengthened, altered or repaired by welding or otherwise, shall not be used again, unless it is
adequately tested and examined by a competent person and certified in writing by him to be in order.
(8) No person who has not completed eighteen years of age and no adult who is not sufficiently trained
the working of lifting machines and acquainted with the hazards of the machines shall be employed
as a driver of a lifting machine whether driven by mechanical power or otherwise, or to give signals
to a driver.
3. Documents required for MHE (Mechanical)

3.1 Form 9 for Hoists and Lifts
Figure 4: - Form 9
3.2 Form 10 for Lifting Machines, Ropes and Lifting Tackles

Figure 5: - Form 10
4. Past Accident Case Studies

4.1 Case Study 01 – Reportable Incident
Nature of Injury: Crush injury resulted in multiple fractures
Body Parts injured: Hip Joint & Right foot
MHE Name: F13 Farana CRANE
Incident Type: Reportable Incident
Brief Description:
A team of four people were doing movement of one cage

ladder segment 4m long, 150kgs weight by 13ton Farana Crane.
Victim & his colleague were guiding the material using tag rope
tied at both ends of the ladder. Other two people are crane
operator & signal man. Victim was holding the tag rope by being
at rear left of the cage ladder. During that time, Crane operator
looked ahead to give way for the approaching vehicle and
moved the crane
towards left side. Figure 6: - Case Study-1
Inadvertently victim came close to front left side of crane wheels, which crane operator also did not
notice nor given any caution. Suddenly victim got hit by crane & his right ankle got entrapped between

tyres & road. By the time crane operator realized to stop the crane, victim’s right leg was dragged up to
1.8m distance by crane tyres. This resulted in crush injuries & fractures on his right-side hip, thigh and
foot.
Possible Root Causes:
 As the ladder was having 4mtrs length, according to it, the farana boom was not extended while
marching. Due to that victim was stood by holding tag rope at near to the front wheel of the farana.
 Driver didn’t notice that, victim came close to the front wheel of farina which caused the injury.
Good Practice to Avoid Such Incidents:
 Marching of Farana with long and heavy materials shall be limited upto 50 mtrs radius in materials
yard and work locations.
 Tractor trolley shall be used for shifting of such materials from material yard to work locations.
4.2 Case Study 02 – First-Aid Case

Nature of Injury: Swelling with pain
Body Parts injured: Left Foot Ankle
MHE Name: Long platform trolley
Incident Type: First-Aid Case
Brief Description:
A victim and his co-worker were transferring the

materials from one place to another with the help of long
platform trolley. Victim was pulling the trolley from front side
and his co-worker was pushing it from behind. Suddenly
victim was stopped from front, which his co-worker didn’t
notice and keep pushing the trolley from behind. During that
course of time, victim’s left foot ankle got trapped between
the trolley frame and road which resulted in a swelling with
pain on his
LH foot ankle. Figure 7: - Case Study-2
Possible Root Cause:
 Trolley was handled by two people at a time – Unsafe Act
 Boxes were stacked in such way that, vision of co-worker was blocked while handling it.
 Miss communication
 Victim was pulling the trolley being at frontside, while his co-worker was pushing the trolley being at
rear side.
Good Practice to Avoid Such Incidents:

 Never pull a trolley while being at frontside
 It is better and safer to push than pull the trolley

 Never overload the trolley
5. Safe Operation of MHE

5.1 Steps for safe lifting –
 One dominant foot ahead of the other in
the direction of the movement
 Grasp the load from the palm not from the
root of the finger
 Keep back straight, no need to keep
vertical
 Keep the load close to the body, not away
from the body
 Start lifting with the thrust of the rear foot,
keeping the load close to your body as
you lift with your legs, not with your back
 Keep the head in correct position. It is
also necessary to keep the CG of the
load as
near as possible Figure 8- Safe Lifting Techniques
5.2 Steps for safe handling –

 Cover potholes and make it even to prevent trolley from
toppling
 Provide rubber tyres on wheels to minimize noise and
damage to flooring
 Load should be evenly distributed to prevent tilting
 Don’t overload the trolley
 Height of materials should not obstruct your vision
 Secure load on trolleys with ropes, whenever necessary
 Always try to push the trolley instead of pull it
 Handle should be held at the front, not on the sides to avoid
knuckle injuries
 Pathway should be clearly marked
 Park the trolleys in such a way that, they don’t obstruct
passageways Figure 9- Safe Handling of Trolley
5.3 Manual Handling – General Do’s & Don’ts

Figure 10: -Manual Handling – General Do’s & Don’ts
5.4 Mechanical Handling – Hoist
Figure 11: - Mechanical Handling – Hoist

Practical No: - 2
Aim: - To study about Illumination & workplace visibility.
Objective of study
● To understand the importance of proper illumination from a human factor point of
view. To know about proper ambient lighting for areas where people work to provide
safety and prevent accidents.
● Light energy consumption contributes 20 to 45 % in commercial buildings and about
3 to 10 % in industrial plants. Hence, to increase awareness of energy saving in
lighting systems realized with minimal investment cost.
● It may be necessary to consider modification of the lighting design in order to achieve
the desired energy saving.
● To try to produce light sources with higher luminous efficacies, better color rendering
properties and longer life expectancies.
● Hence three primary considerations to ensure lighting systems and energy efficiency.
● Establish adequate light levels to maintain productivity, improve security and increase
safety.
● Matching the proper lamp type to the intended to work consistent with color ,
brightness control and other requirements.
● Selection of a more efficient light source possible in order to minimize the power cost
and energy consumption.
Illumination definitions
● For a rational or an adequate lighting, the quantity and quality of illumination, both
are essential. Some basic concepts, units and symbols are as follows:
A. Luminarie is a complete lighting unit including the lamp, globe, reflector, housing
and support that is integral with the housing.
B. Luminous (or light) flux is the quantity of light emitted per second by a light
source. It is the radiant power or luminous flux i.e. rate of propagation of radiant
energy evaluated by the eye. Its unit is lumen (lm) and the symbol F.
C. Luminous Intensity is the luminous flux emitted per unit of solid angle in a given
direction. Its unit is candela (cd) and the symbol l.
l = F/w, where w is the solid angle.
D. Illumination is the luminous flux that strikes a unit area. The area - the work plane
- is where the most important tasks in the room or space are performed. Its unit is
lux (lx) which is symbol E.
Illuminance can be expressed as

E = F/A = lm / m2
Where, E = Illumination or light intensity (lm/m2, lux)
F = luminous flux (lumen, lm)
A = area (m2)
● When calculating artificial illumination of industrial premises, the concept of mean

illumination usually applies to a horizontal plane 0.8 m above the floor level, also
known as the workplace plane.
● Measuring Units Light Level - Illuminance
● Illuminance is measured in lux in the metric SI system or foot candles (ftcd) in the
imperial system.
1 lux = 1 lumen / m2
= 1 lumen / (3.28084)2 ft2
= 0.092 lumen / ft2
= 0.092 foot candle or ftcd
1 foot candle (ftcd, fcd) = 1 lumen / ft2

= 1 lumen / (0.3048)2
m2
= 10.76 lumen / m2
= 10.76 lux
E. Luminance (Brightness) is the luminous flux (directly seen by the eye) reflected
by a surface in a given direction. Its unit is candela / m2 and the symbol L.
L = l r / s,
where, r is the reflection factor or coefficient of reflection
r = Fref / Ffal
where, Fref = luminous flux reflected from a surface
Ffal = luminous flux falling on that surface
● Background is the surrounding surface, real or artificial, against which the object can
be visualized. The background is said to be light if the reflection factor is greater than
0.4, semi-dark if it is 0.4-0.2 and dark if less than 0.2.

F. Contrast is the relative luminance between an object and its background and its
symbol is C.
Where the background has a luminance L2 and the object a luminance
L1 (L1>L2), it can be expressed as C = (L1-L2)/L(average).
Contrast is a dimensionless magnitude ranging between 0 and 1. It may be
high, soft or low.
Here, (B) to (E) are quantitative and (F) & (G) are qualitative indices of
illumination.
General principles of good lighting
General Principles or requirements of good lighting are as follows:
1. Adequate illumination.
2. Avoidance of glare.
3. Avoidance of shadow.
4. Uniform lighting.
5. Appropriate contrast.
6. Appropriate color contrast.
7. Color effect
8. Avoidance of flicker and stroboscopic effect.
1. Adequate Illumination:
• Good illumination needs sufficient quantity of illumination necessary for avoiding

discomfort to the worker and undue strain on eyes- Its requirement varies from place to
place, person to person and with the age of person also.
• For example, for very fine work like distinguishing black thread on black cloth, intensity
of 2000 lux is required but for exit road, car parking, storage area 20 lux is required. 65%
of the subjects of one study judged intensity between 10 to 30 foot-candles or 100 to 300
lux, the most comfortable for reading.
• The quality of illumination depends on three factors - diffusion, distribution and color value.
•
2. Avoidance of glare:

● Glare is the condition in which brightness or the contrast of brightness interferes with
vision. Glare is produced by excessive light.
● It can be considered at three levels. (types)
(1) Direct or disability glare:
Direct or disability glare comes directly from the light source to the eye and
impairs the ability to see clearly. This is due to excessive light focused on the eye
and scattering of light inside the eye.
(2) Discomfort glare:
Discomfort glare is due to liberal (less) or bright (more) light. It causes
visual discomfort without necessarily impairing the ability to see and may
occur from unscreened windows in bright sunlight or when over-bright or
unshaded lamps in the workroom are too strong in brightness for the workroom
environment.
(3) Indirect or reflected glare:
Reflected glare is glare that comes to the eyes as a glint (flash) or reflection of
the light source from some polished or shining surface. It is caused by a mirror
image of the bright light sources reflected from shiny or wet workplaces such as
glass or plated metal. These reflections distract or distort attention, make important
detail difficult to see and reduce contrast or cause acute discomfort.
3. Avoidance of shadow:
● Shadow affects the amount of illumination and is caused not by poor lighting but - by
fixing light sources too wide apart or in wrong positions so that light is obstructed by
some object.
● Light (faint) shadow may be allowed but dark (dense) shadow that conceals hazard or
indicates wrong thing is not desirable, as it may cause an accident.
● Shadow on the staircase, near the door for entry or exit, near the tool rack or on the
work (job) table is not at all desirable and must be removed by providing extra or
local light or shifting the light source or the object causing shadow.
4. Uniform lighting:
● The human eye can clearly perceive differences in luminance of over 50%. It takes
time to adopt sudden variation in the intensity of lighting, particularly from higher to
lower intensity.
● Uniform distribution of lighting is desirable. Distribution of light requires two
problems to solve

(1) uniformity of illumination

(2) elimination of shadows.
● In uniform lighting, the distribution of light with a maximum and minimum
illumination at any point should not be more than one-sixth above or below the
average level in the area. Indirect lighting is the best method for producing uniform
illumination.
● Here all the usable light is reflected light, high points of light from the bulb striking
the eye directly are out of the visual field. The disadvantage of indirect light is its
cost, since considerable light is lost through absorption. However, its benefit is worth
more than its extra cost.
5. Appropriate contrast:
● The ability to see detail depends upon the contrast between the detail and its
background. The greater the contrast, difference in luminance, the more readily the
seeing task is performed.
● The contrast recognises the object easily and increases visual performance. If the
difference between the object (job or seeing task) and its background is not
noticeable, it is difficult to work. A black machine in black background (darkness) is
difficult to notice. There should be a minimum contrast between the visual target
detail and its background.
6. Appropriate color contrast:

● It refers to the appearance of coloured objects when illuminated by a particular
light source. It is the property of light which facilitates the perception of
surface colors and depends on the spectral composition of the light.
● For example, a red surface will appear red only if the light falling on it
contains red, but it will appear brown under the yellow of sodium street
lighting.
7. Color effect:
It refers to the appearance of coloured objects when illuminated by a particular light
source. It is the property of light which facilitates the perception of surface colors and
depends on the spectral composition of the light. For example, a red surface will
appear red only if the light falling on it contains red, but it will appear brown under
the yellow of sodium street lighting.

8. Avoidance of flicker and stroboscopic effect:

All lamps working on alternating current give light which pulsates at twice the supply
frequency. This type of discontinuous light of almost all frequencies can effect, in
which a rotating or reciprocating object can appear to be stationary, or moving slowly,
or even appear to be rotating in the opposite direction etc. This false belief can cause
accidents in the industrial situation. It is a real hazard in the presence of moving
machinery.
Types of lighting, sources

Types of lighting as follow
1. Day, natural or general lighting
In our country natural sunlight available during most of the days is called
daylight or day lighting. Its varying intensity from sunrise to sunset provides
harmonious variation of the visual environment inside or outside a building and is
normally welcomed for the visual task. It is the cheapest light and should be
effectively utilized by proper design of roof, doors, windows and ventilators.
2. Artificial lighting
During night time i.e. in the absence of daylight, artificial light is the only
remedy. Even during day time where the day lighting is insufficient to provide
prescribed illumination due to any obstruction or weather effect, it will be necessary
to supplement the natural lighting by artificial lighting designed to operate
permanently during day time.
Natural Lighting Artificial Lighting

3. Direct and indirect lighting:
● Direct Lighting means light falling on objects directly from source – natural or
artificial. Thus direct light from the Sun or electric tube on the job or book is called
direct lighting. Its first reflection is to the eye, therefore, it should not be excessive,
otherwise it may cause reflected glare or eye strain.
● Indirect lighting is reflected or diffused light coming after reflection of light from
some surface or coining through some transparent surface. Its benefit is to avoid
direct glare and to make the light of comfortable brightness.
● Semi-direct or semi indirect light is a combination of direct and indirect light. Direct
light from a window and simultaneously reflected light from a lamp is of this type of
light. Where direct or indirect light is insufficient, lighting level is increased by this
type of combination.

Legal requirements
The Factories Act, 1948

Section 17, Lighting
1. In every part of a factory where workers are working or passing there shall be
provided and maintained sufficient and suitable lighting, natural or artificial, or both.
2. In every factory all glazed windows and skylights used for the lighting of the
workrooms shall be kept clean on both the inner and outer surfaces and, so far as
compliance with the provisions of any rules made under sub-section (3) of section 13
will allow, free from obstruction.
3. In every factory effective provision shall, so far as is practicable, be made for the
prevention of
(a) glare, either directly from a source of light or by reflection from
a smooth or polished surface;
(b) the formation of shadows to such an extent as to cause eye-strain or
the risk of accident to any worker.
4. The State Government may prescribe standards of sufficient and suitable lighting for
factories or for any class or description of factories or for any manufacturing process.
Gujarat factories rules, 1963
Rules 30 to 34 Prescribed Under Sub-sec. (4) of Sec. 17
● 30. Lighting-Application and commencement:
● Subject as in these Rules provided Rules 30 to 34 shall apply to factories in
which persons are being regularly employed in a manufacturing process or
processes for more than 48 hours a week, or in shifts provided that nothing in
these rules shall be deemed to require the provision of lighting of a specified
standard in any building or structure so constructed that, in the opinion of the
Chief Inspector, it would not be reasonably practicable to comply with such
requirement.
● Rules 30 to 34 shall come into force, in respect of class or description of
factories, on such dates as the State Government may, by notification in the
Official Gazette, appoint on this behalf.
31. Lighting of interior parts:
1. The general Illumination over those inter parts of a factory where persons are
regularly employed shall be not less than 30 meters candles measured in the
horizontal place at a level of 91.4 centimetres above the floor:
Provided that in any such parts in which the mounting height of the light source of
general illumination necessarily exceeds 7.6 meters measured from the floor or where
the structure of the room or the position or construction of the fixed machinery or
plant prevents the uniform attainment of this standard, the general illumination at the
said level shall be not less than 10 meters candle and where work is actually being
done the illumination shall be not than 30 meters candles.
2. The illumination over all other interior parts of the factory over which persons
employed pass shall, when and where a person is passing, be not less than 5 meters
candles at floor level.

31. Lighting of interior parts:-

3. Artificial lighting in accordance with the following standards shall be provided
and used in the interior of cotton ginning factories at time when artificial lighting
necessary and is ordinarily used :
(i) by means of electricity, to the satisfaction of the inspector, one
lamp per six gins, each lamp of not less than twenty-five candles power;
(ii) by candles placed in glass lanterns of pattern approved by the
Inspector, not less than one such lantern for every two gins.
4. The standard specified in this Rule shall be without prejudice to the provisions of any
additional illumination required to render the lighting sufficient and suitable for the
nature of the work.
32. Prevention of glare:

1. Where any source of artificial light in the factory is less than 4.9 meters above floor
level, no part of the light source or of the lighting fitting having a brightness greater
than 1.5 candles per square centimeter shall be visible to persons whilst normally
employed within 30.48 meters of the source, except where the angle of elevation from
the eye of the source or part of the fitting as the case may be exceeds 20°.
2. Any local light, that is to say, an artificial light designed to illuminate particularly the
area or part of the area of work of a single operative or small group of operatives
working near each other shall be provided with a suitable shade of opaque material to
prevent glare or with other effective means by which the light source is completely
screened from the eyes of every person employed at the normal working place, or
shall be so placed that no such person is exposed to glare therefrom.
33. Power of Chief Inspector to exempt:

● Where the Chief inspector is satisfied in respect of any particular factory or part thereof
or in respect of any description of workroom or process that any requirements of Rules 30
to 32 is inappropriate or is not reasonably practicable, he may by order in writing exempt
the factory or part thereof or description of workroom or process from such requirement
to such extent and subject to such condition as he may specify.
34. Exemption from Rule 31:

1. Nothing in Rule 31 shall apply to the parts of factories specified in Part I of the Schedule
annexed hereto.
2. Nothing in sub-rule (1) of Rule 31, shall apply to the factories or parts of factories
respectively specified in Part II of the said Schedule.
Schedule
Part I
Parts of factories in which light sensitive photographic materials are made or used in an
exposed condition or where such exposing operations are carried on.

Part II
Cement works, Works for the crushing and grading of limestone, Gas Work, Coke Oven
Works, Electrical stations, Flour Mills, Maltings and Breweries.
Parts of factories in which the following processes are carried on:
Concrete or artificial stone making, Conversion of iron into steel, Smelting of iron ore, Iron
or steel rolling, Hot rolling or forging, tempering or annealing of metals, Glass blowing and
other working in molten glass, Tar distilling, Petroleum refining and blending.
Case Study 01
Case Study 02

Case Study 03
Case Study 04

PRACTICAL NO : 3
Aim: To study about Heat stress with respect to Work Place Safety
HEAT STRESS: Human body cannot tolerate excessive temperature. Heat stresses produced
by very hot or cold exposures cause adverse effects on health and safety of work people.
Therefore, environmental temperature control is also permanently needed for well-
functioning of human body. Ventilation helps in removing excessive temperature.
Heavy physical work or heavy work load causes heat stress and strain and increase metabolic
heat, body temperature, sweating, heart rate etc. To maintain (control) body temperature,
ventilation is necessary.
PHYSIOLOGY OF HEAT REGULATION
Heat effects on human body and their control measures are mentioned below.
Heat Stress and Thermo Regulation:
There are two types of animals - Poikilotherms whose body temperature equals the
environmental temperature and Homeotherms whose body temperature fluctuates within a
small range to maintain the temperature stability for metabolic functions. Human body
maintains the temperature @ 36 to 39.5° C (96.8 to 103.1" F). To maintain this small range of
thermal stability against too high or too low environmental temperatures, the homeotherms
(which includes us) have to undergo some stresses which adversely affect performance and
efficiency.
Heat Stress is the burden or load of heat that must be dissipated if the body is to remain in
thermal equilibrium and is represented by the sum of metabolic heat (physical work) and
environmental heat load.
The environmental factors are governed by the air temperature, humidity, air movement and
the temperature of surrounding (radiant heat exchange)
Human body exposed to Sun a main source of heat

Sources of heat - Solar radiation and -hot processes

Physical work contributes to the total heat stress of the job by producing metabolic heat in the
body in proportion to the intensity of the work.
Clothing affects the heat stress. Cotton clothing is most comfortable as it soon absorbs
sweating and dissipates heat. Synthetic clothing, though looks good, adds to sweating and
increases heat stress.
Heat Stress of any given work environment is considered as the combination of both climatic
and non-climatic factors leading to heat gain by the body by convection and radiation and/or
limiting heat dissipation from the body.
Climatic factors are: air temperature, humidity, radiant temperature and air movement.
Non-climatic (personal) factors are: metabolic workload (degree of physical work), clothing,
age, sex, body build, acclimatization, physical fitness and ethnic differences.
Heat Strain is the physiological or pathological change (response) resulting from heat stress
viz. rise in body temperature, sweating, heart rate etc. The severity of strain depends on
prevailing stress, age, physical fitness, degree of acclimatization and dehydration of the
worker. When the strain becomes excessive, discomfort or distress is felt.
THERMAL ENVIRONMENT AND ITS MEASUREMENTS
Before controlling temperature, humidity and air movement it is necessary to measure their
adequacy. Subsequent measurement is also necessary for the, satisfaction that whether they
are properly controlled or not. Some methods and equipment are explained below for this
purpose.
Temperature Measurement:
The mean radiant temperature of the surroundings is calculated (not measured) from the
values of dry bulb air temperature, the glob temperature and the air velocity.
Thermometers placed at the height 1.5 m above floor level and not within I’m from any
heating device are used to measure the air temperature. For precise measurement and
recording of temperature, thermographs are used. Recording period may be as per
requirement.

The Glob thermometer is a black-painted (mat), hollow copper sphere, 15 cm in diameter,

into which a thermometer is inserted. It therefore measures temperatures which include
radiant heat effects. It is preferable to a dry-bulb thermometer. Rule 18A(1) of the
Gujarat Factories Rules 1963 provides for a glob thermometer of 15 cm diameter to be kept
in the environment for not less than 20 minutes and consideration of the temperature recorded
by it, if it exceeds the dry-bulb temperature of the air.
The glob is suspended at the point of measurement, about 1.2 m above the ground, not
contacting any solid. Thus, the globe gains heat by radiation and loses by convection (not
conduction). When thermal
equilibrium is reached (by @25 minutes)/ the reading in the thermometer gives the globe
temperature tg.
Wet Bulb Globe Temperature (WBGT) : It embraces in a single value the effect of
radiation, ambient air temperature and humidity. It is the weighted value of the wet and dry
bulb temperature and globe thermometer readings, calculated using temperature
measurements alone thereby eliminating the need to measure air velocity.
Humidity Measurement:
Psychrometers or wet and dry bulb hygrometers are used to measure relative humidity of the
air. Hydro-graphs are used for continuous recording of the air humidity where the humidity
requirements are most stringent. The two temperatures of dry and wet bulbs are used with a
psychometric table or chart to determine relative and absolute humidity, dew point and other
conditions of an air-water mixture. The direct dial hygrometers are also available.
A whirling hygrometer (sling Psychrometers) is used to assess the ambient air temperature
and humidity. The dry and wet bulb assembly is rotated at 60 rpm till the readings become
steady. The reading of the dry bulb gives the ambient temperature while drop between dry
and wet bulb temperature is an indication of relative humidity by using a psychometric
chart.
STATUTORY PROVISIONS
Central Government Act
Section 13 in The Factories Act, 1948
Ventilation and temperature.—
(1) Effective and suitable provision shall be made in ever factory for securing and
maintaining in every workroom—
(a) adequate ventilation by the circulation of fresh air, and
(b) such a temperature as will secure to workers therein reasonable conditions of comfort and
prevent injury to health; and in particular,—
(i) walls and roofs shall be of such material and so designed that such temperature shall not
be exceeded but kept as low as practicable;
(ii) where the nature of the work carried on in the factory involves, or is likely to involve the
production of excessively high temperatures, such adequate measures as are practicable shall

be taken to protect the workers therefrom, by separating the process which produces such
temperatures from the workroom, by insulating the hot parts or by other effective means.
The State Government may prescribe a standard of adequate ventilation and reasonable
temperature for any factory or class or description of factories or parts thereof and direct that
1[proper measuring instruments, at such places and in such position as may be specified, shall
be provided and such records, as may be prescribed, shall be maintained].
2[(3) If it appears to the Chief Inspector that excessively high temperatures in any factory
can be reduced by the adoption of suitable measures, he may, without prejudice to the rules
made under sub-section (2), serve on the occupier, an order in writing specifying the
measures which, in his opinion, should be adopted, and requiring them to be carried out
before a specified date.]
Heat Index :
The Heat Index is a measure of how hot it really feels when relative humidity is factored in
with the actual air temperature. To find the Heat Index temperature, look at the Heat Index
Chart below or check our Heat Index Calculator. As an example, if the air temperature is
96°F and the relative humidity is 65%, the heat index--how hot it feels--is 121°F. The red
area without numbers indicates extreme danger. The National Weather Service will initiate
alert procedures when the Heat Index is expected to exceed 105°-110°F (depending on local
climate) for at least 2 consecutive days.
NWS also offers a Heat Index chart for areas with high heat but low relative humidity. Since
heat index values were devised for shady, light wind conditions, exposure to full sunshine can
increase heat index values by up to 15°F. Also, strong winds, particularly with very hot, dry
air, can be extremely hazardous.
Heat is a natural hazard, and much is known about the effects of high temperatures on the
human body.

The Effects of Heat on the Body

Healthy adult persons have efficient heat regulatory mechanisms, which cope with increases
in temperature up to a particular threshold. The body can increase radiant, convective, and
evaporative heat loss by vasodilatation and perspiration. High temperatures cause the clinical
syndromes of heat stroke, heat exhaustion, heat syncope, and heat cramps. Severe heat stroke
occurs when the core body temperature exceeds 103°F and leads to multiple organ
dysfunction. Heat stroke has a substantial case-mortality ratio, and progression to death can
be very rapid (within hours). In survivors, the permanent damage to organ systems can cause
severe functional impairment and increase the risk of early mortality.
Everyone should take special precautions to avoid heat‐related illness in unusually hot
weather when working outdoors or in unconditioned indoor environments. People suffer
heat‐related illness when their bodies are unable to regulate internal body temperature. In
hot weather, the body normally cools itself by sweating. Under some conditions, however,
sweating isn’t enough. Such conditions include high humidity, where air movement is
limited, working in the direct sun, heavy physical exertion and poor physical condition.
Some medical conditions and medications can also reduce the body’s ability to tolerate
heat. Still, heat‐related illness is preventable by following these guidelines when working
outdoors in hot weather:
 Drink small amounts of cool water frequently, regardless of your activity level.
Drink throughout the day.
 Replace salt and minerals. A sports beverage can replace the salt and minerals you
lose in sweat.
 Wear appropriate clothing. Choose lightweight, light‐colored, loose‐fitting
clothing.
 Protect yourself from the sun by wearing a wide‐brimmed hat. (Sunglasses and
sunscreen—SPF 30 or higher—are also recommended.)
 Schedule outdoor work carefully. If outdoor work must be done in hot weather, try
to limit it to morning hours. Limit sun exposure during mid‐day hours. Consider
rotating outdoor work schedules among your co‐workers.
 Pace yourself. Start slowly and pick up the pace gradually.
 Monitor yourself for the signs and symptoms of heat‐related illness, listed below.
 Take time to cool down. Rest often in shady areas. A few hours in air conditioning
can help you stay cooler later in the heat.
 Use a buddy system. When working in the heat, monitor the condition of your co-
workers and have someone do the same for you.
 Monitor those at high risk. Some people are at greater risk than others, including
people who are overweight, people who overexert themselves, and people with
heart disease or high blood pressure, or who take certain medications.
 Take time to acclimate to heat and humidity. A heat wave is stressful to your body.
You will have a greater tolerance for heat if you limit physical activity until you
become accustomed to it.
Signs and symptoms of heat‐related illness include headache, dizziness, light headedness,
fainting, weakness, mood change, mental confusion, upset stomach or vomiting. One
experiencing the above symptoms should be taken to the Hospitals emergency room as
soon as possible.

Departments with employees who normally work outdoors or in unconditioned indoor

environments need to address heat stress in their Hazards Management Plan by including
written safe job procedures appropriate to their work. Supervisors are to provide heat stress
training for these employees.
Beat the Heat: Three Simple Steps
Heat illness can be prevented through the steps of water, rest, and shade.
Water
Drink plenty of fluids throughout the day. Don’t wait until you’re thirsty to drink water.
A good rule of thumb is to drink four cups of water every hour. It is best to drink a small
amount of water every 15 minutes.
Caffeine and alcohol are diuretics; they strip the body of fluids. If you drink coffee in the
morning and/or alcohol last night you MUST replenish the body with lots of fluids. You
need to drink several glasses of water before starting your day.
Rest
Rest breaks help your body recover.
Shade
Resting in the shade or in air-conditioning helps you cool down.
While you are waiting for help…
You can help a co-worker in distress while you are waiting for help to arrive:
 Move the worker to a cool, shady area.

 Loosen the person’s clothing.
 Fan air on the worker.
 Apply cool water or ice packs to his or her skin.
These simple steps could save a person’s life.
More Steps to Reduce Risk
Here are some other ways to prevent illness from the heat:
 Report symptoms of heat illness right away.

 Wear light-colored cotton clothing.
 Wear a hat.
 Wear sunscreen to prevent sunburn.
 Watch out for your coworkers.
 Know where you are working in case you need to call 911.
Heat-Related Illness: Know the Signs

It is important to know the signs of heat-related illness. Acting quickly can save lives.
 Heat stroke is the most serious heat-related illness. Usually, when your body builds
up heat, you sweat to get rid of the extra heat. With heat stroke, your body can’t

cool down. The symptoms include: confusion, fainting, seizures, very high body
temperature and hot, dry skin or profuse sweating.
 Heat exhaustion happens when your body loses too much water and salt through
sweating. Symptoms may include headache, nausea, dizziness, weakness, thirst and
heavy
sweating.
 Heat fatigue, heat cramps, and heat rash are less serious, but they are still signing
of over exposure to heat.
If you feel any of the symptoms of heat-related illness, or you see a coworker in distress,
tell your supervisor right away.
Suggested Measures to Prevent Heat Stress:
There are many steps that can be taken to prevent heat stress. Some of these steps can be
taken by the employee, while other preventive measures can be implemented by
supervisors and departments. Work environments can be changed to reduce the risk of heat
stress. Every situation is different. The best combination of ways to prevent heat stress
depends on the particular work being done, the environment in which it must be done and
the employees doing the work. Consider the following suggestions below to find the best
combination of ways to prevent heat stress for your situation.
Preventive Measures Supervisors Can Take
As explained in the Heat Stress Policy, departments and supervisors with employees who
normally work outdoors or in unconditioned indoor environments need to address heat
stress in their Hazards Management Plan (HMP) by including written safe job procedures
(i.e., preventive measures) appropriate to their work and the situation. Preventive measures
selected for inclusion in the HMP Job Safety Analysis are at the discretion of the
employee’s supervisor and department. Preventive measures that can be implanted by a
supervisor are also called administrative controls or work strategy controls.
Administrative controls are strategies using managerial involvement to limit exposure to
a particular hazard. In the case of heat stress, administrative controls limit the amount of
time an employee is actually exposed to elevated temperatures. Administrative controls
can be changes to how the job is performed, or work schedule changes to when the job is
performed.
Rest and Cool Down Breaks
Consider changes to your break practices to lower the risk of heat stress. Possible changes
during heat-stressed conditions include:
 Encourage employees to take breaks and hydrate any time they feel necessary.
 Pace the job to allow more frequent breaks for fluid intake and sufficient recovery
time.
 Take a break in a shaded area or an air conditioned building.
Work Schedule Changes

Consider changes to your work to lower the risk of heat stress. Possible changes include:

 When feasible, departments can schedule routine maintenance and repair work,
which exposes employees to heat-stressed conditions, until cooler periods of the
day or cooler seasons. Limit sun exposure during mid-day hours.
 If a job is essential for continuing university operations, consider implementing a
worker rotation schedule every hour or sooner. Allow sufficient recovery time for
each worker.
 Implement summer work schedules (e.g., 6:00 a.m. to 2:00 p.m.).
 Permit heavy work only from 7:00 a.m. to 9:00 a.m. or earlier.
 Complete all other moderate to light work before 12:00 noon.
 If extensive PPE is required, then those jobs should be scheduled for the cooler part
of the day (i.e., early mornings).
Other Preventive Measures in the Work Environment

Engineering controls are physical changes made to the environment. To minimize the risk
of heat-related disorders, consider these steps:
 Open windows and add fans to increase air movement in order to provide air
cooling and ventilation of heat.
 Shield radiant heat sources or local exhaust at the point of heat generation.
 Provide shaded areas during remote outdoor work (e.g., constructing temporary
shelters using tarps)
 Equip tractors, lawnmowers, and other outdoor equipment with cabs or canopies.
Health and Safety Problems in Hot and Cold Environment:

Problems in Hot Environment:
Types of health disorders caused by exposures to high heat are as under :
1. Skin disorders - prickly heat, skin cancer.
2. Systemic disorders - heat stroke, heat exhaustion, heat cramp, water deficiency, salt
deficiency.
3. Psycho neurotic disorders - mild chronic heat fatigue, acute loss of emotional control.
These disorders can cause following effects

1. Heat or sun stroke due to excessive rise in core (body) temperature 'resulting from failure
of thermo regulatory mechanism.
2. Heat Exhaustion due to loss of body fluid (with salt) in sweating.
3. Heat or muscle cramps due to profuse sweating and salt loss, drinking much water and
failure to replace body's salt loss.
4. Fainting due to more blood in the skin and lower part of the body, less return to the heart
for pumping to the brain
5. Heat Rush or Prickly Heat likely to occur in hot and humid environment where sweat is not
easily removed from the skin surface and sweat glands plugged.
6. Transient heat fatigue due to prolonged heat exposure.
Safety Problems are : Accidents due to sweating palms, dizziness, forging of safety glasses,
contact with hot surface, molten metal, steam etc., and physical discomfort and fatigue.
Other safety problems due to increased temperatures are:

1. Increase in corrosion rate.

2. Increase in pressure in a confined space.
3. Decrease in reliability of electronic devices.
4. Decomposition of liquids generating contaminants that may plug orifices so equipment fails.
5. Burns to personnel and reduction in their efficiency.
6. Fire and explosion. Liquid expansion & overflow.
7. Melting of metals and thermoplastics. Loss of ductility and effects on metals.
8. Weakening of soldered seams.
9. Distortion of warping of parts.
10. Peeling of finishes, blistering of paint.
11. Decreased viscosity of lubricants.
12. Increased evaporation and leakage of liquids (fuels, lubricants, toxic liquids).
13. Increased reactivity, gas diffusion etc.
14. Breakdown of chemical compounds.
15. Increased electrical resistance and opening or closing of electrical contacts due to
expansion.
The Causes of temperature rise are also many and include generation or absorption of heat
from - fire or explosion, electrical heating, solar heating, friction, spark, gas compression, hot
weather, hot working of metal, nuclear reaction, exothermic chemical reaction, lack of
insulation from thermal sources, failure of cooling system, poor heat dissipation capacity,
biological, physiological or organic decay processes.
Similarly there are hazards of low temperature also.
Problems in Cold Environment:
Adverse effects of cold stress are. mental dullness, poor decision making and loss of
consciousness (at 32 to 30°C body temp.) As protections, insulating dry clothing (e.g.
woollen sweaters, mufflers, coat etc) must be provided to workers, if they have to work
below the atmospheric temp. 4°C (40°F).
Local tissue freezing may occur at temp <- 1°C (32.2°F) irrespective of wind speed. At air
temp = 2°C (35.6°F), wet clothing should be immediately changed. As wind speed increases
or/and air temp
decreases, number of breaks should be increased and work period should be decreased.
Ventilation and Heat Control
Chilled wind should be diverted or obstructed by partitions or shielding. Contact of
evaporative (low boiling) liquid should be avoided otherwise chilling effect will increase by
evaporative cooling.

Such protections are hardly required in our country due to moderate temperature.
Control of Heat Stress:
Heat stress should be measured to find appropriate control measure. Heat stress monitors with
or without air probe are available and they are useful for area heat stress monitoring. Personal
heat stress monitor with sensor is available for personal heat stress monitoring.
How to control atmospheric conditions so that varying effects on workers can be reduced to a
minimum is a good task for safety engineers. The remedies varying from plant to plant should
be determined from the specific study of the plant (including workers) itself. Ventilating
system which moves and filters the air and which controls the temperature and humidity is a
good control. Various engineering, administrative, statutory and personal protective controls
can be applied to minimize heat stresses. Methods of engineering control and personnel
management are given below:
Methods of Engineering Controls :
Refer heat balance equation to control the effects of parameters M, C, R & E following
control measures are necessary
H = M-E ± C ± D ± R-P-U
To reduce heat of metabolism i.e. gain by M - Reduce level of physical activity by sharing
work load with others or by using mechanical means. Schedule cooler periods for work.
Increase rest periods.
To reduce high air temperature i.e. gain by C - Insulate hot equipment. Provide canopies
with fans over hot equipment to drive away hot air. Improve general and localized ventilation
over personnel.
Provide exhaust ventilation, local cooling, evaporative cooling, refrigeration, isolation,
substitution, relocation and redesign as per need. Use ventilated suits against excessive heat.
To reduce radiation temperature, i.e. gain by R - Insulate hot 'equipment. Use reflective or
absorptive shielding between the heat source and man. Paint the surface of hot equipment or
shield or
clothe it by using white colour for short wave of solar radiation and aluminum color for infra
red radiation. Wear protective clothing of reflective surface of polished metal or paint or
ventilated suits.
Interpose line of sight barrier. Cover exposed parts of the body. Use fans to move air and
exhaust ventilation.
To reduce high humidity (restriction on loss by E) - Prevent steam leaks. Improve general
ventilation. Apply dehumidification in confined spaces. Use ventilated suits for high
humidity. Decrease humidity and increase air speed.
Methods of Personnel Management (Administrative efforts):
1. Provide ample supplies of cool water or flavored drinks.
2. Provide extra salt where required.

3. Ensure lightweight, loose fitting clothing. In conditions with no radiant heat load, use as
little clothing as possible. With high radiant heat loads, clothing should cover skin; where
possible, clothing should be of cotton and white.
4. Ensure quickest development of acclimatization. Lack of salt, lack of water or poor
physical condition retards acclimatization.
5. Where possible do not employ men in hot conditions if they are : obese, suffering from any
cardiovascular disease, suffering from or recovering from febrile illness, over 45 years of.
age, physically unfit and suffering from any skin disease or if they fail to sweat properly.
6. Where possible, arrange for men who are to work in hot surroundings to spend their first
two weeks working in cool surroundings in the morning and in the heat in the afternoon.
(This - will help acclimatization)
7. Analyze Working situations for estimation of heat load through various channels. Apply
physical methods to control hazard; if necessary amplify by control of work and rest routine.
8. Rest periods should be taken in cool surroundings. Men may effectively 'cool off even
when they continue to work in cool conditions.
9. In extreme conditions man may : wear ventilated suits, be pre-cooled by immersion in cool
water and be cooled down by spraying them with cool water.
10. Train in first-aid for heat strain symptoms.
11. Pre-employment and periodic medical examinations for proper placement of individuals
considering their age, sex and physical fitness and
12. Observation of individual physiological responses to heat and to change their job or place
if necessary.
Acclimatization is an important factor for a worker to work for a long period in hot
environment.
Acclimatization means the habit by which a person adapts himself to living and working in a
hot and humid atmosphere. It is manifested as a reduction in the heart rate and internal body
temperature at the
expense of increased sweating.
The factors affecting physiology of acclimatization are (1) Process of thermal regulation (2)
Cardiac output and heart rate (3) Sweating.
Sweating starts when the skin temperature exceeds 33 °C. There are some 25 lacs sweat
glands in a body of 70 kg man. During the period of acclimatization, the sweating rate may
rise from
1.5 lit/ h to 3.5 lit/h. The maintenance of a body temperature 37 °C is achieved by constant
adjustment of the process of thermogenesis and thermolysis. An acclimatized person should
not lose more than I lit/h and the rectal
temperature should not exceed 38 °C.

The following factors help acclimatization to high temperatures:

1. Persons having less than 50 kg body weight, more than 45 years of age and maximum
oxygen consumption less than 2.5 lit/min should not be selected. Females get difficult to
acclimatize.
2. Liquids should be taken in small quantities and often from the start of exposure to high
temperatures.
3. The intake of fatty foodstuffs should be reduced.
4. Small doses of vitamins B and C are supplementary.
5. Work breaks during shift should be increased. During rest cold drinks reduce stress.
6. Heat resisting barriers which include insulation over the heat source, polished reflectant
shields, absorbent shields (being cooled by air or water) and personal protective equipment
(e.g. water jacketed clothing).
Training
Train workers before hot outdoor work begins. Tailor the training to worksite conditions.
Employers should provide a heat stress training program for all workers and supervisors
about the following:
 Recognition of the signs and symptoms of heat-related illnesses and administration of

first aid.
 Causes of heat-related illnesses and steps to reduce the risk. These include drinking
enough water and monitoring the color and amount of urine output.
 Proper care and use of heat-protective clothing and equipment and the added heat load
caused by exertion, clothing, and personal protective equipment.
 Effects of other factors (drugs, alcohol, obesity, etc.) on tolerance to occupational heat
stress.
 The importance of acclimatization.
 The importance of immediately reporting any symptoms or signs of heat-related
illness in themselves or in coworkers to the supervisor.
 Procedures for responding to symptoms of possible heat-related illness and for
contacting emergency medical services.
Supervisors should also be trained on the following:
 Implementing appropriate acclimatization.

 What procedures to follow when a worker has symptoms of heat-related illness,
including emergency response procedures.
 Monitoring weather reports.
 Responding to hot weather advisories.
 Monitoring and encouraging adequate fluid intake and rest breaks.
Hydration
Employers should provide the means for appropriate hydration of workers.
 Water should be potable, <15°C (59°F), and made accessible near the work area.

 Estimate how much water will be needed and decide who will get and check on water
supplies.
 Provide individual drinking cups for each worker.
 Encourage workers to hydrate themselves.
Workers should drink an appropriate amount to stay hydrated.
 For moderate activities in the heat that last less than 2 hours, drink 1 cup (8 oz.) of
water every 15–20 minutes.
 If sweating lasts for several hours, drink sports drinks containing balanced electrolytes.
 Avoid alcohol and drinks with high caffeine or sugar.
 Generally, fluid intake should not exceed 6 cups per hour.
Rest Breaks
Employers should ensure and encourage workers to take appropriate rest breaks to cool down
and hydrate.
 Permit rest and water breaks when a worker feels heat discomfort.
 Modify work/rest periods to give the body a chance to get rid of excess heat.
 Assign new and unacclimatized workers lighter work and longer, more frequent rest
periods.
 Shorten work periods and increase rest periods:
o As temperature, humidity, and sunshine increase.

o When there is no air movement.
o If protective clothing or equipment is worn.
o For heavier work.
Extreme heat is a major weather-related hazard. Even a short period of exposure can be so
taxing on the body that it results in a heat-related illness. Although outdoor physical activity
may be unavoidable, heat-related illnesses and fatalities are preventable by using NWS
forecast tools like Heat Index (which tells you how temperature feels to the human body in a
shady area) or alternatively, Wet Bulb Globe Temperature (WBGT), before heading outside
What is WBGT ?
A Wet bulb measures the temperature read by a thermometer covered in a wet cloth. As water
evaporates from the cloth, evaporation cools the thermometer. This mirrors how the human
body cools itself with sweat.A black globe is used to measure solar radiation. Solar radiation
heats the globe and wind blowing across it cools the globe.
A Dry bulb calculates the air temperature measured in the shade. It is the temperature you
would see on your thermometer outside.
With WBGT forecasts available by region up to 7 days in advance, it is a useful tool for
planning ahead.
Who should use WBGT?
This experimental tool is most useful for active, acclimatized people such as outdoor
workers, athletes, and anyone else performing strenuous outdoor activities — and has been
used for decades by military agencies, OSHA, and marathon organizers.

What should you do if WBGT deems outdoor activity dangerous?

Always follow the advice of your local officials before engaging in outdoor activities, as
WBGT guidelines vary geographically since temperatures fluctuate by region and so does the
body’s response to exercising or working in heat. OSHA recommends the following
protective measures for outdoor workers:
Acclimatize workers starting the first day working in the heat and after any extended absences
Provide shade for outdoor work sites
Schedule work earlier or later in the day
Use work/rest schedules
NWS has multiple tools to assess the potential for heat stress due to extreme temperatures.
The following tools can inform the issuance of NWS official heat watches, warnings, and
advisories. Each of these tools integrate other weather parameters to provide a deeper level of
information beyond what the actual air temperature can tell us.
Wet Bulb Globe Temperature (WBGT) : WBGT uses temperature, humidity, wind, solar
radiation, and other weather parameters. It’s a particularly effective indicator of heat stress
for active populations such as outdoor workers and athletes.
WBGT can be used to inform activity modifications during exercise or outdoor work. For
instance, The American College of Sports Medicine bases its guidelines for the intensity of
sport practices on WBGT, and it is therefore utilized by athletic programs in many school
districts.
The Occupational Safety and Health Administration (OSHA) recommends protective
measures for outdoor work:
Acclimatize workers starting the first day working in the heat and after any extended absences
Provide shade for outdoor work sites
Schedule work earlier or later in the day
Use work/rest schedules
Limit strenuous work (eg., carrying heavy loads)
Use relief workers when needed
keep indoors cooler. Transmission capacity across electric lines is reduced during high
temperatures, further straining the electrical grid. Water resources are also strained as
conventional power plants require large quantities of water for cooling and crops may need
increased water consumption, and people increase water consumption to stay hydrated and
cool. Heat can have lasting impacts as crops may be damaged, reducing production which
leads to short supply and or increased cost to the farmers and consumers.

Industry Description Heat stress measurement Management's
Worker's perceptions
sector of unit results perceptions
Management had
Based on responses available an
The unit
provided by around 40 occupational safety
employs
workers from different and health policy
around 4,800
work locations, heat with specific
workers.
stress is perceived as a provisions for
Work
seasonal problem that management of
locations
recurs every year. The heat stress. This
assessed for
term ‘heat stress’ was included conduct of
heat stress
understood as being routine
exposure
synonymous with the environmental
included
term ‘summer.’ Though measurements for
stamping,
there were no reports of heat stress,
body shop,
severe symptoms related provision of
printing, Trim
to heat exposures, the controls (that
Cum Chassis
arrival of the summer included fluid and
(TCF), and
season always signaled electrolyte
quality testing The unit had a long history of
heightened concern supplementation
areas. Except heat stress monitoring
about heat stress in the for workers), and
for quality conducted as part of routine
workers’ minds. The conduct of routine
testing that industrial hygiene monitoring
major complaints from trainings/awareness
involved activities with measurements
the workers, as perceived raising. However,
partial of heat stress made at
Automobile by them to be related to of the 5 senior
exposure to multiple locations since 2003.
assembly heat exposure, included supervisors who
sunlight, other Many work locations
(Case 1) symptoms like skin responded, most
work consistently exceeded the
rashes and acne. Some felt that the
processes recommended levels for heat
also perceived chicken majority of heat
were located stress exposure during peak
pox to be related to heat stress complaints
indoors. All summer months. The paint
exposures.***The are from new
work areas shop recorded some of the
placement of select workers who are
were found to highest levels (with averages
preventive measures not acclimatized, or
be well around 32.4°C).
including provision of limited to those
designed from
water, electrolytes, and who engage in
an ergonomic
fans within the facility heavy work
point of view
had resulted from outdoors such as
with little
repeated complaints maintenance and
evidence of
from workers of gardening. They
physical
discomfort. Nearly half perceived that the
strain. The
the workers interviewed available
company was
felt that provision of engineering
in possession
additional cooling controls (such as
of ISO 14001
mechanisms would blowers, air
(EMS) and
reduce the environmental coolers, air
OSHAS
heat and reduce the conditioners,
18001
frequency of minor ventilators, man
certification.
faults/production errors. coolers, and fans)
that have been

installed as a result
of workplace
monitoring to be
adequate. While 3
of the 5
interviewed
reported that the
workers took long
rest breaks,
sometimes up to
twice as long
during summer
months, they
admitted not
knowing if there
was an impact on
productivity. An
on-site
occupational health
center was
available and
although no
systematic
surveillance of heat
stress was being
maintained. No
incidents of
extreme heat-
related disorders
such as heat stroke
and heat exhaustion
were reported.
Non-specific
complaints of
cramps suggestive
of dehydration
were found to be
more commonly
reported in summer
months.
Automobile The unit The assessment for All of the 15 workers There was no
parts (wheel) employs environmental heat stress was interviewed reported specific policy
manufacturing around 3,000 performed once in 2008 in discomfort throughout available for the
industry (Case workers. order to satisfy requirements the year. Despite no management of
2) Work related to the Occupational process-related heat heat stress.

locations Health and Safety (OSHAS contributions and with Recommendations

assessed for 18001) certification. Most most of the operations from workplace
heat stress locations exceeded the being indoors, workers monitoring were
measurements recommended exposure felt heat was affecting being implemented
included die values with some of the their ability to work due but only partially
casting, highest levels recorded in the to dehydration. Lack of so. The factory
machine shop, die casting area (35.3°C). insulation on the roof medical officer
and and inadequate available on-site
maintenance ventilation was cited as reported several
areas. All the chief concern for cases of workers
work heat-related discomfort. being overcome by
processes are Symptoms of heat exposure over
performed dehydration, the last 2 years.
indoors. No dizziness, cramps, and However none
heat heat-related exhaustion were found
generating were the most commonly recorded in the
processes reported. register. The rest
were rooms for workers
identified. were well
The company ventilated and were
was in provided with
possession of water coolers.
ISO 14001
(EMS) and
OSHAS
18001
certification.
The unit Of the 8 workers There was virtually

employs interviewed most were no recognition of
around 300 The assessment for not aware of the heat stress as a
workers. environmental heat stress was consequences of heat major concern.
Work performed once in 2009 in stress and reported being There were some
locations order to satisfy requirements well acclimatized to heat. cases of
Leather assessed for from a prospective buyer. None of the workers absenteeism during
manufacturing heat stress Most locations exceeded the reported heat affecting the peak summer
industry (Case measurements recommended exposure their performance. months in the past
3) included values with some of the Workers reported the and the HR
degreasing, highest levels recorded in the discomfort while manager cited
splitting, drying area (33.9°C). working with volatile excessive heat as a
dyeing, followed by splitting organic compounds in possible
drying, sizing, (32.7°C). the dyeing area. They explanation. There
and product were however not ready was no heat
inspection to accept Personal protection policy
areas. All Protective Equipments available. With no

work (PPEs) like the half face OHS professional

processes are chemical cartridges and available, no
performed aprons provided as they information could
indoors. Oven felt that increased the be gathered on how
drying was the discomfort from engineering
only work sweating and heat. controls would be
location with implemented
process following
generated workplace
heat. The monitoring
company was recommendations.
in possession Normal rest breaks
of ISO 14001 and liquid
(EMS) replenishment
certification. (water) was being
provided and
perceived to be
adequate for heat
stress management.
The unit Management did

employs have available an
around 900 OHS policy on
workers. Based on responses maintenance of
Work provided by around 30 occupational
locations workers from different standards that
assessed for work locations, heat included
heat stress The unit has a long history of stress is perceived as a measurement of
measurements heat stress monitoring, with seasonal problem that heat stress,
included measurements made at recurs every year. Most monitoring the
furnace, float multiple locations since 2004. felt they would be able impacts on
Glass
bath, Most work locations to work more with better workers, providing
manufacturing
annealing, exceeded the recommended ventilation but admitted engineering, and
industry (Case
paint coating, heat stress exposure during they were seldom able to administrative
4)
storage, and peak summer months. The slow down on account of controls. However,
dispatch areas. furnace area recorded some heat. They did not report the 2 senior safety
All of the highest levels (with specific symptoms supervisors who
work averages around 31.8°C). except for feeling tired. responded felt that
processes are Summers increased the the majority of the
performed level of concern about heat stress
indoors and heat stress in the complaints were
generate heat workers’ minds. received from
with the newcomers who
exception of were not
storage and acclimatized or

dispatch. The were limited to

company was those who engaged
in possession in heavy work in
of ISO 14001 the furnace area
(EMS) and and outdoors, such
OSHAS as maintenance and
18001 gardening. They
certification. perceived that the
available controls
(such as blowers,
air coolers, air
conditioners,
ventilators, man
coolers, and fans)
that have been
installed to be
adequate. An on-
site occupational
health center was
available, although
no systematic
surveillance on heat
stress wasbeing
maintained.
The unit Of the 7 workers There was no

employs interviewed from recognition of heat
around 70 different workplaces, being a major
workers. workers perceived heat concern and the
Work The assessment for stress to be a seasonal management
locations environmental heat stress was problem and did not link expressed that if
assessed for performed once in 2003 as it to the occupational some buyers had
heat stress part of a pilot research project environment. None of not stipulated it,
Textiles measurements aimed at heat stress exposure the workers were aware they would not
manufacturing included bale profiling. Most locations of the possible have engaged in an
industry (Case opening, exceeded the recommended consequences of heat assessment. It was
5) carding, exposure values with some of exposures. Their main not clear how they
drawing, the highest levels recorded in discomfort seemed to be proposed to
roving, and the spinning area (31.8°C) related to cotton fiber convince the buyers
spinning. All followed by the bale opening exposure. All workers with the results of
work area (28.5°C). however cited heat as a the workplace
processes are reason for not using monitoring without
performed PPEs. None reported installation of any
indoors with being slowed down at engineering
no process work by heat except controls.

generated heat perhaps in the middle of

at any of the summer.
work
locations. The
company had
not sought any
certifications
(such as the
ISO 14001
(EMS) and
OSHAS
18001
certifications).
The unit Though the

employs workers did not
around 150 seem to perceive
workers. heat stress as a
Work major concern,
locations Based on the response OHS specialists
assessed for provided by around 32 perceived heat
heat stress workers from the stress to be a major
measurements different workplaces, problem. There
included The assessment for most of the workers were was, however, no
storage, environmental heat stress well acclimatized to the recognition of the
feeding, started in May 2007 in order working environment. possible links
milling, to satisfy requirements related There were no reports of between heat stress
mixing, and to the Occupational Health any major heat stress and productivity
Fertilizers bagging areas. and Safety (OSHAS 18001) related symptoms except losses. No heat
industry (Case All work certification. Most locations for a few reported skin protection policy
6) processes are exceeded the recommended rashes during the peak of was available in
performed exposure values with some of summer. Most of the this company.
indoors with the highest levels recorded in workers seemed to be Cooling
no process the material storage area unaware of the technologies like
generated heat (32.7°C) followed by the symptoms of heat-related blowers, air
at any of the bagging area (32.6°C). disorders. New workers coolers, air
work (who are also perhaps conditioners,
locations. The unacclimatized) reported ventilators, and
company was feeling discomfort man coolers had
in possession during peak summer. not been installed
of the ISO in most of the
14001 (EMS) process areas
and OSHAS despite the
18001 workplace
certifications. monitoring

recommendations.
Normal resting
breaks and liquid
replenishments
(cold water, milk)
were provided.
The unit Despite wide

employs spread recognition
around 800 among workers
workers. about the
Work prevalence of heat
locations Of the 10 workers stress, there was no
assessed for interviewed, all policy for
heat stress perceived heat to be a management of
measurements problem year-round with work-related heat
included stock the summer months of stress. A factory
pile loading, April through June and medical officer was
ground hopper outdoor work being available on-site
loading, reported to be and reported
crushing intolerable. All workers several episodes of
house, boiler, complained about the fainting and cases
Based on a request from the
turbine, and lack of adequate of heat stroke in the
management of the unit,
utilities (pump ventilation. Symptoms past. Three of the 5
WBGT measurements were
Electricity house, reported included supervisors
conducted once in March
generation compressor, dehydration, extreme interviewed did
2008. Most locations
industry (Case and generator) exhaustion, frequent skin admit needing
exceeded the recommended
7) areas. All rashes, and acne. more people and
exposure values with some of
work Chicken pox was time to accomplish
the highest levels recorded in
processes are perceived to be a heavier tasks in
the utilities area (33.2°C)
performed symptom of heat summer. Although
indoors with exposure. All workers workplace
the exception felt that their monitoring had
of the stock productivity was been undertaken
piling area seriously compromised and engineering
that exposes because of the heat and controls
workers to that no measures were recommended,
direct sunlight being taken to reduce or none had been
throughout the mitigate the effects of implemented.
day. There heat exposures. Administrative
was no controls had been
process partially
generated heat implemented,
at any of the which included
work periodic rest breaks

locations. The with fluid

company was replacement and
in possession provision of well-
of the ISO ventilated resting
14001 (EMS) rooms for workers
and OSHAS with water coolers.
18001 Health education
certifications. and awareness
programs on the
effects of heat
stress were being
conducted.
Case studies on heat stress related perceptions in different industrial sectors in

southern India.
Table 1. Results on worker's and management's perceptions
Nature of Potential for impacts on

Heat stress exposure Heat stress perceptions
process productivity
Being largely automated

Mostly non-air conditioned
Workers are well aware batch processes,
workspaces; few heat
and have been responsible potential for productivity
generating processes;
for most low cost losses are high.
1. Assembly ergonomically well
engineering and However, workers often
(automotives and designed in large firms but
administrative stretch their work
automotive parts not in small firms; heat
improvements. Workers abilities to compromise.
manufacturing) exposures exceed limit
see the need for Management is willing
values mainly in the yard,
improvements but to engage in assessment
utility, and some painting
management is mostly of potential productivity
operations.
satisfied with efforts taken. losses
Non-air conditioned
workspaces, many Potential for productivity
Workers are well aware
2. Manufacturing operations expose workers losses not recognized
and perceive it as a well-
large organized to process generated heat, and/or reported.
known seasonal risk.
sector firms limited workload Management is willing
Management too is well
(glass contributions, heat to enhance training
aware and engages in
manufacturing) exposures exceed limit efforts to increase
routine monitoring.
values in many process awareness and avoid
locations. risks.

Nature of Potential for impacts on

Heat stress exposure Heat stress perceptions
process productivity
Non-air conditioned
Workers are generally Potential for productivity
workspaces; although no
aware of risks related to losses and losses from
heat generating processes
heat stress. Many reported health impacts very high
are involved, workplaces
not wearing required as efforts for
are poorly designed and
personal protective clothing recognition, evaluation,
3. Manufacturing ventilated and are often
as the heat loads become and control are rather
semi-organized accompanied by exposures
unbearable. Many also minimal. Management is
firms (textiles, to mists, vapors, and dust
perceive that removal of not very willing to
leather that are aggravated by heat
the chemical exposure will engage in additional
manufacturing) stress exposures. Most
improve their ability to efforts to assess
processes have high
tolerate heat. Management productivity
workload contributions
is unaware and mostly losses, but presumably
with heat stress exposure
disinterested in additional could be motivated with
exceeding in several
control efforts. results from other
process locations.
units/sectors.
Potential for productivity

Workers largely unaware of losses and health impacts
Non-air conditioned work
the problem. Management very high as limited
spaces; only limited
was aware of the problems, efforts for control have
4. Manufacturing monitoring efforts have
especially on account of been taken despite
medium sized been made and, hence,
several heat-related worker several reported
firms (fertilizer only few high exposure
incidents during summer incidents. Considerable
production, areas recognized. Many
months. However, they ground work may be
power gration) processes involve
were largely unwilling to needed to initiate in-
substantial workload
engage in additional house efforts to assess
contributions.
controls. productivity losses
and/or health impacts.

Practical No:-4
Aim: To study about fire hazards and their control measures.
INTRODUCTION:
Fire claims the lives of over 5000 people each year in India. Fire Causes thousands of
disabling injuries, millions of rupees of property damage and countless lost jobs each year.
Knowing the dangers of fire can help prevent fires. Flames, heat and smoke are obvious fire
dangers. Other dangers include: suffocation, toxic vapour, explosions. You can prevent fire
and its deadly damage when you eliminate fire hazards and learn how to respond quickly and
properly to a fire.
FIRE SAFETY INDIAN SAFETY ACT SEC 38 :
➔ In every factory, all practicable measures shall be taken to prevent outbreak of fire
and its spread, both internally and externally, and to provide and maintain-
➔ Safe means of escape for all people in event of fire.
➔ The necessary equipment and facilities for extinguishing fire.
➔ Effective measures shall be taken to ensure that in every factory all the workers are
familiar with the means of escape in case of fire and have been adequately trained in
the routine to be followed in such cases.
➔ The State Government may make rules, in respect of any factory or class or
description of factories, requiring the measures to be adopted to give effect to the
provisions of subsections (1) and (2)
STATUTORY PROVISION:
➔ Rule 66A of the GFR for fire

Protection:
◆ Serious fire & explosion hazards
◆ Access for fire fighting
◆ Protection against lighting
◆ Precaution against ignition
◆ Spontaneous ignition
◆ Gas cylinder
◆ Storage of flammable liquids
◆ Flammable dust, gas vapour waste etc.
◆ Fire exits
◆ First aid fire fighting arrangements
◆ Other fire fighting arrangements
◆ Fire fighting team & drill etc.
◆ Hydrant & sprinklers
➔ Indian standards
➔ Guidelines of Regional tariff advisory Committee (TAC)
➔ NFPA Code (NFC)

What is a fire hazard?
➔ Conditions that favour the development or growth of fire i.e. with oxygen, fuel and
heat.
➔ Fire hazards usually involved the mishandling of fuel and heat.
➔ Fire or combustion is a chemical reaction between oxygen and a combustible fuel.
➔ Sources of ignition are spark, flame, and high temp. are needed.
Fire Phenomena:
Figure 1- Fire Triangle
➔ Fire triangles illustrate the three elements a fire needs to ignite : Heat, fuel and Oxygen.
➔ The fire was extinguished by removing any one of the elements in the fire triangle.
Figure 2- Fire Phenomenon

1. Fuel -
★ combustible material like paper, wood, rags, oil, gasoline, solvents, flammable gases,
vapours.
2. Oxygen -
★ The greater the concentration of oxygen, the bright and more rapid burning.
3. Heat or Sources of ignition-
★ Such as sparks, flames etc. necessary to start the fire initially.

4. Chain reaction -
★ Maintenance of chain reaction through free radicals.

➔ Instead of the old concept of fire triangle, these 4 sides constitute a fire
Pyramid. Class of Fire :
Figure - 3 Class of Fire

Class of Fire Extinguisher :
Figure - 4 Class of Fire Extinguisher

Source of Fire Hazards:
➔ Failure of electrical system and equipment.

➔ Lightning strikes.
➔ Presence of a flammable gas or liquid mixture.

➔ Hot or heated surface.

➔ Hot engines.
➔ Bad Housekeeping
➔ Cigarettes
➔ Welding Cutting
➔ Friction
➔ Self Ignition
➔ Exposure
➔ Ignition Sparks
➔ Mechanical Sparks
Factor contributing in Fire :
Factors contributing to fire %

Electrical 19
Friction 14
Foreign substance 12
Open flames 9
Smoking and Matches 8
Spontaneous ignition 8
Hot surface 7
Combustion sparks 6
Overhead materials 3
Static electricity 2
Miscellaneous 5
Not determined 7
Figure - 5 Factor contributing in Fire

Spared of Fire :
Figure - 6 Spared of Fire
➔ Conduction: - Conduction fire spreads through direct contact between materials. A

conduction fire is spared when a fire heats up a material that’s a good heat conductor.
Like metal, which then comes into contact with a combustible material. The fire can
travel further across a room or building in this manner.
➔ Radiation: - A fire can be spared by radiation when the heat travels through
electromagnetic waves in the air. When fire breaks out, heat will travel in all
directions until it reaches an object which will absorb it. When it reaches a
combustible material, it will smoulder and eventually burn.
➔ Convection: - Convection is the most common cause of fire spreading in domestic &
commercial buildings and is also the most dangerous. Heat Always rises, but in the
setting of an office for example, the heat is trapped once it hits the ceiling and so it
then begins to travel horizontally, thus spreading the fire simultaneously. Any
materials in the room that are combustible will also ignite, further fuelling the fire.
➔ Direct Contact fire :- A direct contact fire is one that spreads simply when the
flames contact other fuel sources which then also catch fire. This process continues
over time, thus spreading further.
Mostly fire devolve in four stage :-
Figure - 7 Stage of Fire

★ Incipient stage :-
➔ No visible smoke, flame or more heat developed. Invisible combustion particles are
generated over a period of minutes, hours or days.
★ Smouldering stage :-
➔ Visible smoke generation. Photoelectric detectors can detect this smoke.
★ Flame stage :-
➔ Flame starts after the point of ignition. Smoke decreases and heat increases. Infrared
detectors can detect this stage.
★ Heat Stage :-
➔ Heat, Flame, Smoke & gases are produced in large amounts. Thermal detectors
respond to this stage.
Control of Fire :
Figure - 8 Control of Fire

(Human Brain without Oxygen survive only 4 minutes.)
★ Cooling :- Limiting temperature by increasing the rate at which heat is lost from the
burning material.
★ Smothering :- Limiting Oxygen by preventing air from reaching the seat of the fire to
allow the combustion process to reduce the oxygen content in the confined
atmosphere until it extinguishes itself.
★ Starving :- Limiting fuel by removing potential fuel from the vicinity of the fire,
removing the fire from the mass of combustible materials or by dividing the burning
material into smaller fires that can be extinguished more easily.
★ Interrupting :- Inhibiting the chemical chain reaction by applying extinguishing
media to the fire that inhibits the chemical chain reaction at the molecular level.
Fire Prevention System :

Figure - 9 Fire Prevention System
★ Smoke detectors
★ Heat detectors
★ Flame detectors
★ Fire evacuation plan
★ Fire alarm control system
★ Manual call points
★ Fire Door
Fire Protection System :
Figure - 10 Fire Protection System
★ Fire extinguisher
★ Fire Hydrant
★ Fire hose reel
★ Sprinkler system
★ Fire water Monitor system

★ Fire tender
★ Siren / Audio / Visual Alarm system
★ Fire emergency kit
★ PPE’S
★ Spill Control Kit
★ ERT
Case Study-1
❖ The Indian Oil Corporation’s POL (Petroleum Oil Lubricants) Terminal,

Sangane, Jaipur, India, 29 October 2009
★ WHAT HAPPENED :-
➔ During the evening shift of 29 Oct 2009, the Terminal was preparing to carry out a
routine transfer of Motor Spirit (MS) to the neighbouring Terminal operated by
Bharat Petroleum Corporation Limited (BPCL). Four employees were supposed to be
on the shift and the operating crew started to prepare the MS tank (tank 401-A) for
pumping to BPCL terminal. At about 6.10 pm, while preparing the MS tank for the
transfer, a huge leak occurred from a ‘Hammer Blind Valve’ at the bottom of the tank.
The leak resulted in a jet of MS directed upwards from the valve under the hydrostatic
pressure head of MS in the tank. The liquid MS rapidly generated vapours which
made the operator lose consciousness. The fact that this critical activity was initiated
after normal working hours led to delay in responding to the situation. The shift
officer tried to help the operator but was also affected by the vapours and barely
managed to evacuate the area. The 2nd operator, who was in the canteen and was
contacted by the shift officer, rushed to the tank but also lost consciousness. The 3rd
operator on the shift had earlier left for home and was not available for initiate any
rescue or mitigating steps. With no other operating crew available to initiate control
actions, the leak remained uncontrolled for 75 minutes. After 75 minutes, the vapour
cloud ignited causing a huge explosion followed by a fireball covering the entire
installation.
➔ It is notable that in the case of the Jaipur incident, the vapour cloud was not visible.
Personnel on site were aware of the presence of the vapour by its odour. Some
personnel were able to make their escape from the site, whilst others were either
incapacitated by the MS vapors or were caught within the vapor cloud when it ignited.
➔ The fire which followed the explosion spread to all other tanks and burnt for 11 days.
All the petroleum products stored in the Terminal at the time of the accident (approx.
60 million litres) were consumed in the fire and the installation was totally destroyed.
Buildings in the immediate neighbourhood were heavily damaged. Minor damage and
window panes breakages occurred within a radius 2 km from the site. Eleven people
lost their lives in the accident - six from IOC and five outsiders, and several others
were injured. There were factories and industrial complexes in close proximity to the
site.

★ WHY IT HAPPENED :-
➔ The immediate causes of the accident were the non-observance of normal safe
procedure which involves a sequence of valve operations during line up activity and
an engineering design which permitted use of a ‘Hammer Blind Valve’. A large area
at the top of these valves can remain completely open every time the valve position
has to be changed. It was through this open area that the liquid MS leaked when the
tank was prepared for pumping to BPCL) because another valve connecting to the
tank was also open when the Hammer Blind was in the changeover position.
➔ The root causes were the absence of site specific written operating procedures,
absence of remotely operated shutdown valves and lack of understanding of hazards,
risks and consequences.
➔ Formation of a large vapour cloud
➔ At the time the leak and subsequent explosion occurred, calm, low wind speed,
conditions prevailed. This, coupled with the nature of the release (an upwards jet of
MS), is likely to have assisted in the production of vapour. Post incident analysis
indicates that a flammable vapour cloud covered much of the IOC site, bound by a
perimeter wall which would have contained most of the cloud. The cloud diameter
was approximately 1000 m, almost four times that which developed in the Buncefield
accident (12/2005).
➔ Explosion severity
➔ The explosion resulted in widespread severe pressure damage over almost the entire
site. The evidence indicates that the vapour cloud explosion generated overpressures
that were in excess of 200kPa over most of the IOC site. The nature of damage was
similar to that observed at Buncefield (12/2005) with crushing of oil drums above
liquid level, severe damage to buildings and severe damage to vehicles. Areas
exhibiting high overpressures included many open regions, without trees, bushes or
pipework. In these areas, a deflagration would not be sustained and overpressures
would have decayed. The overpressure damage evidence is therefore not consistent
with the vapour cloud explosion involving only deflagration. Directional indicators
were also inconsistent with the explosion resulting from a deflagration only.
➔ The exact source of the transition to detonation cannot be determined due to the
limited evidence from the Pipeline Division area.
➔ The directional indicators point to the source of the detonation being in the Pipeline
Division area in the north east corner of the site. Unlike Buncefield, the possibility of
the detonation occurring as a result of flame acceleration in trees does not appear
consistent with the evidence. The most likely cause of the detonation is flame entering
either the Pipeline Area control room or the pipeline pump house, causing a confined
or partially confined explosion that then initiates a detonation as it vents from the
building. In drawing this conclusion it would seem necessary for some of the
directional evidence to be affected by lack of symmetry in the vapour cloud. The
exact source of the transition to detonation cannot be determined due to the limited
evidence from the

Pipeline Division area.

➔ Implications
➔ Immediate measures
➔ Introduction of measures to make emergency action possible from remote locations.
➔ Introduction and enforcement of site operating procedures to reduce human error,
improve operating discipline, improve site communications and ensure availability
and competency in the use of personal protective equipment.
➔ Introduction of dual level gauges and alarms, detectors and CCTV systems;
➔ Introduce a requirement for QRA to be undertaken on larger sites. Long-term measures
➔ Design and layout improvements to prevent loss of hydrocarbon containment;
➔ Improvement to firefighting capabilities.
➔ Better training, performance evaluation criteria and safety oriented corporate policies.
➔ Making the safety function independent and autonomous, reporting directly to the
company
➔ CEO; Strengthening the internal safety auditing functions and providing professional
safety
➔ auditing training; Siting criteria should be informed by QRA.
➔ Review of land use legislation in the vicinity of major hazard facilities and the role of
local and
➔ state governments in such matters;Country-wide review of major hazard facilities from
➔ Security view-point.
★ LESSONS LEARNT :-
➔ Facilities and installations with inherently high hazards should incorporate
redundancy in safety systems and ensure their upkeep at all times.
➔ Management should ensure that reliable systems are in place to give timely feedback
on the current practices and state of readiness in different facilities.
➔ Management must ensure that identified actions are being carried out.
➔ A high priority on safety from the senior and top management groups will send the
right signals down the line to ensure safety and production.
➔ High degree of operational competence should be maintained at all times by building
on the combined knowledge and experience of all the professional groups. The
lessons learnt from all major incidents should be shared and widely disseminated in
the entire Industry preferably through an appropriate website.
Case Study-2
❖ Surat fire Incident 24th May 2019

➔ Incident Brief Detail of surat Fire incident
➔ On 24 May 2019, a fire occurred at a coaching centre (commercial complex) in
Sarthana area of Surat in the Gujarat state of India Twenty-two students died and
others were injured in an academic coaching centre Owner of the Institute, Builder
and two officials from Gujarat Fire Safety Department (Fire service Gujarat) were
arrested.

➔ How the fire started (Surat Fire Incident)

➔ Fire Started with a Short Circuit at Ground Floor.
➔ Then Fire Spread to other floors and the Coaching Centre which was at Terrace!
★ Lapses in SURAT Fire Incident :-
➔ Spread of Fire from Ground Floor to Terrace.
➔ Inflammables are hugely used like Fluxes and Tires as seats.
➔ Fire Tender was 45 minutes away and Hydraulic ladder reached in 45 minutes.
➔ Ceiling Height was just 5 feet.
➔ 16 students died due to asphyxiation.
➔ Makeshift Dome was the building on the terrace where the actual tragedy happened.
➔ The Short Circuit happened on the Air Conditioner Circuit.
➔ 3 died as they jumped off the terrace of the building.
➔ No Safety Equipment in the building.
➔ Heavy traffic and people taking videos at the incident site.
➔ 2 Floors was built without permission
➔ There was no audit conducted for building.
➔ Another Staircase was locked.
★ Learning of SURAT Fire Incident:-
➔ Lack of Passive Fire Protection. An adequate Passive Fire Protection.
➔ measure restricts the spread of fire and smoke.
➔ Interior coatings, internal walls etc. are spreading the fire fast. Fire Load Must be
calculated and checked on regular intervals.
➔ At least for 2 hours fire-fighting capacity must be available within every commercial
and industrial establishment.
➔ National Building Code of India shall be followed for safety compliance.
➔ Smoke is more dangerous than fire. Smoke Extraction System, Ventilation and
Maintaining Air Changes per Hour are critical aspects.
➔ Members of Structure, Wall, Floor and Roof etc. shall be as per National Building
Code of India which guide on fire rating of each.
➔ Continuous running loads will have fire hazard. Thermography and electrical audits
will help to improve every time.
➔ Inadequate exit staircase could have been the reason. Based on each floor's occupant
load, travel distance, number of exit must be calculated in a scientific manner rather
than having one or two staircases.
➔ Requirement of Safety Equipment and Training & Awareness on how to use it might
have saved many lives.
➔ If not able to extend support, others should not hamper the rescue team.
➔ Adherence to statutory will not only save the building owner/occupier from legal
battle but it is for Personnel and Property Safety. In the end it has
business/commercial benefits.

➔ All high rise buildings and industrial complexes must conduct a third party audit
every two years.
➔ Maintaining the equipment/facility “ready to use” is very critical which over a period
of time building occupants ignore.
➔ Learning from previous or similar incidents is very important to improve safety
standards of each premises.
★ Do’s & Don’ts
● DO’S :
➔ Store flammable liquids, gases, solvents, chemicals in stable racks, correctly labelled.
➔ Keep chemicals in a cool and dry place away from heat.
➔ Where hazardous chemicals are used / stored, ensure adequate ventilation and prohibit
smoking.
➔ All receptacles for waste should be emptied at regular intervals.
➔ Welding /Cutting jobs should be carried out under strict supervision.
➔ Before welding operations, all traces of flammable material must be removed to a safe
distance.
➔ Good Housekeeping must be ensured.
➔ Keep all machinery clean and lubricate it to avoid friction and overheating.
➔ Faculty electrical appliances should be repaired / replaced immediately.
➔ Switches and fuses should conform to the correct rating of the circuit.
➔ Keep smoke/Fire Check doors closed.
➔ Keep means of escape clear of obstructions.
➔ Emergency organisation must be set up.
➔ Impart elementary firefighting training to occupants.
➔ Fire Rescue drills should be carried out at regular intervals.
● Don’ts:
➔ Don’t smoke in prohibited areas.
➔ Don’t plug too many electrical appliances in one socket.
➔ Don’t paint fire detector/sprinkler heads .
➔ Don’t place obstruction in means of escape.
➔ Don’t use damaged cords and avoid temporary connections.

Practical No:-5
Aim: To study about Electrical hazards & Its Safety
INTRODUCTION
Why to know about Electrical hazard?
 A variety of kitchen appliances and other electrical equipment have touched almost
every corner of our modern life.
 But it is to be handled with care, because its contact with human body is dangerous
and proves fatal if not properly controlled by engineering and manual precautions.
 2-7% of total fatal accidents happens due to electricity
What is Electrical Hazard?
An Electrical Hazard can be defined as a serious workplace that exposes workers to shock,
burns, fire & explosion, arc flash/blast.
What are the Electric hazards
Primary
Electric Shock or burn : Body becomes part of electrical circuit, Current enters the body at
one point and leaves at another.
Fire and Explosion. Happens when electrical faults develop into fires when combustible
materials are present
Secondary
Person falling from height (during electrical job): Workers in elevated locations who
experience a shock may fall, resulting in serious injury or death
Dropping tools in electrical systems: Workers may drop any tools in energized electrical
panel
Electrical Hazards
Arc Flash/Arc Blast
 Sudden release of electrical energy through air when a high-voltage gap exists and
there is a breakdown between conductors
 Gives off thermal radiation (heat) and bright, intense light that can cause burns
Effect of electrical parameters on human body
Physiology of Electric Shocks

 It is the current, not voltage that causes physiological damage, but current is related to
Voltage & Resistance as per Ohm’s law. (V=IR)
 The blood is good conductor of electricity, but the skin is highly resistive. Body
resistance of each person is variable, therefore effect on them is also variable.
 DC current maintain involuntary grip which prolongs the current flow. AC current
produces fibrillation every cycle whereas DC produces only once.
Electric shock severity
 Severity of shock depends on multiple factors like
 Current value 10mA for 5sec < 100mA for 1sec

 Time of its passing through the body
 Type of Current (AC/DC)
 Current frequency (1000Hz < 60Hz)
 Path of the current through body (Near Heart or nerve system)
 Person’s age, gender, dry/wet skin
 Weather condition (Wet, CO2 gas)
 Type of Floor (Insulated, Uninsulated)
How current damages to body
 20 to 50 mA current passing through heart stops, Impurity of blood increases as the heart
is not working. Oxygen supply to brain stop, if artificial respiration is promptly given to
the heart, the patient will mostly recover.
 If the current is increased 80 to 500 mA, the heart beat will stop and every fiber of it will
contract haphazardly causing fibrillation. This will stop the entire blood circulation. The
heart will never recover and death results after a few minutes. But it is possible to
defibrillate the heart by using a device known as defibrillator. By this device a counter
shock is given to the heart which reverts the heart muscles to their normal shape.
 Electric burns are caused due to high current flowing through body. Due to high voltage
and heavy current, sparking takes place and cloths also burn. This causes thermal burns
and if they are extensive, the victim may die. Burning takes place due to heat generated as
per Joule’s Law.
Heat = I × R × t (t= time)
Effects of current on body

Effect of Electric Current on Men and Women
Effect of Voltage
 For 50Hz frequency for same person at different voltage resistance is decreased & current
value increases, Body resistance becomes practically zero at high voltages.

 Approximate threshold shock voltages at 50 c/s are as under:

 Threshold of feeling 10 to 12 V
 Threshold of pain 15 V
 Threshold of severe pain 20 V
 Threshold of hold-on 20 to 25 V
 Threshold of death 40 to 50 V
 Range of fibrillation 60 to 2000
V Resistance of skin
It is safe to assume a value of 500 ohms for dry work places and 200 ohms (or less) for persons
working in wet places. Body resistance is practically zero at high voltages
SAFETY MEASURES & PRECAUTIONS
Safety Measures
 Isolation
 Insulation

 Current limitation
 Earthing
 Other Precautions
Isolation
 Live electric wires/parts should be kept out of reach from the normal working Cable trench
 Transformers provision at a safe height with wire fencing
 Segregation or a locked room
 Circuit breakers and power isolation switches
Insulation
Cable, conductors and leads should be insulated with standard material

Double insulation
Personal insulation means to protect the self by dry clothing, rubber shoes, rubber mat etc
Current limitation
 Fuses, circuit breaker or isolators.

 Fuses upto 10 amp rating are designed to blow at three times its rated value and those
above 10 amp, at twice the rated value.
 A 5 amp fuse does not mean that it will blow at 5 amp. It only means that it is capable of
carrying current of 5 amp continuously without getting hot.
 Unsafe practice to tie a thick or more wires in a fuse.
Earthing
equally important as fuses checked frequently for continuity
Other Precautions
 Working space, Means of access, proper lighting

 Use of PPE
 Avoidance of loose, broken or open wiring, contact of metal parts and
 trained and competent personnel.
 While working on live conductor or equipment full sleeves are more useful as dry cloth
gives some protection against shock.
 Don't wear or keep any metallic ornament or metallic part on body.
Static Electricity
 Static electricity is a surface phenomenon associated with the contact and separation of
dissimilar surfaces.

 Friction is not necessary to generate electrostatic charge, it increases the release of

electrons and production of ionised particles.
Examples
 Contact charging by two dissimilar materials in contact.
 Plastic films passing over metal rollers
Fuse Amp Earth resistance in ohm (max)
5 15.3
10 7.6
20 5.7
30 3.8
60 1.9
100 1.1
200 0.59
 Powders flowing through duct
 People walking over carpets may become highly charged.
 Liquid flow through pipes generates charge due to adsorption of impurity ions.
Lightning
 Control of Static Electricity

 Earthing (grounding) and bonding of equipment, pipe joints, flanges and parts
 Increasing the conductance of floors, footwear, wheels and tyres for personnel and
moving equipment
 Increasing the conductivity of non-conductors by conductive additives, surface layers,
films and humidification of the atmosphere.
 Increasing the conductivity of the atmosphere by ionisation.
 Using antistatic and conductive materials and static eliminators
 Earthing of moving machinery.
 All tanks, vessels, pipelines containing solvents or flammable liquids or gases should be
separately earthed. Bonding of pipe lines at flange joints necessary unless metallic
contact (continuity) is in between the flanges.
 Tank wagons and road tankers should be earthed while loading or unloading with
flammable liquid or gas.
 Rail-track should be earthed and jumpers to be provided to connect rail to rail.
Overload and other protections

 In industrial buildings, appropriate protection at switch-boards and distribution boards for

all circuits and sub-circuits against over current and earth faults is necessary.
 The ratings and settings of fuses and the protective devices shall be coordinated
 Majority of electrical accidents can be avoided if
 Live parts are insulated in effective and durable manner and positioned safely
 Conductive parts of the equipment or machines should be earthed or double insulated and
 All components must be so dimensioned as to withstand design stresses
Power Cutting Devices (Means of Cutting of Power)
Where rapid operation is required switches, switch with' fuses, isolating links or circuit
breakers used.
 Important Safety Requirements in Design and Use of Switches, Switch-Fuses, Circuit-
Breakers and Isolating Links.
 Sufficient capacity for making and breaking contacts.
 Cover for switch.
 Handle spindle should be a close fit in die hole in order to prevent injury from arcs inside.
Handle should be insulated.
 "On" and "Off" position in switches and circuit breakers should be clearly marked.
Types of Protections
 Capacity and Protection of Conductors, points and Connectors

 All apparatus and conductors should be of sufficient size and strength. They should be
covered with insulating material and placed or enclosed as to prevent danger, viz.
 Conductors in conduit
 Conductors in flexible metallic tubing
 Conductors in metal trunking
 Conductors with metal sheeting
 Insulated cables like V.I.R. and C.S.T. Cables
 cables in trench.
Earth Fault Protection
All non-current carrying metal parts of electrical equipment, should be earthed. Such parts
are:
 Metal conduits, steel trunking and cable sheets

 Non-current carrying metal parts
of
 Switchgear, fuse and starters
 Generators and motors
 Lighting fittings and Other electrical equipment or appliances.
 Earth Leakage Circuit-Breakers (ELCB):
If an earth leakage circuit breaker (ELCB) is provided, it will operate due to rise in earth
voltage or current and open the circuit as fuse opens. This will stop the current towards
equipment or machine, it will be de-energised and its contact will become safe.
Lockout and Tag-out

 Lockout and tag out are generally industrial practices indicating 'warning' that the
equipment or machine so locked or tagged out shall not be used till that lock or notice is
removed
 Lockout means making the equipment / machine inoperative or power - isolated so
that it cannot be started or used. Locked label or notice of 'Lockout' indicates that this
equipment or machine is faulty, under repair or-maintenance and is locked for the purpose
of not using it till this lock or notice exists.
 Tag-out means to tie a tag on the equipment or machine to indicate that it is under
repair or maintenance and not to be touched or used. Tag out is most essential when lockout
is not possible. It can be used in addition to lockout for further precaution.
 Procedure of lock out

 Before locking or tagging, inform the concerned operators and users that line, switch, valve
or equipment will be isolated or de-energized and give them time to complete or stop their
work.
 Plan the shut down and make the system off.
 Insert lock and attach tagging.
 Test that the isolation is positive and as, per expectation.
 When repair / maintenance work is over, open the locking and tagging.
 Again inform the concerned people that locking / tagging is removed and they can work as
usual.
Protection against Surges and Voltage Fluctuation:
When equipment is switched on, momentarily initial excessive currents are known as current
surges or transient current. Surges may be more in starting cold circuits than the hot circuit
i.e. restarting of the previously live circuit which was closed for a short while. For example,
when large banks of filament lamps are switched on, current surge arises, because they have,
much lower resistance when cold than when hot.
If a live lamp circuit is made off and soon reenergised, it will face fewer surges.
Therefore, fuse or circuit breaker rating should consider this surge phenomenon
Switching large power transformers or starting up motors driving high inertia loads,
also cause large current surges if closure occurs near maximum voltage. H is therefore
important to ensure that the motor and starter are both suited to the duty. Failure to do this
may cause the motor to burn out or the starter to explode.
Voltage fluctuation
 From the electricity supply, lines have become a common phenomenon at many places.
Supply voltage goes down resulting in reducing speeds of fans, motors, machines etc. and
reducing lamp lighting. Again, it comes and stabilizes the condition. Such voltage
fluctuation, if on higher side, may blow fuses or protection and if on lower side, reduces
the productivity or effect of equipment.
 Automatic voltage regulator or voltage stabilizer, either built-in with the equipment
(mostly with household appliances like freeze, TV etc.) or external are readily available.
 Voltage fluctuation on either side is harmful. It 'accelerates or decelerates speed of
machine or production. It damages furnaces by over or under heating. It increases or
decreases lighting, ventilation, voice etc. and many power dependent parameters. Change
in temperature affects reaction rate in chemical processes

Earth, Insulation and Continuity Tests:
When electric current passes through its expected resistance (load) path, its energy is
utilized in heating, rotating or doing the required function. But when due to insulation failure,
breaking, opening or loosening of conductor or directly touching to any metal part, tool or a
human body, the current passes through the line of least resistance i.e. instead of passing
through its regular machine or equipment circuit, it jumps (diverts) to the metal part or human
body and tries to flow through the lowest resistance to the lowest potential.
Now the earth has an extremely low electrical resistance and practically zero voltage,
the leaking current (i.e. earth or fault current) tends to flow through the metal part or the
human body to the earth if they are touching the earth. If the human body is separated or
insulated from the earth by insulating material like rubber gloves, rubber shoes, rubber mat,
wood etc., the current will not flow through the body and the shock can be avoided.
Similarly, metallic exposed part if not earthed, will remain live and if some one
touches it or metal contact between the exposed part and the earth is available, the current
will flow to the earth.
No Load Protection:
Over current condition is generally known as 'overload' condition. It should be

protected by equipment which will operate at excess (more than rated) current and stop the
supply. Similarly low current or low voltage condition is said to be 'no-load' condition and it
also needs to be protected. Simple running of an electric motor without rotating the pump,
generator or machine shaft, is known as no-load working. It draws minimum current
depending on winding resistance. With the same resistance, if the voltage is reduced, it will
reduce the current. In such condition, the use of fuses as a tripping device is generally
preferred.
In low voltage system if the circuit is direct current type or heavily loaded, the slow
operation of fuses (low current) often results, in arcing or flashover followed by burning of
the contacts and this is dangerous for service personnel.
STATUTORY REQUIREMENT AND STANDARDS FOR ELECTRICAL SAFETY
Overview
There are many different electrical safety standards that need to be followed in the
workplace to protect the integrity of the building as well as make sure employees stay safe
while on the job. That includes preventing electrical shocks, electrical fires, and other
electrical hazard related issues. Consensus standards, such as electrical safety standards, are
often developed by safety companies, governmental agencies, or other ANSI accredited
businesses that work to find the best practice methods in particular situations.
In terms of electrical regulations, OSHA often makes a point to incorporate by reference
consensus standards created by organizations such as the NFPA who have been
appropriately accredited by ANSI. Those incorporated standards then become regulations
which are enforced by government agencies, such as OSHA. All of which can come with
serious penalties if not followed.

With that being said, standards are simply best practice recommendations, and there is no
enforcement measures possible. Following standards for electrical safety, however, is still in
the best interests for all companies. In fact, doing so can still save a business from being
cited by OSHA under the general duty clause for not providing employees with the safest
environment possible.
OSHA Electrical Safety Regulations
The best-known name in workplace safety is the Occupational Safety and Health
Administration, or OSHA. OSHA regulates many different aspects of workplace safety,
including basic electrical safety. Some of their most important electrical standards include
the following within the General Industry section:
29 CFR 1910.137 Electrical Protection Equipment – OSHA requires that the right electrical
protective equipment is worn or used whenever working on dangerous electrical systems.
This particular standard goes over the design, marking, and testing requirements of
electrical safety equipment.
29 CFR 1910.269 Electric Power Generation, Transmission, and Distribution – Those who
work in electrical power generation, transmission, and distribution need to follow the
special instructions for this industry. It covers the specifics on operation and regular
maintenance to these electrical systems.
OSHA also has specific guidelines for working on electrical systems while at sea. The
electrical standards pertaining to the Maritime Industry include:
29 CFR 1915.181 Electrical Circuits and Distribution Boards– Applicable to ship repair
only, this standard defines the criteria necessary for working on electrical circuit boards.
29 CFR 1917.157 Battery Charging and Changing– This standard primarily goes over who
is able to change batteries, where they can be changed, and what to look for in terms of
hazards.
OSHA has also approved of 28 state plans for electrical safety. The stipulation here is that
the state plans must have both standards and enforcement plans that are as effective as
OSHA’s already existing regulations. With that being said, the state plans are allowed to be
stricter regarding electrical safety, but they cannot be more lenient than OSHA.
NFPA Electrical Safety Standards
The National Fire Protection Association, or NFPA, is another group that provides safety
standards focused on electricity. The NFPA’s most famous set of standards is NFPA 70 and
is also known as the ‘National Electrical Code’ or NEC. There are nine chapters included in
the NEC that cover the subjects
However, many states have yet to adopt the most recent version made in 2020, as the NEC
is updated around every three years. There are even states that are still stuck using the 2008
edition.
The other standard put out by this organization that is well known is NFPA 70E. As a much
more narrowed approach in terms of standards, NFPA 70E sets forth safety requirements
that
offer a great balance between workplace safety and productivity. The standard itself covers
shock protection boundaries, electrical equipment, arc flash safety, arc flash hazards,
common electrical hazads, lockout-tagout systems, and other electrical hazards. Now,
ANSI/NFPA 70E is not federal law but rather works as a baseline for local laws in each
state.
Regardless, while the NFPA doesn’t have any legal enforcement power, they are among the
most respected agencies in the country and are voluntarily followed by millions of
companies. If a company doesn’t follow the standards, they can’t claim to be NFPA
compliant.
Factories Act and Rules:
However the Factories Act and Rules do not contain any details of electrical safety and
therefore no effective implementation of the electrical safety is possible through this Act.
No prosecution is possible for such purely electrical causes except u/s 7A.. Only section 36
A speaks of portable electric light of less than 24 V and section 37 requires effective
enclosure to sources of ignition. Which includes flame proof electric fittings.
Rule 86 of the Karnataka Factories Rules, 1969 provides as under:
"Electricity - (1) No electric installation shall be provided in factory, so as to be dangerous
to human life or safety in the opinion of the Inspector. Provided that the Inspector may issue
an order in writing, specifying the arrangements necessary for adequate safety, in addition
to what is provided under Fundamentals of Industrial Safety and Health 11- 4 Electrical
Safety the provisions of Indian Electricity Act or Rules there under.
(2) In the main switch board or switch boards of factories, there shall be provided earth
leakage and overload relays. The earth leakage relay shall be so provided that the leakage
current shall not cause electrocution or other hazard."
These provisions are insufficient to scrub violations of electrical safety rules. This may be
due to the separate Electricity Act and Rules as follows:
Electricity Act and Rules: Electricity Act 2003 and Rules' 1956 &2005 require many safety
aspects. Under these rules the consumer is responsible to maintain his electrical installation
fully safe and certified. An inspection by Electrical Inspector is also required.
List of Indian Standards.
Many IS are available on electrical safety such as :

 Current passing through human body, effects 8437,
 Drilling machines, flameproof, for use in mines 9192, fuses 2086, 1884, 3106,
 transformers. Safety 1416,
 lifts dimensions 3534,
 lighting fittings - flameproof 2206 (Part I to 4),
 safety requirements for luminaries 1913/ waterproof 3528,
 water tight 3553,
 power connector; 5561,
 shock-equipment for protection against 9409,
 strength test for solid insulating material 2584,
 electrical accessories 5133,
 apparatus and circuit intrinsically safe 5780,
 control devices operating electrical apparatus 7118,

 flameproof enclosures -2148,

 for use in explosive gas atmosphere 7693,

 spark test apparatus for 9166, testing 649,
 appliances-household, safety requirement 302,
 connections for lighting fittings, screwless 6585,
 for explosive atmosphere 8239, 8240 8241, 4691, 7389, of machine tool 1356,
 installation - classification of hazardous areas 5571, 5572,
 filled protection of electrical equipment 7724,
 safe magnet telephones for use in hazardous atmosphere 6539,
 safety for rectifier equipment 6619,
 insulating materials 8765, 4249, 6792,
 environmental tests 8999, 9000,
 layout in residential buildings 4648
 measuring instruments for explosive gas atmosphere 8945, relays 3842, 5834, 3231,
 resistance-material test 3635,
 power stations - fire safety 3034, wiring 732, 1653, 3837, 2669,
 dust-proof electric lighting fittings 4012,
 dust-tight electric lighting fittings 4013,
 dust-tight ignition proof enclosures 11005,
 flash back (flame) arrester 11006,
 lightning arrester 4850 (withdrawn),
 building protection against lighting 2309,
 indicating instruments 1248, 3107, 9319, induction motors 900, starters 5124,
switches push button 4794, heavy duty 4047,
 electrical equipment for use in medical practice 8607 (Part I to 8), warning symbols
for dangerous voltages 8923,
 safety requirement for measuring instruments 9249,
 safety requirements for refrigerators, food freezers 10542,
 building for installation of electric apparatus for gas atmosphere, rubber mats 5424,
rubber gloves 4770, safety for audio amplifiers 1301, electric wiring in hospitals
7733, wiring voltage exceeding 650 volts 2274, not exceeding 650 volts 732,
overhead power and telecommunication lines concrete poles 7321 and portable
methanometer (electrical type) 9937.
 static electricity, guide for control 7689,
 electro heat installation, safety requirement 9080,
 guide for safety procedures and practices in electrical work 5216,
 danger notice plates 2551,
 earthing, code of practice 3043,
 IS:5216 - Guide for Safety Procedures and Practices in Electric Work - Part I :
General and Part 2 : Life Saving Techniques must be followed strictly. A form of
permit-to-work and special instructions while working with such permit are given in
Part 1. Use of IS for hazardous area classification, equipment to be used in such area
and earthing practice are also recommended.
 SP 30 National Electric Code compiling many IS on electrotechnology, and SP 31 on
treatment for electric shock are most useful for safety purpose. Other special
publication SP 39 on low-voltage systems, SP 48 on electric irons, SP 49 on electric
water heaters, SP 50 on electric radiators and SP 51 on electric stoves are also useful.

National Electric Code (NEC) :
This Code was adopted by the Indian Standards Institution on 15-6-84 and was first
published in - August 1985. Its number is SP:30-1984. The object as stated in the Code, is to
complement the Indian Electricity Rules 1956 by way of elaborating as well as
recommending practices to comply with their requirements. This Code is to provide
information in a consolidated form to electrical engineers and contractors in the country
who are concerned with the design and operation of electrical installations. The subject
matter is divided into the following seven parts :
1. General and Common Aspects.
2. Electrical Installation in Standby Generating Stations and Substations.
3. Electrical Installations in Non-industrial buildings.
4. Electrical Installations in Industrial Buildings.
5. Outdoor Installations.
6. Electrical Installations in Agriculture Premises, and
7. Electrical Installations in Hazardous areas.
Code of Practice for Electrical Wiring Installation
IS − 732 (1989)
Section − Electrical Installation
Application − Design of installation, selection and erection of equipment, inspection and
testing of wiring system
Code of practice for Earthing
IS − 3043 (1987)
Section − Electrical Installation
Application − Design, installation and calculation of Earthing system
Lightning arrester for Alternating Current System
IS − 3070 (1993)
Section − Electro technical: Surge Arresters
Application − Identification, ratings, classification and testing procedure of Arrester

Practical No: -6
Aim: - To study Effective ventilation for safe work place.
INTRODUCTION ABOUT VENTILATION AND ITS PURPOSE AND TYPES

Ventilation means providing air or supply free movement of air within spaces. It is process
of Replacement of Indoor air with fresh outdoor air. It is movement of Indoor air out and
outside air to inside in closed area.
 Clean, fresh and uncontaminated air is a basic need of life. Industry has many
pollutants which Contaminate air and heat stress is generated due to hot processes.
Hence, It is mandatory to Well designed and effective ventilation system Need to be
developed for the industry for workplace for workers to overcome the breathing
problems and Health hazard.
3. BASIC PURPOSE OF EFFECTIVE VENTILATION
 Air is life and fresh air is the first need for survival of living humans on the earth.
Absence of air bring death within a few minutes. Clean air is needed for Human
body. Therefore good/effective ventilation need for Living creatures within space.
 Human body cannot tolerate excessive temperature. Heat stresses produced by very
hot or cold exposures cause adverse effects on health and safety of work people.
Therefore environmental temperature control is also permanently needed for well-
functioning of human body. Ventilation helps in removing excessive temperature.
 Carbon dioxide is continuously exhausted by all human beings. Much more
contaminate pollution added by manufacturing processes to pollute air. Therefore
cleaning of air and supply of fresh air with sufficient oxygen are also necessary. This
is possible by good ventilation and pollution control techniques only
 Heavy physical work or heavy work load causes heat stress and strain and increase
metabolic heat, body temperature, sweating, heart rate etc. To maintain (control) body
temperature, ventilation is necessary.
Fig 1:- Human Exposed to Sun Fig 2: - Sources of heat - Solar

a main source of heat. radiation and -hot processes

 Where due to weather or atmospheric conditions or process parameters, excessive

temperature is unbearable or uncomfortable, air conditioning or HVAC systems are
also necessary. Conversely where air heating is necessary as in case of excessive cold
climate, it must be provided.
 While designing of Industrial Building, Natural ventilation is provided. If natural
ventilation is not sufficient for these purposes, mechanical ventilation, cooling system
or other techniques must be employed to achieve satisfactory results.
 Infact of the above Basic purpose of Good/effective Ventilation
 Main four functions of ventilation are (1) to supply sufficient fresh air (2) to
distribute it throughout the work room (3) to remove polluted and hot air and (4) to
maintain comfortable working conditions
4. Ventilation System can be classified as below
Fig 3: - Ventilation System
5. Types of Ventilation
 Ventilation systems are of two types (1) Supply air system and (2) Exhaust system.
Supply air system has two purposes (A) heating, ventilating and air conditioning
(HVAC) for comfortable environment and (B) to replace exhausted air from the
plant. Exhaust system is of two types: General and Local exhaust type. General
exhaust system is for heat control and/or removal of contaminant by dilution
ventilation and Local exhaust system is for capturing contaminant at source.

 Natural Ventilation : Natural ventilation is induced because of two reasons (1)

outside wind pressure i.e, wind action and (2) temperature difference of the air inside
and outside the room i.e. chimney effect. There is a positive pressure on windward
side and negative pressure on leeward side. By providing adequate openings in these
pressure areas, natural ventilation can be achieved.
 Mechanical Ventilation: Mechanical ventilation is employed for building i.e.
workroom and also for process for removal of contaminants.
Fig 4: - Saw tooth For Ventilation
 Local Exhaust Ventilation: Ventilation effected by exhaust of air through an

exhaust appliance, such as hood with or without fan located as closely as possible to
the origin of contaminants so as to capture effectively the contaminants and convey
them through ducts to a safe point of discharge (e.g. dust collector, scrubber, flare
etc.).
 It is applied at the release points of contaminants (dust, gas, fumes, particles etc.) to
reduce their concentration in the workroom below TLVs. Such points shall be
enclosed except where access is necessary for the process, but in that case, the exhaust
appliance shall confine the contaminants as much as possible
 The volume of air required is calculated from the area of openings and the capture
velocity sufficient to prevent outward escapement. The sizes of the ducts shall be
calculated from the volume of air required and duct velocities necessary to convey the
contaminants with minimum static resistance.

Fig 5: - Elements of Local exhaust system
6. Legal Requirements
 Sec. 13 of the Factories Act requires effective, suitable and adequate ventilation in
every factory, by the circulation of fresh air and such a temperature to provide
comfort and prevent health injury to workers. It also requires well designed walls,
roofs and insulation of hot parts to reduce the excessive temperature.
 Sec. 14 requires local exhaust ventilation at the source of dust, fume or other
impurity, with the enclosure (hood or cover) on such source (point of origin), to
prevent inhalation and accumulation in the workroom, of such injurious or
offensive dust and fume.
 Sec.l5 provides for artificial humidification and rules 19 to 29, GFR, prescribe dry
and wet bulb temperatures, details of hygrometer and manner of introducing
steam.
 If Chief Inspector of factory observed higher excessive temperature, he may
prejudice writing in the Order to occupier.
 Sec. 16 calls for 'a minimum 14.2 m" (height 4.2 m max.) of breathing space per
worker.
 Rule ISA of the Gujarat Factories Rules (GFR) prescribes workroom temperature 30
“C (86°F) at height of 1.5 mt, air movement of at least 30 m/min with 6 air changes
per hour, a schedule for dry and wet bulb temperatures and ventilating area more than
15% of the floor area. See Part 6.4 for details.
 Rule 102 (GFR, 1963) and many Schedules there under require effective local
exhaust ventilation on dust/fume/gas generating processes and their test report in
Form No. 26A.

7. Safety Aspects
 POOR/BADVENTILATION IN FACTORY
 Poor/Bad Ventilation are opposite of the effective Ventilation.
 No way for air circulation,
 Wrong Design of Ventilation,
 No Job Satisfaction due to work place climate condition,
 Air contaminated due to process gas,
 If, you don’t feel good and due to environment condition against Poor Ventilation,
you may report to your Superior for further course of action to avoid unsafe act during
work.
Fig 6: - Ventilation is badly obstructed
Fig 7: - Poor ventilation in factory while handling of Asbestos.

Practical No: -7
Aim: - To study about machine guarding
1. Statutory Requirements.
2. Indian Standards.
3. Ergonomics of Machine Guarding:
(1) Meaning of Ergonomics.

(2) Aims of Ergonomics.
(3) Human Factors in design of machine and work.
(4) Safe Job Methods (Procedures):
(A) Some Methods.
(B) Man-Machine Chart.
4. Principles of Machine Guarding:
(1) Elimination of Hazard.
(2) Need and Importance of Machine Guarding.
(3) Groups of Dangerous Parts:
(A) According to Motions
(B) According to H. A. Hepburn.
(4) Requisite Characteristics of Guards.
5. Types of Guards:
(1) Some Types.
(2) Incidental Safety Devices and Methods.
(3) Guarding of Different Machines.
6. Materials for Guard Construction.
7. Maintenance and Repairs of Guards.
1. STATUTORY REQUIREMENTS
Besides its basic need, machine guarding is a statutory requirement since a century. With the
growth of industrialization need of machine guarding was noticed and incorporated by the
enactment of the first Factories Act in England in 1844 and in India in 1881. The Act was
amended in 1891, 1911,1922, 1923, 1926, 1931, 1934, 1948, 1976 and 1986 to gradually
include more & more aspects of safety & other provisions. The present Act known as the
‘Factories Act 1948’ contains Chapter-IV on safety which includes many provisions of
machine guarding. The Gujarat Factories Rules 1963 provides further details to supplement
these provisions. The whole subject of the Factories Act and Rules is separately dealt with in
Chapter-25, but some relevant portion is given below :
Definitions:
Power means electrical energy or any other form of energy which is mechanically transmitted
and is not generated by human or animal agency. Prime mover means any engine, motor or
other appliance which generates or otherwise provides power. Transmission machinery
means any shaft, wheel, drum, pulley, system of pulleys, coupling, clutch, driving belt or
other appliance or device by which the motion of a prime mover is transmitted to or received
by any machinery or appliance. Machinery includes prime movers, transmission machinery
and all other appliances whereby power is generated, transformed, transmitted or applied.
Belt

includes any driving strap or rope. Maintained means maintained in an efficient state, in
efficient working order and in good repair.
Fencing of Machinery:
Section -21 requires that every moving part of a prime mover, flywheel, headrace and tailrace
of water wheel and turbine, lathe, electric generator, motor, rotary converter, transmission
machinery and every dangerous part of any other machinery shall be securely constructed,
positioned or fenced by safeguards of substantial construction and constantly maintained and
kept in position while the parts of machinery they are fencing are in motion or in use.
Work on or near machinery in motion:
Section 22 requires that any examination, lubrication, adjusting operation, mounting or
shipping of belts while the machinery in motion shall be carried out by a specially trained
adult male worker wearing tight fitting clothing supplied by the occupier and his name shall
not handle a belt at a moving pulley unless the belt is not more than 15 cm in width, the
pulley is a normal drive (no flywheel or balance wheel), the pulley, joint and pulley rim are in
good repair, there is reasonable clearance to work, secure foothold/handhold are provided and
any ladder being used is secured fixed or held by a second person. At that time other parts in
motion shall be securely fenced to prevent contact. Woman and young person are not allowed
to do such work.
Employment of young persons on dangerous machines:
On power presses except hydraulic presses, milling machines, guillotine machines, circular
saws and platen printing machine no young person shall work unless he has been fully
instructed regarding their dangers and precautions to be observed and has received sufficient
training to work on that machine and is under adequate supervision by a person who has a
thorough knowledge and experience of that machine (Sec. 23 & Rule 57)
Striking gear and devices to cutting off power:
Suitable striking gear or other efficient device to move driving belts to and from fast and
loose pulleys and to prevent the belt from creeping back on to the fast fully shall be used and
maintained. Driving belts not in use should not rest or rid upon shafting in motion (for which
belt hangers are necessary). Other devices for cutting off power are necessary in every work
room. Such devices shall be so locked to prevent accidental starting of the machinery.
Self acting machines:
45 cm or more clear space is necessary from the end of maximum traverse of any self-acting
machine or material carried thereon.
Casing of new machinery:
Every set screw, bolt, key, gearing shall be completely encased or guarded to prevent
danger. Work near Cotton-openers:
No woman or child shall work in a room where cotton opener is at work. If the feed-end is fully
partitioned from the delivery end, their employment on feed-end side is permissible.

Revolving machinery :
Effective measures are necessary to ensure not to exceed the safe working peripheral speed of
every grinding wheel, revolving vessel, cage, basket, flywheel, pulley, disc or similar
appliance driven by power. A notice indicating such speed, shaft or spindle speed and the
diameter of the pulley in case of grinding wheel shall be affixed near each such machine.
Pressure Plant:
Safe working pressure of any part of the plant or machinery operating at a pressure above
atmospheric pressure shall not be exceeded. Rule 61 and 61A prescribe much details. Form
No. 11 and 11A are the testing reports necessary. Such pressure vessel should be of good
construction, sound material, strength, thickness, free from patent defect, safe condition and
fitted with safety devices such as suitable safety valve, pressure gauge, stop valve drain cock,
reducing valve, automatic pressure control device, thermometer, pyrometer, rupture disc etc.
Further Safety Precautions:
Rule 54 prescribes machine guarding details in respect of cotton textile or artificial fiber
machinery, cotton ginning machinery, wood-working machinery and rubber mills. Rule 102
also prescribes details of 20 types of dangerous operations (schedules) for the safety
purposes. Part 5 (2) of this Chapter describes guarding of some such machines.
2. INDIAN STANDARDS :
Many Indian Standards are available. A few are given below :
Subject I.S. No.
1. List of IS on Safety –
2. List of IS on Mechanical Engineering –
3. List of IS on Foundry Industry –
4. List of IS on Automobile Industry –
5. List of IS on Agricultural Equipment Industry –
6. Unfired Pressure vessels 2825–1969
7. Belting for power transmission 2122–1973
(Part – I for Flat belt, Part–II for Vee–Belt)
8. Care and practice of abrasive wheels 1991–1973
9. Degrees of protection provided by enclosure for rotating 4691–1968
Electrical machinery
10. Wood working machines (part – I to XXIV 8964–1978
&1979

These standards are useful from design to maintenance purposes.

3. ERGONOMICS OF MACHINE GAURDING
(1) Meaning of Ergonomics:
As explained by W. T. Singleton in ILO Encyclopedia, literal meaning of ‘ergonomics’ is the
study – measurement – organization of work. It is concerned with making purposeful human
activities more effective. The focus of study is the person interacting with the engineering
environment. The designer should consider complexity arising from human nature and his
limitations. To consider human factors, it studies anatomy, anthropometry, biomechanics,
psychology as useful sciences. To consider design aspect of work, systems, work space,
environment, interface and work situation, it studies technology. Thus an ergonomist is
expected to take an over-all view and identify the key design aspects for particular people
engaged in particular tasks.
As explained by K. Kogi, a Regional Advisor to ILO, ergonomics is a useful tool for fitting
work to people, not people to work. ‘Ergon’ means work and ‘nomos’ means habits or law.
Thus ergonomics is for the purpose of solving the problems of work habits. It requires
designing of proper workspace, working posture, reach, display, communication, skills, work
intensity, sufficient time for rest, good environment, clear understanding and providing
platforms or lift tables, carts, transport ways, proper storage racks, buffer stocks, good
lighting, ventilation and house-keeping, proper guards and good welfare facilities. Thus
ergonomic principles include comfortable posture, balanced and easy motions, adequate rest
and enough variety.
Explaining the historical part, King and Magid state that this work was first used in 1949
when the society, the Ergonomics Research Society was founded in Britain including
anatomists, physiologists, psychologists, industrial medical officers, industrial hygienist,
design engineers, work study engineers, architects, illuminating engineers and others. In USA
the terms ‘Human Engineering’ and ‘Human Factors Engineering’ are used to cover the same
field. Biomechanics and Engineering Psychology are other expressions used.
(2) Aims of Ergonomics:
Its aims are (1) To facilitate what ever a person wishes to do and to ensure that he does it
efficiently. Efficiency includes effective work without detrimental health effects and
minimization of risk to the operators and others. (2) To minimize the possibility of human
error or mistake. To ensure industrial activities with minimal use of energy and materials and
without waste resulting from mistakes (3) To develop knowledge and techniques by the
combined use of many expertise and systems approach. (4) To solve human problems of
work performance by considering human factors in design of machines and work and safe job
methods which are explained below.
(3) Human Factors in Design of Machine and Work
Technology has changed the people’s ways of working but the people have not changed
much. Many times the people do not adapt physically and mentally, a tendency of modern
work methods. This generates negative reactions which also indicate human factors to be
considered while designing work and machines. Some such factors are : (1) Increased stress
(2) Uninterested work (3) errors and accidents (4) Work related diseases (5) Awkward
body

position causing difficulty (6) Repetitive tasks producing boredom and tiredness (7)
Confusing signals causing human errors in hurry (8) Bent or awkward posture while handling
heavy materials and causing back paint (9) Perceptual limitation (10) Short term memory
(11) Incompatibility in man-machine relationship (12) Risk or chance taking (13) Position or
location not suitable to a worker such as unsuitable work height, seat, layout of control and
displays (14) Organization of heavy work and (15) Environment
(4) Safe Job Methods (Procedures)
(A) Some Methods :
Designing of safe machine guarding is not sufficient. For all-round efforts of eliminating
accidents, safe job methods are equally important. They include (1) Various safety appraisal,
analysis and control techniques (2) Plant safety inspection techniques and (3) Accident
investigation and analysis methods.
Constant improvement in job methods is important. It requires four steps: (1) Break down the
job (2) Question every detail of the job (3) Develop a new job method and (4) Apply the
method. The procedure includes (a) Eliminating certain job details by using alternative
methods
(b) Combining some details to reduce hazards and unnecessary transportation, handling,
delay etc. (c) Rearranging certain details into better sequence to reduce hazards, handling,
delay etc. and (d) Simplifying certain details so as to make the work safer and easier.
(B) Man – Machine Chart:
Machines being costly, it is desirable to run them efficiently and economically. The man-
machine chart (Gantt Chart) is a useful device in this direction to identify and eliminate losses
of capacity. Durations of elements of operation of man and machine are recorded in their
sequence, placed side by side and compared. The time of operations, transports and waits
occurring in the operator’s cycle and the time of start up, shut down, machining time and idle
time in the machine cycle are ruled off by proportionate symbol columns. The length of
symbol columns. The length of symbol columns representing a wait period of man and
machine are coloured in red to distinguish it from their productive periods. Per piece machine
operating time, machine idle time, man hours and man delay hours are concluded.
Application of the chart for group work is estimated by first assuming the theoretical crew
necessary to run the machine at the required output and then trying to organize the same
number of practical people to do the job. A general rule ‘To decide first what has to be done
and then how to fit people to do the work and not vice versa’ is followed. The standard times
found by work measurement are divided by a correction factor 1.25 to consider leveling and
compensating rest allowance. The charts are prepared for the purpose of analyzing the present
method of performance of the operation and improving on it. The steps of job improvement
method just described in para (A) are utilized for such improvement.
4. PRINCIPLES OF MACHINE GUARDING
(1) Elimination of Hazard:
The basic steps to prevent accident are: (1) Eliminate the hazard from the machine, method,
material, structure etc. (2) Control the hazard by enclosing or guarding it at its source (3)
Train personnel to know that hazard and to follow the safe job method to avoid it and (4) Use
personal protective equipment necessary.

Thus machine guarding is one of the basic step to eliminate hazard. Actually the machine
should be so designed that all safety points are incorporated by built-in-safety principle and
need of extra guards is minimum. A machine safety checklist given by the NSC, USA is more
effective. It suggests: (1) Design the machine so that it is impossible for an operator to get at
the point of operation or any other hazard point while the machine is working (2) Design the
machine so that corners and edges are rounded. (3) Locate machine controls so that the
operator will not be in the vicinity of the point of operation while actuating the controls (4)
Place the control so that the operator will not have to reach too far or move his body off
balance in order to operate the machine (5) Build power transmission and drive mechanisms
as integral parts of the machine (6) Build overload devices into the machine (7) Design the
machine for single point lubrication (8) Design mechanical, instead of manual, holding
devices (9) Design a mechanical devices for feeding and ejecting parts so as to eliminate the
use of hands for such operations (10) Minimize motor drift-time (11) Provide failsafe
interlocks so that the machine cannot be started when it is being loaded or unloaded or being
worked on. (12) Provide a grounding system for all electrical equipments (13) Provide
standard access platform and ladders for inspection and maintenance of equipment (14)
Design component parts of equipment for easy and safe removal and replacement to facilitate
maintenance and (15) Reduce sources of excessive noise, vibration, heat etc.
(2) Need and Importance of Machine Guarding :
Basic need of machine guarding is to protect against contact with the dangerous and moving
parts of a machine, work in process and failure due to mechanical, electrical, chemical, or
human causes. The guards remove workers’ fear and thereby increase the production. They
allow the operation at higher speeds and compensate the expenditure on guarding.
(3) Groups of Dangerous Parts :
(A) According to Motions :
Dangerous parts to be guarded according to their motions are generally classified as follows :
Group – I, Rotary Motions : (1) Rotating parts alone viz. shafts, coupling, spindles etc. (2) In-
running nips subdivided as (a) Between parts rotating in opposite direction-gears, rolls etc.
(b) Between rotating and tangentially moving parts-conveyors, belt drives etc. (c) Between
rotating and fixed parts-grinding wheel, paper machine felt or roll etc.
Group – II, Reciprocating Sliding Motions : (1) Reciprocating sliding motions and fixed parts
(a) Approach type-danger of crushing, viz. slides (rams) on power presses and forging
hammers, pistons, cross rod of a steam engine and riveting machines. (b) Passing types-
danger of shearing, viz. planning machine, shaper, spot welder clamping fixtures, guillotine
and the shear, powers press etc. (2) Single sliding motion-abrasive or sharp nature of objects
such as saws or crocodile clips on belts.
Group – III, Rotating/ Sliding Motion : A cam gear having sliding and turning movement etc.
fall within this group.

Group – IV, Oscillating Motions : Trapping points between two moving parts or between a
moving part and a fixed object viz. a pendulum, crankshaft etc.
(B) According to H. A. Hepburn:
25 groups of intrinsically dangerous parts of machinery as classified by H. A. Hepburn are as
follows :
(a) Single Revolving Units – Risk of entanglement
(1) Revolving open arm pulleys and other discontinuous rotating parts – Fan blades, spur
gear wheels etc.
(2) Revolving worms or spirals in castings – Meat mincers, rubber extruders, spiral
conveyers.
(3) Projections on revolving parts – Key heads, set screws, cottor pins, compling belts etc.
(4) Revolving shafts, spindles, mandrels and bars – Drills, reamers, boring bar, stock bar,
milling etc.
(b) Single Revolving Units – Risk of cutting or abrading
(5) Revolving high speed cages in castings – Hydro – extractors, centrifuge.
(6) Revolving or oscillating mixer arms in castings – Dough mixture, rubber solution
mixture.
(7) Revolving drums and cylinders-uncased – Rumbler, shaking barrels, rag digesters etc.
(8) Revolving cutting tools – Circular saws, milling cutters, shears, routers, chain
mortisers.
(9) Abrasive wheels Grinding wheels etc.
(c) In Running Parts – Risk of nipping and tearing
(10) In running nips of belt and pulley type-Pulley-blet, chain and sprocket gear, conveyor
belt etc.
(11) Revolving beaters, spiked cylinders and drums – Scutchers, cotton opener, laundry
washers.
(12) In running nips between pairs of revolving parts – Gear wheels, friction wheels,
calendar bowls, mangle rolls etc.
(13) Nips between gears and rack strips.
(d) Reciprocating Tools or Parts – Risk of cutting or crushing
(14) Moving balance weights and dead weights – Hydraulic accumulators, balance weight
on slotting machine etc.
(15) Reciprocating knives and saws – Guillotines for metal, rubber and paper cutting,
trimmers, perforators etc.
(16) Nips between reciprocating and fixed parts other than tools and dies – Sliding table
and fixture, shaping machine and fixture.
(17) Closing nips between platen motions – Letter press platen printing machine, power
presses.
(18) Reciprocating tools and dies – Power presses, drop stamps, relief stamps, bending
press, revolution press.
(19) Nips between revolving control handles and fixed part – Travers gear handles of
lathes, milling m/c etc.
(20) Nips between revolving wheels or cylinders in pans or on tables – Sand mixtures,
edge runners, crushing mill, mortar mill etc.

(21) Nips between fixed parts and unidirectional moving parts – Buckets or hoppers or
conveyors against tipping – bars etc.
(22) Nips between connecting rods or links and rotating wheels, cranks or disc – Flat bed
printing machine, jacquard loom, automatic looms.
(23) Pawl and notched wheel devices for intermittent feed motions – Planer tool feed
motion, power press dial feed table etc.
(c) Running Edges – Risk of cutting
(24) Cutting edges of endless band cutting machines – Band saws, band knives.
(25) Projecting belt fasteners and fast running belts – Bolt and nut fasteners, wire pin
fastners, centrifuge belt etc.
(4) Requisite Characteristics of Guards:
The twelve characteristics, specifications or basic requirements of a guard are :
(1) With its primary purpose of protection, it should also facilitate the work i.e. it should be
convenient, reliable and not hampering the work or production
(2) It should fully satisfy the legal provisions and IS prescribed i.e. it should be a complete
guard and not incomplete or giving any access to the part to be protected. It should be as
close as possible
(3) It should be suitable and effective to the job and the machine. It should not weaken the
machine. (4) It should allow for oiling, inspection, adjustment and repair. If it requires
opening for this purpose, it should be easily and quickly replaceable
(5) It should withstand wear, shock, vibration and long use with minimum maintenance. If it
requires frequent opening and closing, this factor becomes more important.
(6) It should be of proper material and construction. Fire and corrosion resistant material is
preferable.
(7) It should be free from self-hazard such as sharp or rough edges, nails, splinters etc.
(8) If visual watch of operation is necessary, it should be transparent and yet durable
(9) If dusting is possible as in case of machining of wood, rubber, brass, cast iron etc., apart
from the guard, dust suction device should also be fitted as a special guarding
(10) It should be failsafe i.e. if it fails or breaks it should stop the machine or at least it should
give warning (alarm) to stop the machine.
(11) It should be interlocking type i.e. the machine will not start till it is not closed and will
stop soon if it is opened.
(12) It should fulfill special requirement depending upon its purpose viz. distance guard
should provide sufficient protective distance, trip guard must immediately trip the machine
etc.

TYPES OF GUARDS :
Total machine safety can be explained as follows:
 Machine Safety
1.Safety by
construction
2.Safety by position
3.Built-in safety
4. Safety by machine controls
5. Safety by precautions and maintenance
6. Safety by Guarding prime mover, transmission parts and points of operation
 Fixed guards or fencing

1 Total enclosure
2 With .limited access
3 With adjustable access
4 Distance or barrier guard
 Interlock guards.
1 Mechanical interlocking
2 Electrical interlocking
3 Tripguard
4 Control guard
 Automatic guards
1 Mechanical type-sweep, knock or push away guard
2 Photo-electric cell type
 Safety devices
1 Two-hand control
2 Optical sensor
3 Electro-magnetic sensor
4 Mechanical feed (conveyor)
5 Feed tools (tong, magnetic
device) 6 Non repeat device
7 Pedal guard
Safety by Construction: It indicates parts so constructed as to cause no hazard, viz. shaft,
sliding and link mechanism so located or with slow speed that their contact is not dangerous.

Built-in-safety is the similar word for designing and constructing new machinery in such a
way to make the dangerous parts safe by deep housing or position etc.
Safety by Position : This word is used by section 21 of the Factories Act. It means the
situation (out of reach) or position in such a way that normally it is not possible to touch the
dangerous parts. However intentional contact should be prevented. Moving feed opening can
be made safe by position if gravity or remote feeding device is applied. But, then, it is a type
of indirect guarding. A distance of 2.6 m or 8’ – 6” is considered safe by position.
Safety by Guarding : This is most important as other methods are not always possible.
Depending upon the dangerous part, its size, position, speed etc. a guard should be selected.
Generally the parts to be guarded fall within three categories : (1) The prime mover (2)
Transmission parts from the prime mover to the machine and the transmission parts in the
machine itself. It is desirable to minimize them and enclose completely (3) Operating parts of
a machine, of which the points of dangerous operation need effective guarding.
A Machine Guard means any enclosure, barrier or device constructed to prevent a person or
his clothing coming into contact with dangerous parts of the machine. The point of operation
is that part of working machine at which cutting, shaping, forming or any other necessary
operation is accomplished. A guard for it is known as the point of operation guard.
(1) Some Types :
Various types of guards are shown classified in the table. Their suitability should be selected.
Preference should be given to the simplest type of guard ensuring complete safety. Some are
described below and some in subsequent para (2) and (3).
Fixed Guards : They are simple, easy to provide and cover parts as well as throwing particles
if any. They are of various types, materials and design. A minimum thickness of 1.2 mm is
recommended for sheet metal. Guard opening and its distance from the dangerous part should
be fully safe. Such spacing and distance are prescribed and formula is also available, but it is
rather a matter of fact of individual requirement. They should be close fit, robust and should
withstand speed, vibration, impact etc. They should be properly fitted by clamps, bolts etc.
They require special tool for their removal.
Fixed total enclosures are used to cover prime mover and transmission parts such as
headstock gearing, belts, pulleys etc.
Fixed limited access guard provides minimum opening in the guard to insert and remove the
job (material). It disallows finger to trap. If the material is jammed, it requires special tool
and opening and refitting of the guard. They are used on power presses.
Fixed adjustable access guard provides opening through or around guard to accommodate
materials of different sizes. Guards on band saws, jigsaws can be raised or lowered as per the
thickness to cut. Such guard on circular saw or drill tool adjusts automatically as the job or
tool moves. Its disadvantage is that it gives little protection when thin material is processed.
Distance or Barrier Guards make it physically difficult for people to gain access. Nip guards
to in running rolls and fixed railing to planning or shaping machine are of this type.

Interlock Guards make certain that the machine cannot be operated until the guard screen is in
position and conversely the guard cannot be removed until the working parts have stopped.
Mechanical, electrical, hydraulic or pneumatic systems are used to actuate the guard.
Mechanical interlocking of a card machine and electrical (limit or micro switches)
interlocking of headstock covers of many textile machinery are such examples. Many times
the interlocking is by-passed or made ineffective which is not good. This is its disadvantage.
Correct position of micro switch is most important.
Trip Guards are actuated by anyone approaching beyond the safe position and operate a stop
or reverse control viz. trip rod, hand trip on a rubber mill, electronic eye, platen printing
guard, calendars or dough brakes.
Control Guard activates the machine when the guard is closed and opening the guard stops it.
Thus the guard acts as on-off switch. Such guard is useful for the machine which can be
brought to rest very rapidly.
Automatic Guards will ensure that the operator is prevented from coming into contact with
dangerous parts when the machine is set in motion accidentally. This guard is itself actuated
by the movement of the dangerous part. It can only be used where sufficient time is available
to remove the body part from the danger zone viz. sweep, knock or push away guard on a
power press or platen printing machine. Because of its stroke hazard it is hardly used. Photo-
electric guard (device) operates to stop the dangerous part when the light curtain in
interrupted.
Safety by Machine Controls : These should be differentiated from incidental safety devices
(explained in next part) which are external and work like guard for protection. But the
machine itself has many controls as its inherent or attached elements. All levers, buttons,
brakes, pedals, switches, handles, wheels, autocontrols etc. are machine controls to run the
machine safely and efficiently. Such controls should be clearly identified and suitably placed
for ease of operation. Their purpose and direction of movement shall be marked. Each stop
button should accompany start button and they should be sunk to prevent accidental
operation. Where there are more controls nearly placed or on one board clear instruction of
their use must be marked to prevent their false operation.
Safety by Precautions and Maintenance :
Above paras highlight the need of utmost precautions in safe operation and maintenance of
all safety guards, devices and controls. A man has made them and a man can make them
ineffective or misuse. Therefore all precautionary operating measures are necessary in
addition to the machine guarding. The machine operators should be made aware of hazards in
their works, location and operation of machine controls, regular checking of guards, warning
not to make the guards ineffective, repairs, adjustment etc. by specially trained person, need
of wearing tight fitting clothing and protective equipment necessary and using right tools and
equipments.
(2) Incidental Safety Devices and Methods :
Some incidental safety devices (indirect guards) equally useful as machine guarding are as
below :
Two Hand Control : Two push buttons are required to be operated simultaneously thus
keeping the operator’s hands away from the dangerous parts. Such device does not protect an

another man, is prone to faults and cause difficulties on electrically, hydraulically or
pneumatically

powered machines. Therefore such device alone is not advisable. It is used on garment
presses etc.
Optical Sensor: This uses photo-electric cell and a light as explained earlier.
Electromagnetic Sensor : This uses a sensor of electro magnetic field, a coupler and
interconnecting cable and a control unit. Interruption of the field by an operator’s hand causes
an electric signal which initiate the desired control action.
Mechanical Feed : A positioning device like a rotating table moves the parts or material into
the point of operation where the hazard exists thus avoiding human contact there.
Feed Tools : Tools with guards viz. tong, magnetic lifting rod etc. are used to place material
in a press with an intention to save the hand.
Pedal Guard : Such guard on foot-padel of a power press prevents accidental foot-stroke on
the pedal.
Ultrasonic device : Inaudible high-frequency sound senses the presence of any part in the
danger zone. As sound attenuates over distance its application is limited.
Feed Hooper : It extends the feed length to prevent access. It can be used on pug mills etc.
1. Fixed Guard
As its name implies, a fixed guard is a permanent part of the machine. It is not dependent
upon moving parts to function. It may be constructed of sheet metal, screen, wire cloth, bars,
plastic, or any other material that is substantial enough to withstand whatever impact it may
receive and to endure prolonged use. This guard is usually preferable to all other types
because of its relative simplicity.
2. Interlocked Guard
When this type of guard is opened or removed, the tripping mechanism and/or power
automatically shuts off or disengages, the moving parts of the machine are stopped, and the
machine cannot cycle or be started until the guard is back in place. An interlocked guard may
use electrical. mechanical, hydraulic, or pneumatic power or any combination of these.

Interlocks should not prevent "inching" by remote control if required. Replacing the guard
should not automatically restart the machine.
To be effective, all removable guards should be interlocked to prevent occupational hazards.
3. Adjustable guards
Adjustable guards are useful because they allow flexibility in accommodating various sizes of
stock.
4. Self-adjusting guard
Adjusts according to size/position of material
Provides a barrier which adjusts according to the size of stock entering the hazardous area.

(3) Guarding of Different Machines:

Some sample specific guarding is suggested below as examples. The changes necessary as
per own requirement must be incorporated.

Machine Dangerous Parts Types of Guards

Textile Machinery
1. Blow-room m/c Main drive, beater cover, Separate motors, belt shifting
grid bars, dust chamber device, interlock guard, fixed
fencing.
2. Lap m/c Lap forming rollers Inter lock guard
3. Carding m/c Cylinder Interlock guard
4. Speed frames Headstock Interlock guard
5. Calendaring Inrunning rolls or bowls Nip guards
Cotton Ginning :
1. Line shaft to run the Line shaft Wall or fencing with locking
gins. doors.
Wood working machinery :
1. Circular saws The saw A riving knife of prescribed
dimensions and setting.
Adjustable top guard, two metal
plates guard, push sticks.
2. Band saws Top and bottom pulleys Fixed guards
and the blade
3. Planning m/c Cutting slot, freed roller Bridge guard, efficient guard
4. Vertical Spindle Cutter, the wood being Suitable guard, A jig or holder.
moulding m/c moulded
5. Chain Mortising m/c Chain and cutters Suitable guard
Rubber Mills :
1. Rubber mill Inrunning rolls Height more than 96.5 cm, a
distance guard, feed hopper,
trip guard within 1.8 m height.
2. Calendar m/c Inrunning rolls Trip guard within 1.8 m
height, tight wire cable
connected with it.
Base : Statutory provision under rule 54, GFR
6. MATERIALS FOR GUARD CONSTRUCTION

Generally metal is preferred for machine guard construction. Bar, pipe, rod are used for
structural frame. Filler material may be solid, perforated or expanded sheet metal or wire
mesh, where transparency is necessary plastic or glass material can be used. Safety glass and
plastics are also used to protect against flying particles and chips.
Wood guards have limited application due to their poor strength and durability, flammability
and high maintenance cost.
Aluminium guards are preferred where rusting or damage to tools or machinery are
considerable.
When a guard cannot be made to exclude lint, fume, dusting etc. extra ventilation should be
provided. Large guards should have self-closing doors for cleaning. Surrounding space
should be provided for repair and maintenance. Some people use red colour for guards to
show dangerous part while some prefer the same colour that of the machine to consider it as
an integral part of the machine.
7. MAINTENANCE AND REPAIRS OF GUARDS
Section 21 of the Factories Act states that the guards shall be constantly maintained and kept
in position. Such maintenance is obviously necessary because a machine running without
guards or with open or broken guards pose danger. Regular inspection of guards can detect
the guard removed, damaged or requiring repairs. A guard removed for repair should be
replaced at the earliest possible and meanwhile temporary guard should be installed. Good
maintenance increases the life of guards and vice versa. The supervisor should pay constant
attention for this.

Practical No: -8
Aim: - To study about Noise and Vibration
 Noise
 Effect & Hazard of noise
 Human Diseases Caused by Noise Pollution
 Audiometry program
 Measurement of Noise
 Noise control methods
 Vibration
 Harmful Effects of Vibration
 Vibrating Equipment
 Common vibration hazards and controls
 Vibration hazards can be controlled by
 Case study
What is Noise. . .??

 “Noise is any sound independent of loudness which can produce an undesired physiological
& psychological effect in an individual.”
 Noise is basically an unwanted sound. Which is measured in Decibel (dB) unit.
 Characteristics of Noise :
 Noise is a sound but it is unwanted or undesired sound i.e. a sound without agreeable quality.
 The sound waves has following characteristic.
1. Frequency
2. Wavelength
3. Period
4. Sound Intensity or Amplitude
5. Loudness
 Effect & Hazard of Noise :

 Moderate sound (F < 4000 Hz) is good but high sound or noise is hazardous.
 The harmful effects of noise depend upon a number of factors:
1. Noise frequency and intensity.
2. Total length of exposure.
3. Length of exposure at a time.
4. Distance from the noise source.
5. Whether noise is continuous, interrupted, sudden or impulsive.
6. Whether ear protector is worn or not.
7. Individual susceptibility depending on age, health etc.
8. This factors may lead to harm the overall health in the form of :

1. Mental stress & Physical stress.

2. Certain illness & Hearing Loss or deafness.
3. Accidents & Labour productivity
Auditory Effects (Hearing loss) Non-Auditory Effects

Sign & Symptoms of hearing loss are:- These are the effects other than the hearing
loss and mostly temporary in nature. They
may be disappeared if their causative factors
are removed.
Ringing in the ear at the end of the work They are classified as :-
shift slight headache, tiredness, dizziness. a. Speech or Hearing Interference and
Masking
b. Annoyance
c. Distraction
d. Physiological & Behavioural effects
Normal hearing is affected - if background
noise is present, incapability of picking up
conversation, cannot hear ticking clock etc.
Hearing Loss are of two types :-

a. Temporary hearing loss
b. Permanent hearing loss
It is also classified as:-

a. Sensorineural hearing loss
b. Psychogenic hearing loss
 Noise pollution is generally defined as regular exposure to elevated sound levels that may
lead to adverse effects in humans or other living organisms. According to the World Health
Organization, sound levels less than 70 dB are not damaging to living organisms, regardless
of how long or consistent the exposure is. Exposure for more than 8 hours to constant noise
beyond 85 dB may be hazardous. If you work for 8 hours daily in close proximity to a busy
road or highway, you are very likely exposed to traffic noise pollution around 85dB.
 This type of pollution is so omnipresent in today’s society that we often fail to even notice it
anymore:
 street traffic sounds from cars, buses, pedestrians, ambulances etc.
 construction sounds like drilling or other heavy machinery in operation.
 airports, with constant elevated sounds from air traffic, i.e. planes taking off or landing
 workplace sounds, often common in open-space offices
 constant loud music in or near commercial venues
 industrial sounds like fans, generators, compressor, mills
 train stations traffic.

 household sounds, from the television set to music playing on the stereo or computer,
vacuum cleaners, fans and coolers, washing machines, dishwashers, lawnmowers etc.
 Events involving fireworks, firecrackers, loudspeakers etc.
 Conflicts generate noise pollution through explosions, gunfire etc. The dysfunctions, in this
case, are likely caused by the conflict and insecurity and less by the noise pollution in itself,
although that compounds stress levels too.
 Legal Requirements:
 Noise Regulation rules under the environment (Protection) Act of 1996.
 Gujarat factory rule

 It comes under schedule XXIII
For the purpose of this schedule.:-
(a) "Noise" means any unwanted sound.
(b) "High noise level" means any noise level measure on the A weighted scale is 90
decibel
or above.
(c) "Decible" means one-tenth of "Bel" which is the fundamental division of a
logarithmicscale used to express the ratio of two specified or implied quantities, the
number of"Bels" denoting such a ratio being the logarithm to the base of 10 of this
ratio. The noise level (or the pressure level) corresponds to a reference pressure of 20
x 10-6 newtonsper square or 0.0002 dynes per square centimeter which is the
threshold of bearing, that is, the lowest sound pressure level necessary to produce the
sensation of heartingin average healthy listeners. The decible in abbreviated form is
dB. "Frequency" is the rate of pressure variations expressed to cycles per second or
hertz.
(e) "dBA" refers to sound level in decibels as measured on a sound level meter
operating on
the A-weighting new work with slow meter response.
(f) "A-weighting" means making graded adjustments in the intestines of sound of
various
frequencies for the purpose of noise measurement, so that the sound pressure level
measured by an instrument reflects the actual.

 Tips for Avoiding Noise Pollution :

 Wear earplugs whenever exposed to elevated noise levels
 Maintain a level of around 35 dB in your bedroom at night, and around 40 dB in your
house during the day
 If possible, choose your residential area as far removed from heavy traffic as you can.
 Avoid prolonged use of earphones, especially at elevated sound levels.
 If possible, avoid jobs with regular exposure to elevated sound levels.
 Audiometry program :
Audiometry test measure Audiometric test program
An Audiometry exam tests your ability to hear Audiometric testing monitors an Employee’s
sounds. hearing over time.
Sounds vary, based on their loudness (intensity) It also provides an opportunity for employers to
and the speed of sound wave vibrations (tone). educate employees about their hearing and the
need to protect it.
The employer must establish and maintain an

audiometric testing program.
 How audiometry test is done ?

 The hearing test is performed using sounds of single frequency, tested at various
intensity levels and determining the lowest loudness level that the person is able to
hear in each frequency.

 The tone of a single frequency, called pure tone, is presented into the car canal
through an earphone.
 Audiometric testing should be done :

 Employers must provide annual audiograms within 1 year of the baseline.
 It is import to test workers’ hearing annually to identify deterioration in their hearing
ability as early as possible.
 This enables employers to initiate protective follow-up measures before hearing loss
progresses.
 Measurement of Noise :
 Two types of sound measuring devices used in industries.
 1. Sound level measurement or sound pressure level
 2. Dosimeter
1. Sound level measurement or sound pressure level: A sound level meter is handheld noise
measuring device with a microphone. It is also called a Sound Pressure Level (SPL) Meter as
the diaphragm in the microphone responds to change in the air pressure created by sound
waves.

2. Dosimeter: A dosimeter is a special purpose sound level meter that is small enough that your
worker can wear the shift. Dosimeter will measure the noise level exposure wherever your
worker goes and does throughout the workday.
 Noise Measurement Readings :
 Controlling Noise :
Noise exposure can be controlled in several ways:
 Enclose the source of noise.
 Limit worker access to areas of high noise.
 Hearing protection devices (ear plugs)
 Eliminate the source of noise.
 Preventative maintenance on equipment.
 Use tools designed for noise reduction (air nozzles)
 Noise can be controlled at the source, in the path, or at the receiver the path, or at the receiver.
Source: Equipment or process

directly responsible for sound
generation Path: Media sound waves
encounter as they travel from the
source
Receiver: Final destination of concern

for the sound.
 Hierarchy of noise control measures :
 When we are sitting in our home or any place where we are fully or partially
touching the ground and suddenly the earthquake comes which shakes
everything, its vibration.
 When a fully automatic machine stops rotating and in the end vibrates too
much is vibration.
 The extra ordinary motion of anything around us is considered as vibrations.

Vibration
 What is Vibration?
 Main cause of Vibration :

 Unbalanced force in the different parts of the machine.
 Lack of lubricants between two mating surface.
 External load or force which make system vibrant.
 Lack of balancing of force in machine part.
 Earthquakes.
 Winds which may cause vibration in transmission and telephone lines.
 Harmful Effects OF Vibration :

 Produce excessive stresses.
 Produce undesirable noise.
 Reduce the machine element life.
 Partial or complete failure of machine parts.
 Energy waste.
 Types of Vibration :
 Free/Natural vibration
 Forced vibration
 Free Vibration :
 When there is no external force on a body or body itself vibrates without any
external force then vibration in the body is called natural or Free vibration.
 This type of vibration occurs when
a system is set of with an initial input and then allow to vibrate freely.
A system with free vibration vibrates with one or more of its natural frequency.

 Forced Vibration :
 When a body vibrates under external time varying disturbance like load,
displacement, velocity.
 This external physical phenomena may be periodic, random input or steady
state.
 The periodic input can be a harmonic or non-harmonic disturbance. Example
: Reciprocating engine vibration.
 Vibrating Equipment :
 Pneumatic road breakers hammers
 chisels and their variants
 rotary rock drills air tools
 rotary/percussive electric drills
 electric grinders
 Polishers
 concrete mixtures (vibrators)
 tractors
 threshers
 some self propelled equipment
 demolishing hammers
 concrete breakers
 Health Hazards and control :

 Exposure to vibration could have a negative effect on the health of your employees. It
could damage joints, muscles, circulation and sensory nerves.
 Common vibration hazards and controls :

 Hand arm vibration (HAV)
 HAV is caused by regular exposure to high levels of vibration from hand held tools and
equipment. It could also be caused by holding materials in contact with grinding or
cutting operations.
 HAV can affect workers who use power tools and cutting equipment such as

 grinders
 polishers
 strimmer's
 chainsaws
 power drills
 road breakers.
 Vibration white finger :

 This is a condition caused by damage to the circulatory system in the hands and fingers as
a result of contact with vibrating tools. The symptoms are
 tingling
 numbness
 whitening appearance to the fingers.
 After the attack, the fingers affected may become painful, red and throbbing as the
circulation returns.These symptoms may become more severe and frequent with
continued exposure to vibration, especially in cold weather. This can eventually lead to
permanent disability.
 Whole body vibration

 Whole body vibration is caused by sitting, standing or lying on a vibrating surface. This
could lead to
 headaches
 motion sickness
 chronic back pain
 stomach problems
 sleep and visual disturbances.

 Using vehicles off road increases the risk of jolts and jarring. For this reason employees that
drive or operate heavy plant and vehicles such as construction plant, agricultural
machines and quarry vehicles are especially at risk.
 Vibration transmitted through the feet can also be a problem for employees that stand on the
platforms of stationary plant such as rock crushers.
 Anti vibration tools:

 Certain manufacturing companies produce anti-vibration tools such as antivibration
pneumatic chipping hammer pavement breakers and vibration damped pneumatic riveting
guns.
 Anti vibration gloves:

 Anti vibration gloves are made using a layer of viscoelastic material. measurements have
shown that search gloves have limited effectiveness in absorbing low frequency
vibrations the major contributor to vibration related disorders hence they have little effect
on vibration induced finger syndrome, however gloves help from cuts and abrasions and
cold temperatures.
 Vibration damping:
 Vibration dampers are used under machine foundation and machines should be installed
in such a way that dampers come in contact with the building foundation and machine.

 Machine mounted picks replaces hand-operated breakers
 Used hydraulic crushers instead of demolition hammer
 Case Study - 1
 Dr. Jansen of West Germany conducted a study of the psychological effects of noise on steel
workers. Over 1000 workers were interviewed and tested. A group of 2/3 workers who
were working in noise level above 90 dBA was compared to a group of 1/3 workers who
were working in less than 90 dBA noise. The average worker was 41 years old and had
been on his job for II years. Workers of both the groups were matched as closely as
possible according to their economic, social and ethnic backgrounds. The results of
comparison revealed that –

 Workers who worked in less than 90 dBA were easier to interview than those who worked in
more than 90 dBA noise.
 Case Study – 2
 Workers exposed to more noise were found more aggressive, distrustful and in some cases,
paranoiac. A contributory cause of hearing loss was also noted.
 Workers exposed to higher noise had more than twice as many family problems. Thus noise
'affects a worker's behaviour not only on die job, but at home also.
 Case study(London deaths linked to noise pollution in study) – 3

 High levels of noise pollution in the capital have been linked to early death and a greater risk
of stroke.
 A study led by the London School of Hygiene & Tropical Medicine (LSHTM) gathered data
from 8.6m people across London's 32 boroughs.
 Scientists found deaths were 4% more common in adults and the elderly where the daytime
traffic noise was more than 60dB compared to less than 55dB.
 Experts said the study did not imply a causal link.
 Researchers looked at data for people living in London between 2003 and 2010.
 'Pay more attention'
 They analysed road traffic noise levels during the day, between 07:00 and 23:00 and at
night, between 23:00 and 07:00.
 More than 1.6 million people in the city are exposed to road traffic noise levels during the day
above 55dB, the level defined by the World Health Organisation as causing health
problems.
 Case Study – 4 Noise Pollution and Human Health: A Case Study of Municipal
Corporation of Delhi
 Noise pollution, an urban territorial phenomenon, is assuming serious proportions in Delhi,
the third largest urban centre of India. The frequency and intensity of pollution has been
increasing day by day. The present study reviews the data on sources, intensity and health
implications of pollutants collected through household survey using questionnaires from
two contrasting density areas; one from high-density area and another from low-density
area. The analysis reveals that tremendous increase in population, industrial activities,
unchecked growth in vehicular traffic and rapidly changing life style are the major factors
that have created and aggravated the problem of pollution in the study area. The major
health implications include annoyance, disturbance in sleep, interference with
communication and other harmful effects. With the help of regression analysis, the cause
and effect relationship between the intensity of pollution and occurrence of diseases
among sampled households of Delhi has been established by this study. Some suggestions
such as land use and transportation planning are also given in this paper for mitigating
and managing the noise pollution problem in the sustainable urban development
perspectives.

Practical No: -9
Aim: - To study about Plant Safety Layout
Index
• Why Plant Layout
• What is Plant Layout
• General Principles of Plant Layout
• Different Factors to consider while determining plant layout.
• Types of plant layout
• Statutory requirements
• Case Study
Why Plant Layout

Efficiency and safety in industrial operations can be greatly increased by careful planning
of the location, design and layout of a new plant or of an existing one in which major
alterations are to be made. Numerous accidents, occupational diseases, explosions and
fires are preventable if suitable measures are taken right from the earliest planning stages.
Safety has to be involved right from the planning, design and inception stage but well
before in mindset of an individual.
What is Plant Layout ?

Plant layout means arrangement of physical facilities such as machine, equipments, tools,
furniture, occupied buildings, process plants, personal facilities etc. in such a manner so
as to have quickest flow of material at lowest cost and with least amount of handling in
processing the product from the receipt of raw material to the delivery of the final
product.
General Principles of Plant Layout
• Efficient utilization of floor space
• Easy Access for maintenance
• Easy Access for operation
• Maximum exposure to natural light and ventilation

• Allow Enough Space for Future expansion

• Proper roads, walkway, railings for men & materials to avoid delay & obstruction
• Safe control room location
• Emergency escape route to onsite personnel
• Prevent confinement where release of flammable substances may occur
• Wind direction indicator and speed indicator
• Easy locations for fire extinguisher, fire alarms, PPEs, emergency assembly point,
medical centre, ambulance van
• Use of appropriâtes colour coding, notices, signs, labels, posters
Site Selection criteria
Factors considered for Plant layout

• Construction & operating costs.
• Process requirements
• Convenience of operation
• Convenience of maintenance
• Safety
• Future Expansion
Wind Rose
A wind rose diagram is a tool which graphically displays wind speed and wind direction
at a particular location over a period of time.
Inherent Safety
The major principle in Inherent Safety is to remove the hazard altogether. The best
method to achieve this is to reduce the inventory of hazardous substances such that a
major hazard is no longer presented. However, this is not often readily achievable. Other
possible methods to achieve an inherent safer design are:

Fail safe design (valve position on failure)

• Simpler processes.
• Reduce hazardous process conditions (Temperature / Pressure)
• Substitution of hazardous substance by less hazardous alternatives
Domino Effects
Protection against domino effects in case of fire can be achieved by inherent safety
principles like, ensuring that the distances between plant items are sufficient to prevent
overheating of adjacent plants. If this is not possible then other methods such as fire
walls, fire protection, Fire Proofing on equipments etc. may be considered.
Fire Proofing
FireWall

Reduction of Risk
• Locating all high volume storage of flammable / toxic material well outside
process areas
• Locating hazardous plant away from main roads
• Provision of dyke walls
• Hazardous area classification (Zone 0, Zone 1 & Zone 2)
Hazard Area Classification – Zones
Dyke Wall
• Positioning of Occupied Buildings

• Distance between plant and occupied buildings

• Evacuation routes not blocked

• Person more site responsibility at non hazardous area
• Occupied buildings not sited on downwind of hazardous plant
area Example:- Case Study No :- 3
Aggregation / Trapping of flammable vapours

• Flammable vapours could lead to hazardous event
• In such case all parts of buildings shall have well ventilation by natural of force
• Flammable storage at open air site so that if any minor leaks can be dissipated by
natural ventilation
• Example:- Case Study No.:- 1
Types of Plant layout
1. Process or Functional layout

It offers better and more efficient supervision through specialization at various levels.
Break down of equipment can be easily handled by transferring work to another
machine/work station.
2. Product or Line layout

Only one type of product is produced in an operating area. This product must be
standardized and produced in large quantities.
A single machine break down may shut down the whole production line.

3. Fixed position layout

This layout is flexible, so if any rearrangement of men & material required, it can be done
easily. This project takes long time to finish the job, so if there is any shortage of material
or men, it can be met later. Large space required for storage/movement of material near
product.
Fire Safety in For Industrial Plant Layout

• Industrial plants in particular, are very vulnerable to fires. Heavy machinery,
flammable chemicals and waste products, extensive electrical systems, as well as
a high volume of people all contribute to the possibility of a fire outbreak.
Sometimes Unsafe Layout/arrangements in plant leads to uncontrollable fire.
• Effective Layout with Proper Escape route can mitigate Fire Accident.
• Common Factors leading to Fire due to Unsafe Layout
• Locked and obstructed doors
• Un-marked or lack of marking exits
• Travel distances to exits is excessive
• The absence of a fire alarm
• No emergency action plan, fire prevention plan, and no automatic fire suppression
plan
• There are four components to OSHA’s workplace fire safety standards: Exits,
Emergency escape routes, Fire extinguishers and Emergency plans.
Exits and emergency escape routes

• At least 2 exits doors or other means of escaping are required
• Fire doors are to be kept clear from the inside when employees are in the building
as well as be unlocked
• Fire exit routes must be clearly marked with exit signs and be free of clutter

Fire extinguishers
If employees are required to fight small fires, the right type of extinguisher needs to be
available and up to date. A proper fire extinguisher has to approved for the type of fire
hazards in the plant, maintained, and routinely inspected.
For the employees to use the fire extinguisher, they must be trained about the hazards of
fighting a fire, learn how to operate the fire extinguishers, and the protocol for alerting
other employees of the fire emergency.
Statutory requirements
• FA-1948: Section 6, GFR-1963 Rule: 3(A)3(B)3(C): drawings, plans of factory
• FA: Section-12 & GFR: Rule-18 : Disposal of Waste/ Effluents system
• FA: Section-13, GFR: Rule-18(A): Ventilation & temperature
• FA: Section-16: Over crowding
• Before commencement: 9.9 cubic meter (350 cubic ft.)
• After commencement: 14.2 cubic meter (500 cubic ft.)
• FA: Section-17, GFR: Rule-30 to 34: Lighting
• Not less than 30 meter candles at workspace
• FA section-18, GFR Rule-35 to 40: Drinking water
• 1 water center for every 150 workers
• FA section-19, GFR Rule-41 to 50: Latrines & Urinals
• latrine for every 25 females , 1 latrine for every 25 males
• FA section-20, GFR Rule-51 to 53: Spittoons
o Shall be placed on a stand or a bracket 91.4 cm high
• FA section-32: Floors, stairs and means of access
• FA section-38, GFR Rule-66, 66(A): Precautions in case of Fire
o Means of escape in fire
o Fire protection, emergency exit & escape route
o Fire fighting equipments, automatic sprinklers, fire hydrant
• FA section-41(A): Constitution of Site Appraisal Committee
• FA section-42, GFR Rule-69: Washing facilities
• FA section-43, GFR Rule-69(A) : Facility for drying of clothing
• FA section-45, GFR Rule-70, 70(A), 71: First aid appliances, ambulance room
• FA section-46, GFR Rule-72 to 78: Canteens
• FA section-47, GFR Rule-79: Shelter, rest rooms, lunch rooms
• FA section-48, GFR Rule-80, 83(A): Creches for more than 30 women workers
• Case study - 1. (Dupont la Porte toxic chemical release)
• The November 15, 2014 incident occurred in DuPont La Porte’s Lannate a Unit,
which produced insecticides. Part of the Lannate process occurred inside a closed
building.
• where most of the methyl mercaptan release occurred. The Lannate process used
methyl mercaptan, a toxic and flammable chemical.
•
4 people died at dupont chemical plant toxic gas release.

Case Study - 2 (Surat fire incident)

On 24 May 2019, a fire occurred at a coaching center (commercial complex) in Sarthana
area of Surat in the Gujarat state of India Twenty-two students died and others were
injured.
Reason: Short Circuit happened on Air Conditioner Circuit.
Fire Started with Short Circuit at Ground Floor.
Then Fire Spread to other floors and Coaching Centre which was at Terrace.
Investigations:
No emergency exit was available. No fire extinguishers were available.
Poor ventilation.
New Rules & regulations:
Fire extinguisher should be available in each classroom & regularly renewal.
Entry & exit separate doors should be available & proper ventilation must.
Inspection/checking by Government personnel every year.
ELCB must.

Case Study - 3 : Field Cabin Shifting from Hazard Risk Area to Safe Area
Brief Description:-
Earlier the field cabin of the respective plant (As shown in previous slide
image) area situated in-between the major sections of the plant where high Pressure &
high temperature Explosive gas mixture Containing H2, CO, H2S Operated. So in case of
any unavoidable situations for the Safety of field personal, The cabin was relocated to
safe area where Potential Hazard Risk is lower.

Practical No: -10
Aim: - To study about Good Housekeeping and 5S
INTRODUCTION OF HOUSEKEEPING :-
 Industrial housekeeping is generally classified as good or bad (poor) housekeeping.
For the purpose of evaluation, ranking or marking, it is further classified as excellent,
good, average, below average and poor or bad housekeeping. The concept of good
housekeeping is emerged from the results of bad housekeeping, which is the direct
cause of many accidents.
 The term Good Housekeeping is sometimes loosely understood as simple floor
cleaning or broom stick operation. But it is not so.
 It has a wider meaning including up-keeping of all industrial activities in orderly
manner to minimize the accidents due to improper planning, placement, arrangement,
handling etc. everywhere in the industrial premises.
 In short it can be explained as a “place for everything and everything in its proper
place.” It pays attention on removing all unsafe conditions in the plant and thereby
increasing safety and productivity.
 Housekeeping is not just a need-based cleaning. It is more than that. In addition to
regular daily cleanliness, it includes orderly arrangement of tools, equipment,
materials and process flow. It is an integral part of industrial activity that reduces
accidents, increases cleanliness, attractiveness and comfort, production, productivity
and improves employee’s morale and public relations.
CAUSE OF BAD HOUSEKEEPING : -

ACCIDENTS DUE TO POOR OR BAD HOUSEKEEPING I.E. THEIR CAUSES ARE:
Striking against or falling over machine parts, cuts from objects left protruding from benches
and especially on construction sites, punctures by nails protruding from objects or lying
anywhere, falls on floor left slippery, greasy or damp, badly stacked materials, fires due to
accumulation of combustible waste or leakage of flammable materials, cabinet drawers left
open, dangerous dust or chemicals on floors and not cleaning them quickly, congested aisles,
no toe-guards or hand rails, overloaded waste containers, broken lockers and washrooms,
dirty and unsafe walls, ceilings and windows, lint and dust on bearings of machines, tools left
on machines or walkways, poor lighting, unsafe handling of chemicals, spillage of oil, grease,
acid etc. on floors, pipes of air, water, steam and oil not properly maintained, no marking of
safety and traffic signs, signals, loose or unsafe wiring etc. These should be the targets of
planning for good housekeeping.
Indicators of Bad Housekeeping:
Objects & Materials on Floor:
Excessive materials, waste, debris, tools lying anywhere, congested aisles, walkways and
workplace, spillage of oil, grease, acid etc., dropped or thrown down materials and disorderly
piled material as obstruction.

Poor Storage Practices:

Unsafe store design and unsafe piling i.e. too high or improper piling, overloaded waste bins,
storing in aisles or obstructing doors, passage ways, storage of excessive material in work
room.
Equipment out of Place:
Wrongly parked vehicles, trucks, trolleys and wrongly placed tools, equipment, material,
ladder, wire ropes etc. where they should not be.
Dirty walls, windows, ceilings, floors etc.:
Dirty walls, windows, ceilings, floors, lighting fixtures, lint and dust on bearings or moving
parts, open locker/ drawer, slippy or dirty washrooms, latrines, urinals, canteens and
workplaces.
Poor waste disposal system:
Failure to provide receptacles or containers for waste and scrape, overflowing pans, dripping
containers and unsafe handling of cutting oils etc., inadequate or leaking exhaust system,
scrubber, treatment plant etc., emission of gas, fumes, vapours, accumulation of dust and no
provision for cleaning device.
Fire Hazards:
Accumulation of rubbish, oil, oil soaked rags or cotton waste, paper and packing material,
substances causing spontaneous ignition e.g. dusts, oils, solvents, fertilizers, sugar, leather
scraps, jute, hemp, hay etc., uninsulated hot piping, hot bearings, sparks, welding-cutting in
flammable area or unsafe manner.
Chemical Hazards:
Nowadays chemical factories are increasing and workplace pollution due to chemical
exposure is also increasing. This spoils the atmosphere and housekeeping. Splashes, leakage,
dripping and escape of chemicals pose danger to health and safety and result in bad
housekeeping. Acids, alkalis, solvents, pesticides and many dangerous chemicals change the
colour and status of a factory.
Others:
Poor lighting, dark colours, poor ventilation, noise and vibration, broken tools, ladders, stools
etc., open or loose electric wiring, no hand railing, no toe guard, no machine guarding, no
fencing on pits, platforms and floor openings, drawers left open etc.

Benefits of Good Housekeeping:-

GOOD HOUSEKEEPING INCREASING SAFETY AND PRODUCTIVITY AS UNDER:
 It is an essential routine support to industrial safety and health.
 A large number and wide range of accidents due to bad housekeeping can be
eliminated by good housekeeping.
 It aids to good maintenance and working as complementary to it and increase overall
safety and productivity.
 Clean, hygiene and safe plant environment increase attractiveness and morals of the
employees.
 Machines, tools and equipments work better in clean condition and boost up the
workmanship.
 If tools are placed in easy to find manner, jobs run smoothly and give good results.
 Clean and well-maintained floors, stairs, walkways, doors, windows, lifts, latrines,
urinals, washing facilities, furniture, records, dresses, first-aid and protective
equipments and proper layout of materials, tools and process flow certainly avoid
many accidents.
 Constant monitoring and control of hazardous chemicals, their processes and
emissions minimize many hazards.
 Much floor space or area is utilized because of proper access to machines and
equipments for cleaning and maintenance purpose.
 The fine and sophisticated instruments, equipment and personal protective equipment
give better results when kept in good and clean condition and checked regularly.
 Accidents due to stepping on or striking against objects or fall of persons and objects,
stumbling, tripping, bumping, body caught between objects etc. are well controlled.
 Majority of small fires result from and spread by poor housekeeping conditions.
Sources of ignition due to oily cotton waste, solvent spillage, oil dripping, friction,
sparks, flames, smoking etc. can be prevented by good maintenance and
housekeeping.
 A clean and well maintained plant can be operated at a leaser cost.
 Production increases due to reduced obstacles and wastage of time and speedy
availability of materials, equipments, tools etc.
 Repair and maintenance work become easy due to easy access and clean space
availability.
 Aisle traffic becomes smoother and speedy. Truck/trolley collisions become less.
 Employee moral is boost up due to orderly things, neatness and cleanliness, sufficient
space to work, good lighting, colour and ventilation and mostly due to reduced
possibilities of accidents and injuries.
 Outside visitors, market people, Government authorities, local community and the top
management are attracted and overall image of the company rises up.
Origin of 5S :-
 Firstly, 5S was implemented at Toyota Motor Corporation as part of their production
system, namely (Toyota Production System)TPS.
 The use of 5S as a strategy for achieving business excellence has been evident in
Japan since the Second World War.
 Introduced 5S in early 1980’s for considerably enhancing the environmental
performance in production and services. Since its introduction and acceptance by
Japanese’s firms in Japan.
 5S was popularized by Taiichi Ohno, Toyota engineer who is also known as the
Father of 5S.

 NDP(Nation Demonstration Project)was designed to test TQM approach for health

care quality and safety improvement
 NDP was conducted in US (1989-1990) and Japan (2000-2004)
 Many private hospitals in Asia, Europe, and US are practicing KAIZEN-TQM
approaches for health care quality, hospitals management and safety improvement
Why 5S was invented?

 Taiichi Ohno recognized the best way to manage cost was to eliminate waste in every
form. In doing so, he identified the “Seven Wastes”, which he defined as:
 Wait Time with No Value Added
 Overproduction – Making Too Much
 Over-Processing or Adding Non-Value Activities
 Unnecessary Transportation
 Excessive Movements or Motion
 Inventory
 Introduction to 5’S
 5S is a philosophy and a way of organizing and managing the workspace and work
flow with the intent to improve efficiency by eliminating waste, improving flow and
reducing process unreasonableness.
 It is for improvement of working environment. It help to have a basis of strong
management of workplace.
 The word “5S(five S)” was generalized in1980’s in manufacturing sector in Japan, as
Toyota Production System (TPS) became famous in the sector and “5S activities”
were set as one of the bases of TPS Service industry started to used “5S” in 1990’s.
 Positive attitude is very important for implementation of 5S activities.
 It is not “Cleaning Campaign” 5S activities are to create good working environment
through reduction of “Muri”(overburden), “Mura”(unevenness), and “Muda”(waste)
 5S can identify and reduce “abnormalities” and “waste”, improve “team work”,
“cleanness”, “safety” and “productivity” It is a basis of organization management.
Needs of 5S:
 To eliminate the wastes that result from “uncontrolled” processes.

 To gain control on equipment , material and inventory placement & position.
 Apply control techniques to eliminate erosion of improvements.
 Standardize improvements for maintenance of critical process parameters.
5S is becoming popular for seven solid reasons:
1. Visible results enhance the generation of more and new ideas
2. The workplace gets cleaned up and better organized
3. Hospital and office operations become easier and safer
4. Results are visible to everyone - insiders and outsiders
5. People are naturally disciplined
6. People take pride in their clean and organized workplace
7. As a result the company’s good image generates more better.

Targets of 5S
 Zero changeovers leading to product/ service diversification
 Zero defects leading to higher quality
 Zero waste leading to lower cost
 Zero delays leading to on time delivery
 Zero injuries promoting safety
 Zero breakdowns bringing better maintenance
1S – SEIRI (SORT)
SORTING - SEGREGATE THE WANTED AND UNWANTED ITEMS
Make a list of all the items in the department.
The list should include raw material, wip, finished product, tools, tackles, dust bin, facilities
like chair, table, bins etc. nothing should be left unlisted.
Appropriate authority should decide which items can be disposed off and which items need to
be kept in the department.
Items marked for disposal should be disposed off in a safe manner.
RED TAG HOLDING AREA: When going through the 5S process in the “Sort” function,
sometimes it is not clear whether an item, or piece of equipment should be kept or removed.
A Red Tag area will help the team temporarily

2S – SEITON (SET IN ORDER)

SET IN ORDER - PLACE FOR EVERY THING & EVERYTHING IN IT’S SPACE.
 After disposing unwanted material, provide appropriate place for every
item that has to be kept in the department.
 Set in order is for organizing the items or materials at the workplace.
 We can use an organized workplace more efficiently and effectively
 To arrange all necessary items for the economy of movement.
 Place according to the frequency of use.
 Provide safe storage – heavy items at a low level, light items at height.
 If any item is missing then we can easily find out it.
 Place should be distinctly identified and marked.
3S – SEISO (SHINE)
SHINE - CLEAN THE PLACE THOROUGHLY AND KEEP EVERY THING
IN IT’S PLACE.
 After Sort and Set In Order, the workplace requires regular cleaning.
 Clean every thing including material, floor, containers, walls,
windows, equipments etc.
 If necessary painting also should be done.
 While painting follow colour codes wherever applicable.
 Cleanliness makes defects easier to detect.
 Aids efficiency and reduces accidents
 Creates a better working environment

 Cleaning is not just the job of a housekeeper, it is everyone’s responsibility.

 The best approach is that who work in a workplace is also responsible for cleaning
that area.
4S – SEIKETSU (STANDARDIZE)
STANDARDIZE -Maintain high standards of housekeeping at workplace at all times.
 establishing the standard rules to maintain the perfect hygiene and safe environment
at the workplace.
 the necessary systems are formed in order to maintain the continuance of these
good practices at the workplace .
 standards should be very communicative, clear and easy to understand.
 maintain high standards of housekeeping at workplace at all times.
 ensure that people keep the items at designated place after it’s use.
 if possible, design the system such that if some thing is missing from the place, it is
easily highlighted

5S - SHITSUKE (SUSTAIN)
 Always Practice : Train employees disciplined for practicing 5S system continuously
so that the habits and culture within the organization.
 This is by far the most difficult S to implement and achieve.
 People tend to resist change and even the most well-structured 5S plan will fail if not
constantly reinforced.
 It creates an educating, cooperating, discipline system and inspection for
protecting the best present situation.

Wrap-up:
 Positive attitude is very important for implementation of 5S activities
 5S activities are to create good working environment through reduction
of overburden, unevenness, and waste.
 5S can identify and reduce “abnormalities” and “waste”, improve “team work”,
“cleanness”, “safety” and “productivity”
 It is a basis of organization management

Practical No:- 11
Aim: - To Study about safety at work Place






General Laboratory Safety Rules
A standard list of basic laboratory safety rules are given below, and must be followed in
every laboratory that uses hazardous materials or processes. These basic rules provide
behavior, hygiene, and safety information to avoid accidents in the laboratory. Laboratory
specific safety rules may be required for specific processes, equipment, and materials,
which should be addressed by laboratory specific SOPs.
Basic Safety Rules
Basic safety rules for laboratory conduct should be observed whenever working in
a laboratory. Many of the most common safety rules are listed below.
 Know locations of laboratory safety showers, eyewashstations, and fire

extinguishers. The safety equipment may be located in the hallway near the
laboratory entrance.
 Know emergency exit routes.
 Avoid skin and eye contact with all chemicals.
 Minimize all chemical exposures.
 No horseplay will be tolerated.
 Assume that all chemicals of unknown toxicity are highly toxic.
 Post warning signs when unusual hazards, hazardous materials, hazardous
equipment, or other special conditions are present.
 Avoid distracting or startling persons working in the laboratory.
 Use equipment only for its designated purpose.
 Combine reagents in their appropriate order, such as adding acid to water.
 Avoid adding solids to hot liquids.
 All laboratory personnel should place emphasis on safety and chemical hygiene at
all times.
 Never leave containersof chemicals open.
 All containersmust have appropriate labels. Unlabeled chemicals should never be
used.
 Do not taste or intentionally sniff chemicals.
 Never consume and/or store food or beverages or apply cosmetics in areas
where hazardous chemicalsare used or stored.
 Do not use mouth suction for pipetting or starting a siphon.
 Wash exposed areas of the skin prior to leaving the laboratory.
 Long hair and loose clothing must be pulled back and secured from entanglement
or potential capture.
 No contact lenses should be worn around hazardous chemicals – even when wearing
safety glasses.
 Laboratory safety glasses or goggles should be worn in any area where chemicals
are used or stored. They should also be worn any time there is a chance of splashes
or particulates to enter the eye. Closed toe shoes will be worn at all times in the
laboratory. Perforated shoes or sandals are not appropriate.
 Determine the potential hazards and appropriate safety precautions before
beginning any work.
 Procedures should be developed that minimize the formation and dispersion of
aerosols.
 If an unknown chemical is produced in the laboratory, the material should be
considered hazardous.

 Do not pour chemicals down drains. Do NOT utilize the sewer for chemical waste
disposal.
 Keep all sink traps (including cup sink traps and floor drains) filled with water by
running water down the drain at least monthly.
 Do not utilize fume hoods for evaporations and disposal of volatile solvents.
 Perform work with hazardous chemicalsin a properly working fume hoodto
reduce potential exposures.
 Avoid working alone in a building. Do not work alone in a laboratory if the
procedures being conducted are hazardous.
 The PEL and the Threshold Limit Values (TLV) will be observed in all areas. If
exposure above a PEL/TLV is suspected for an ongoing process, please contact
EHS immediately.
 Laboratory employees should have access to a chemical inventory list, applicable
SDSs, Department Laboratory Safety Manual, and relevant SOPs.
 Access to laboratories and support areas such as stockrooms, specialized
laboratories, etc. should be limited to approved personnel only.
 All equipment should be regularly inspected for wear or deterioration.
 Equipment should be maintained according to the manufacturer’s requirements
and records of certification, maintenance, or repairs should be maintained for the
life of the equipment.
 Designated and well-marked waste storage locations are necessary.
 No cell phone or ear phone usage in the active portion of the laboratories, or
during experimental operations.
 Clothing made of synthetic fibers should not be worn while working with flammable
liquids or when a fire hazard is present as these materials tend to melt and stick to
exposed skin.
 Laboratory coats should not be stored in offices or break rooms as this
spreads contaminates to other areas.
 Computers and instrumentation should be labeled to indicate whether gloves should
be worn or not. Inconsistent glove use around keyboards/keypads is a source of
potential contamination.
 Avoid wearing jewelry in the lab as this can pose multiple safety hazards.
Laboratory Specific Safety Rules

Safety rules for laboratory specific operations will be provided in appropriate laboratory
SOPs.

Practical No:- 12
Aim: - To Study about Transportation of Chemicals
CMV Rule – 9
 Educational qualification for drivers of goods carriages carrying dangerous
or hazardous goods.
 Ability to read and write one Indian language and English, and also posses a
certificate having successfully passed a course consisting of following syllabus and
periodicity connected.
 Period of training 3 days (for first time)
 Period of training 1 day (for
every year)
 Syllabus:
• Defensive driving questionnaire – First Day
• Advanced Driving skill and training. –
Second Day 1. Discussion
 2. Field test training(1 driver at a time)
• Product safety – Third day 1. Product information
 2. Emergency Procedure
 CMV Rule – 129
 Vehicles Transporting Goods of dangerous or Hazardous nature to human life.
• Shall display a distinct mark of Class Label appropriate to the type of
dangerous goods as specified.
• Shall be equipped with safety equipment for preventing fire, explosion or
escape of hazardous or dangerous goods.
 Shall be fitted with Technograph(a instrument to record the lapse of running time of
the motor vehicle, time speed maintained, acceleration, declaration etc.,) conforming
to the BIS specifications.
 CMV Rule – 129A
 Every vehicle carrying goods of dangerous or hazardous nature Shall be fitted with a
SPARK ARRESTER
 CMV Rule – 131
 Responsibility of the consignor for safe transport of dangerous or hazardous
goods
 The consigner should ensure the following
• A.The goods carriage has a valid registration to carry the said goods B.The vehicle is
equipped with necessary first aid, safety equipment
 and antidotes as may be necessary to contain any accident C.The transporter or
owner shall has full and adequate information about the goods being transported.
 D.The driver of the goods carriage is trained in handling the dangers posed during
transport such goods.
 Every consigner shall supply to the owner full and adequate
information about the goods being transported
• CMV Rule – 132 Responsibility of the Owner
 The owner should ensure
• A . The vehicle has a valid registration to carry the said goods & It
is safe for transportation
• B. The vehicle is equipped with necessary first aid, safety equipment, tool
box and antidotes as may be necessary to contain any accident.

 The owner should satisfy him self that the information given by the consigner is
full and accurate in all respects.
 The owner shall ensure that the driver is given all the relevant
information in writing as given in annexure ‘v’
 The owner and the consigner shall lay down the root for each trip, unless directed or
permitted other wise by the police.
 The owner to ensure that the driver holds a driving licence as per the CMV rule 9
 CMV Rule – 133 Responsibility of the Driver
 The driver should ensure the information given to him (Annexure ‘V’) is kept
in the drivers cabin.
 The vehicle while in motion, and when it is parked in a place and at
all times should be kept safe from fire, explosion, and any other risk under
his supervision or some other competent person above the age of 18 years.
 CMV Rule – 134
 Emergency information panel as specified should be placed on vehicles
 Place for Fixing Emergency Information Panel
 CMV Rule – 135 Driver to be Instructed

 The owner shall ensure to the satisfaction of the consigner that the driver
has received adequate instruction and training to enable him to under
stand the nature of goods being transported by him, the nature of the risks arising
out of such goods, precautions he should take while the vehicle is in motion
or stationary and the action he has to take in case of any emergency.
 CMV Rule – 136
 Duty of the Driver to Report
 Driver to report to the police station about the accident and also
inform the owner regarding the accident.
 CMV Rule – 137 Class Labels
 The class labels namely Explosives, Non-flammablegases,
 Flammable Gasses, Poision (Toxic Gases), Inflammable liquids,
Inflammable Solids etc.
 HAZARDOUS GOODS CLASS LABELS
 Hazard Material MODE OF TRANSPORTATION
 TAPS ( pipe line)
 PLANE (Air Ways )
 SHIP (Water Transport )
 TRAIN (Rail Transport )

 MOTOR VEHICLE (Road Transport)
 Need Of HazMat Training
 Learning to properly transport hazardous materials and hazardous waste helps

protect you and the public. This Training, Preparing to Transport Hazardous
Materials, provides you with basic information needed to be a safe and effective
driver.
 Hazardous materials training is important to protect people, the environment, and
property. All of these are at risk if you violate the hazardous materials regulations.
 Hazardous materials training is also required by law as per 9 of CMV Rule.

Hazardous materials training is important to protect your Transport driver's license
and your job. Both of these are at risk if you violate the regulations.
 Wilful violators are subjected to punishment as per law.

 It is vitally important to use Emergency Information Panels on vehicles transporting
hazardous materials. At an accident scene, the correct Emergency Information
Panels can save lives and protect the environment. In addition to the environmental
and health reasons.
 Required Training for Highway Transportation
 The motor vehicle act requires training for all drivers of vehicles used to transport
hazardous materials, because most of the hazardous materials are transported on
highways, and most incidents/accidents involving hazardous materials are caused
by human error.
 Specific training includes:

 1). Defensive Driving.
 2). Advanced Driving Skills
And Training. a). Before
starting
 a). UN classification/ UN Panel b). Product information
 c). Emergency procedure
 Hazard information system

 Transport Emergency card (Trem Card): Informs the driver and cleaner about the
nature of dangerous goods, and steps to be taken during emergency, and some
important phone numbers also given.
 Production factory should provide Trem Card pertaining to the goods in the vehicle
and the Trem Card should be in the vehicle.
 Emergency Information Panel: It describes the nature of the goods in the vehicle,
showing status, quality and during emergencies it informs some steps to be taken by

other road users and fire engine office. It is exhibited on both sides of the vehicle and
at its front & rear.
 Dimensions of Emergency Information panels
 Places for fixing Emergency Information pannels on Vehicles
• HAZARDOUS GOODS CLASS LABELS
 Non-flammable gases

 Inflammable Liquids
Inflammable solids, substances liable to spontaneous combustion; substances which on

contact with water, emit inflammable gases
 Inflammable Solids
 Substances liable to spontaneous combustion

 Substances which in contact with water, emit inflammable gases
5. Oxidizing substances and organic peroxides

 Oxidizing substances

Organic peroxides
poisonous (toxic) substances and infectious substances
• Poisonous (toxic) substances
 A driver of a vehicle used to transport hazardous materials must:
 Receive training before operating the vehicle for 3 days at a recognized institution
 Recurrent training must occur every year for one day. Hazmat employers are
responsible for certifying that each hazmat employee has received the required
training and for keeping detailed records of when and what training was given. If
you are a self-employed owner-operator, this responsibility may be yours.
 TYPES OF GOODS
 ordinary goods (not dangerous):
 Stones ( granite, marble, lime Etc )
 Steel ( iron, silver, copper Etc )
 Gravel ( sand, iron ore, mud, clay Etc)
 Dangerous goods :
 Liquids ( petrol, diesel, kerosene, furnace oil, acids Etc ).
 Gas (L.P.G, C.N.G Etc )
 Explosives( TNT, fire crackers, blasting materials Etc )
 Power full chemicals that can affect our breathing (such as Insecticides,
Irritating acids, sulphuric and Etc)

 To carry things safely from one place to other place.

 Handle dangerous materials safely:
 We should carry dangerous goods only in closed packs. It should not be exposed
to heat and air.
 Avoid spreading on your body.
 3. Blasting materials should be kept safely and should be handled carefully. 4.
Materials which catches fire easily should not be near to fire.
 Should learn first aid and practice.
 Give first preference to safety of life and avoid pollution.
 Driver:
 1.Driving license- as per CMV Rule “ 9”.

2.Proper trem card and written instructions.
 Consignment:
 1.Invoice.
 2.Excise Gate pass. 3.Weighment card. 4.Consignment receipt
 5.Transport emergency card ( trem card).
6.Written instructions for driver
 7.Public liability Insurance ( PLI ).
 TANK AND IT’S PARTS
 Master valve ( Emergency valve ).
 Pressure / Vacuum valve ( tamata valve ).
 Emergency hole passage (went plug ).
 Dip pipe.
 Fill pipe ( filling pipe ).
 Discharge valve.
 Manhole.
 Precautions for safety

 Vehicle’s Inspection:
 In good condition to run on road.
 Safety instruments.
 Emergency equipment inspection.

 Fire protection equipment inspection.

 All types of intoxicating agents prohibited.
 Smoking or open flame is prohibited in the cabin or near the vehicle.
 Agarbatties or other flammable materials are prohibited in driver’s cabin.
 Precautions to be taken:
 Do not leave the vehicle without attender.
 Driver or cleaner should be near by.
 Away from residence areas and mobs.
 On level ground.
 Not to abstract movement of other vehicle.
 Switching on parking lights during night times.
 Vehicle key should be with driver.
8. Do not rest near or under the vehicle.9
Keep other people away from the vehicle.
10 Load the vehicle according to permit and R.C book.
11 Do not take extra load than prescribed.
12 Take help while taking the vehicle in reverse.
13 Drive on prescribed routes only.
14 Do not allow other passengers in to the vehicle.
15. In empty tank or cylinder leftover metrical is dangerous.
16. Tank should be empty while repairing or welding any part of the tank.
17. Keep acid away from body.
18. Do not inhale gas or acid.
 BEFORE STARTING THE VEHICLE
 Inspect round the vehicle.
 See that any one is resting or sleeping near or under the vehicle.
 Hose and earthing cables are separated from the vehicle.
 Remove the wheel chocks (stoppers ) from the wheels.
 Tyre pressure and condition.
 BEFORE LOADING
 Check around the vehicle.
 Check the safety instruments.
 Proper emergency information panel.
 Proper trem card.
 Written instructions for driver and cleaner.
 No sharp things should be projected from the vehicle.
 DURING LOADING
( CYLINDERS, DRUMS OR BOXES)
 Stop the engine of the vehicle.
 Keep wheel chocks (stoppers) for all wheels.
 Smoking, lighting of cigarettes, agarbatties or flamable articles are prohibited.
 Do not load eatables or any other things with hazardous/poisonous goods.
 Load heavy materials below and light materials above.

 Do not load leaking cylinders, drums, or boxes.

 Do not load extra load than prescribed load.
 Tie the cylinder, drums or boxes with a strong rope.
FILLING OF THE TANK (BULK LOADING)
 Stop the vehicle engine.
 Keep wheel chocks (stoppers) for all wheels.
 Smoking, lighting of cigarettes, agarbatties or flammable articles are
prohibited.
 Put loading hose after fixing earthing cable.
 After filling ensure that there is no leakage.
 If there is any leakage immediately repair it or get it repaired (safety
instruments should be used).
 After filling loading hose, earthing cable and wheel stoppers should be
removed (safety instruments to be used).
 SAFETY FOR THE VEHICLES WITH DANGEROUS
MATERIALS
 Do not go away leaving the vehicle.
 Park the vehicle away from residence areas and mobs.
 Drive the vehicle on permitted routes.
 Do not allow passengers in to the vehicle.
 Do not allow unlicensed persons to drive.
 LEASE FOLLOW THE FOLLOWING INSTRUCTIONS
 Get technical check up of the tank truck (regularly).
 Remember that you are going on long journey and you have to return safe.
 See that the brakes are effective and intact. Check whether there is any play in the
steering wheel.
 Head lights, tail lamps, parking, and indicator lights should be properly
working.
 Tyres should be in condition and should have required air pressure.
 Check water in radiator, check battery, check engine oil quantity.
 Road signals should be with you – study them and follow them.
 EMERGENCY MEASURES
 Ordinary Accident, Leakage or fire:
 Stop the engine.
 Apply hand breaks.
 Put stoppers under all wheels.
 Remove trem card keep it with you.
 Keep away other people from the accident place.
 Stop the traffic and make them alert.
 All flammable and burning materials are prohibited
 Smoking is prohibited.
 Inform nearest police station immediately.
 In case of fire is suspected, inform the fire services.
 If necessary remove the people from area about 250 sq.mts and stop the
movement of other vehicle.
 First aid to injured.
 Give first preference to life saving and pollution and then material.
 Inform your owner, consigner and loading company.
 Regular inspection of vehicle by the driver or cleaner is necessary.

 Engine key should be with driver.

 Leakage or spreading:
 If possible take the vehicle away from residential areas to open place.
 Soke leaking material with dust, sand or saw dust.
 Bury it in a safe place or burn it.
 Do not drive the vehicle in water such as river , drain etc.
 If possible fill in steel drum with lid.
 If possible leaked or spread material should be shifted in to other tank.
 In case any leakage of liquid gas, the place should be cleaned with sufficient water.
 Ensure that the liquid gas is not flowing in drains or any other water.
 Inform the nearest fire service station.
 If possible try to stop the inflammable leakage with safety measures.
 Stand in opposite direction of the air.
 If possible stop the traffic and keep the people away at least 250 meters of radius.
 Fire protection equipment should be kept ready.
 Limitation of speed on the road and inside the factory:
 Follow speed restrictions imposed, Never deviate.
 For example speed limit – should be 25km per hour (Follow rules ).
 Not to enter prohibited area or road.
FIRST AID
 Body infection:
 Remove the effected clothes and shoes.
 Clean the skin by soap.
 Consult the doctor.
 Infected clothes should be washed and wore. Do not use infected
shoes. Infection of eye:
 1. Immediately clean the eyes with cold water for 15 minutes.
2. Consult the doctor.
Infection by inhaling:
 1. Remove the person to a open and fresh air area from the polluted area. 2.
If breathing is stopped, try to give artificial breathing.
 Try to take the help of a doctor as early as possible.
 Stomach is effected:
 1. Follow the instructions
of trem card. 2. If
prohibited do not try to
vomit.
 3. 50 ml Luke warm water should be given for drinking. 4. Do not give any
thing to unconscious person.
 Stomach is effected:
 Follow the instructions of trem card.
 If prohibited do not try to vomit.
 50 ml Luke warm water should be given for drinking.
 Do not give any thing to unconscious person.

Practical PDIS 102

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GNFC-PDIS (102-Safety Engineering-1)

Name of Student: - Chauhan Rutvikkumar Mahendrabhi

This is to certify that, Mr. Chauhan Rutvikkumar Mahendrabhai.

Post Diploma in Industrial Safety 1

2 To study about Illumination & workplace visibility 16 to 24

3 To study about Heat stress with respect to Work 25 to 47

5 To study about Electrical hazards & Its Safety 60 to 72

6 To study Effective ventilation for safe work place 73 to 77

7 To study about machine guarding 78 to 93

8 To study about Noise and Vibration 94 to 106

11 To Study about safety at work Place 125 to 131

12 To Study about Transportation of Chemicals 133 to 144

Post Diploma in Industrial Safety 2

1. Introduction to Material Handling Equipment (MHE)

Figure 1:-Material Handling Equipment

Post Diploma in Industrial Safety 3

Figure 2: -Manual-Material Handling Equipment

Figure 3: - Powered or Mechanical -Material Handling Equipment

Post Diploma in Industrial Safety 4

1.2 Hazards of manual and material handling are due to

Manual Handling Mechanical Handling

1.3 Accident can be avoided if safety professionals should study,

Post Diploma in Industrial Safety 5

Persons Max. weights of goods

2.3 Mechanical Handling – As per FA, 1948

Post Diploma in Industrial Safety 6

2.4 Mechanical Handling – As per GFR 1963

Class 1 or description of hoist or lift Requirement II which shall not apply

2.5 Mechanical Handling – As per FA, 1948

Post Diploma in Industrial Safety 7

2.6 Mechanical Handling – As per GFR, 1963

Post Diploma in Industrial Safety 8

Post Diploma in Industrial Safety 9

3. Documents required for MHE (Mechanical)

Post Diploma in Industrial Safety 10

4. Past Accident Case Studies

A team of four people were doing movement of one cage

Post Diploma in Industrial Safety 11

4.2 Case Study 02 – First-Aid Case

A victim and his co-worker were transferring the

Good Practice to Avoid Such Incidents:

Post Diploma in Industrial Safety 13

 Never overload the trolley

5. Safe Operation of MHE

5.2 Steps for safe handling –

5.3 Manual Handling – General Do’s & Don’ts

Post Diploma in Industrial Safety 14

Figure 10: -Manual Handling – General Do’s & Don’ts

5.4 Mechanical Handling – Hoist

Figure 11: - Mechanical Handling – Hoist

Post Diploma in Industrial Safety 15

Aim: - To study about Illumination & workplace visibility.

Illuminance can be expressed as

Post Diploma in Industrial Safety 16

● When calculating artificial illumination of industrial premises, the concept of mean

1 foot candle (ftcd, fcd) = 1 lumen / ft2

Post Diploma in Industrial Safety 17

• Good illumination needs sufficient quantity of illumination necessary for avoiding

Post Diploma in Industrial Safety 18