UNIT IV SAFETY MANAGEMENT

UO1:- State the General Safety

Norms for the given Case.
Learning Objective:-

► To understand the importance and need of safety management.

► To know the General Safety Norms.
► Apply safety norms in case of woodworking machine.

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 Contents :-

1. Introduction.
“Take hold of safety before an accident takes
2. What is Industrial Safety? hold of
3. Why it is important? you, remember safety starts with you”
4. Need of Safety Management System.
5. General Safety Norms.
6. Case of Woodworking Machine.
Atul Waghulde
Lecturer in Mechanical Engineering

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Industrial Safety:-

1. Industrial safety primarily is an activity of management with

reducing, controlling, eliminating hazards, risks, accidents
from industries to protect its employees and assets.

2. Industrial safety is defined as the law, policies, and

protections put in place to ensure plant and factory worker
protection from hazards that could cause injury.

3. A quality or condition of being safe or protected from

danger, injury, damage, loss and accidents.

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Importance of safety:-
1. Because each and every employee in the industry desire to work
in a safe and protected atmosphere.
2. It is a duty and moral responsibility of the industry to look after
employee’s protection.
3. Because every year millions of industrial accidents occur which
result in loss of production time equivalent to loss in millions of
man and machine hours.
4. A serious workplace injury or death changes life forever-for
families, friends, communities and co-workers. Human loss and
suffering is immeasurable and intolerable that is why it is
necessary to maintain industrial safety.

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Need for Safety Management System.:-

1. It is a Comprehensive management system designed to

manage safety elements in workplace.
2. It includes policy, objectives, plans, procedures,
organizations, responsibilities and PDCA activities.
3. It is a continuous improvement process that reduce
hazards and prevent incidents. It protects health and safety
of employees.
4. It ensures better working environment for employee and
place employees in jobs suitable to their restrictions.
5. It manage significant safety risks including aviation,
petroleum, chemical, electricity generation etc.
6. EHS enables companies to improve workplace health and
safety by identifying and managing safety risks, tracking
nonconformances, assigning corrective and preventive
actions, providing the tools for employee training and
injury record keeping.

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General Safety Norms:--

1. Be sure to perform job safely.

2. Be sure to know hazards and how to protect it.
3. Wear the required PPE (personal protective equipment) necessary
for welding, cutting operation etc.
4. Use equipment ,tools and machines properly.
5. Keep work areas and emergency exits clear.
6. Always work clear of suspended load-head and foot protection.
7. Avoid tracking hazardous materials, lockout of energy sources.
8. Switch off main supply and always hang a tag i.e. Work In Progress.
9. Avoid lack of oxygen on a place that could cause immediate
respiratory failure.
10. Serious care must be taken where toxic gases and vapors can
poison the worker. To be Continue….

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General Safety Norms:--

11. Be sure the use of norms of compressed gas cylinder.

12. Eliminate fire hazards.
13. Report all misses ,incidents, injuries and illnesses
immediately.
14. Inform supervisors of Unsafe Conditions.
15. Prevent Slips and Trips. Never override interlock safety
switches.
16. Never remove equipment grounding straps or leads.
17. Always remove all rings, bracelets, medallions or anything
which could get caught in moving machinery or may
conduct electricity. Always read the manufacturers data
and information sheets. To be Continue….

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Introduction:-

Safety
1. means continuing and healthful living without injury and freedom from danger of harm.
2. refers to precautions taken by people to prevent accident, damage loss, harm and pollution.
3. improves the working condition for better health.
4. creates an accident free environment boosts the morale of teams working in any hazardous
situations in industries.
5. safeguards human life particularly in high risk areas to reduce risk of people and processes.
6. helps to increasing rate of production, reducing production cost and damage to equipment and
machinery, preventing premature death of workers who are an asset to the society.
7. requirements considered by management as a part of responsibility arises from industrial acts.

Footnotes

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General Safety Norms:--

18. Always when working with electricity, keep your left hand in
your pocket where possible to avoid providing an electrical
path through your chest and heart.
19. Do not work when you are tired or taking medicine which
makes you drowsy or affects your reactions and
concentration.
20. Do not work under poor lighting conditions and in wet
clothing.
21. Do not work in areas which are damp.
22. Never assume a circuit is off. Always check for power with
the appropriate instrument.
23. Always follow safety rules and regulations .

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Case 1 :- Safety Norms for Woodworking Machine:-

1. Always wear safety glasses or goggles, foot wear ,dust masks or a face shield
2. Wear hearing protection that is suitable for the level and frequency of the
noise you are exposed to in the woodworking area, the noise level from the
machine is too high. Damage to hearing may occur.
3. Use gloves to protect hands from splinters when handling wood but do not
wear them near rotating blades and other machinery parts where the gloves
can catch.
4. Make sure the guard is in position, is in good working condition, and guards
the machine adequately before operating any equipment or machine.
5. Make sure the equipment is properly grounded before use.
6. Check that keys and adjusting wrenches are removed from the machine before
turning on the power.

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Case 1 :- Safety Norms for Woodworking Machine:-

7. Inspect stock for nails, staples, loose knots or other defects before cutting,
planning, routing or carrying out similar activities.
8. Make sure that all machines have start and stop buttons within easy and
convenient reach of an operator.
9. Ensure that all cutting tools and blades are clean, sharp, and in good
working order so that they will cut freely, not forced.
10. Turn the power off and unplug the power cord before inspecting,
changing, cleaning, adjusting or repairing a blade or a machine. Use a
"push stick" to push material into the cutting area. Jigs are also useful in
keeping hands safe during cutting procedures. Keep hands out of the line
of the cutting blade.
11. Ensure that the floor space around the equipment is sufficient to enable
you to machine the size of work piece being processed safely. Use
extension tables or roller supports for large workpieces.

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 Case 1 :- Safety Norms for Woodworking Machine:-

12. Woodworking machines should be fitted with efficient and well-maintained local
exhaust ventilation systems to remove sawdust or chips and good lighting for clear
observation.
13. Electric power cords should be above head level or in the floor in such a way that
they are not tripping hazards.
14. Keep work area free of clutter, clean, well swept, and well lit. Good housekeeping
practices and workplace design will reduce the number of injuries and accidents
from slips, trips, and falls.
15. Keep the area free from water and moisture. Do not use electrical equipment
outdoors in the rain.
16. Always keep your attention on the work. if you must talk to another person, turn off
the equipment first.

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Summery:-

 Meaning of Safety

 Definition of Safety

 Importance

 Need of SMS

 Understanding of General Safety Norms with example.

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CO4:- Apply Principles of safety
management in activities.

UO2:- Suggest preventive

measures of plant activities in
given situation.
Learning Objective:-

► To understand the Important Preventive Measures.

► To Suggest Preventive Measures of the situation like handling Electrical
Equipment’s.

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Contents:-

A. Important Safety Measures .

1. Safe Workplace and Working Condition. At Work, At Home – Let Safety Be
2. Safe Material Handling. Known.
3. Prevention of Electric Accidents.
4. Safe Activities.
5. Education and Training.
6. Use of Personal Protective Equipment’s.
7. Good Housekeeping.
8. Safe Working Methods.
9. Accident Prone Areas.
10. Safety Programmes.
11. Safety Awareness. Atul Waghulde
B. Case of Electrical Equipment’s. Lecturer in Mechanical Engineering.

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 1.Safe Workplace and Working Condition.

1. Passageways between working places, roads, tracks and alleys, etc. must
never be obstructed, and enough space to move and operate.
2. For adequate lighting, ventilation and natural day light ,etc., the heights
of the working rooms and windows should have adequate dimensions.
3. Floors must be of non skid type, satisfactorily plane and easily cleaned
and absorb sounds.
4. In enclosed rooms, to have comfortable conditions, to controlled air
temperature, air purity, humidity of air. Proper ventilation is a must if the
manufacturing processes give rise to dust, smoke, fumes, etc.
5. Whether natural or artificial, there should be sufficient illumination, of
adequate colour of light, continuous and uniform and free from glare.
6. Select and purchase machines and processes which produce little noise
and isolate in separate closed cebine.

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 2.Safe Material Handling:-

1. To avoid premature fatigue of transport workers, full use

should be made of mechanised materials handling equipment.
2. Use mechanical means of conveyance to ensure the safety of
men engaged in material handling.
3. During transport, sharp materials, sharp edged goods, poles
etc., should be covered.
4. Goods should be piled up such that they do not collapse due to
impact or vibrations.
5. All material handling equipment should be promptly repaired
and adequately maintained on priority basis.
3. Prevention of Electric Accidents:
1. Electrical insulation should be periodically tested.
2. Use proper tools for testing and repairing.
3. Repair Work should be done after switching the power off.
4. Use safety equipment's such as insulated tools and rubber
gloves whenever necessary.

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 4. Safe activities in the following situation.:-

1. Repair work on the machine should not be done when it is running.

2. All the tools should be kept at their proper places.
3. Chips should not be removed by hand.
4. Worker should be trained about correct procedures and safety Precautions.
5. Constant warning, publicity and play cards carrying slogans are also helpful to
reduce accidents.
6. To avoid danger, inflammable materials should be kept away from general
storage at a safe distance. Fire extinguishers should be kept at suitable places.

5. Education and Training:-

1. Ensure everyone has the proper safety training relating to the hazards of the job.
2. Take advantage of Environmental Health and Safety online training programs.
3. It is each employee's responsibility to take an active role in maintaining safety.
4. Understand Four E’s of Safety Engineering, Education, Enforcement, Enlistment.

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 6.Use of Personal Protective Equipment’s:-

 (a) Protection of Head:

1.Safety hard hats 2.Rubberized hats for protection against liquids (chemicals)
3.Ear protectors..
 (b) Protection of Face:
1. Face mask 2. Face shields 3. Welding helmets.
 (c) Protection of Eyes:
1.Goggles of case-hardened and clear glass for protection against impact.
2. Eye cup goggles for protection against flying objects and dust.
3. Eye cup goggles impervious to chemicals for protection against acids splashes.
 (d) Protection of Lungs:
1. Airline respirators. 2. Cartridge respirators. 3. Oxygen or air-breathing apparatus.
4. Gas mask.
 (e) Protection of Other Body Parts, e.g., Hand, Foot, Leg, etc.:
1. Protective asbestos clothing. 2. Gloves. 3. Safety shoes. 4. Foot guards.
5. Safety body belt. 6. Aprons.

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7. Good housekeeping:-

1. Good housekeeping minimizes fatigue and discomfort to the workers and motivate them.
2. It reduces the chances of fire and other hazards.
3. Increases the life of machinery, equipment and tools.
4. Improves productivity and quality of the product.
5. Better utilization of floor space.
6. Enhances the moral of workers.

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 8.Safe Working Methods:-

1. Always use appropriate tools, equipment and protective equipment’s.

2. Always remove all rings, bracelets, medallions or anything which could
get caught in moving machinery or may conduct electricity.
3. Always read the manufacturers data and information sheets.
4. Do not work when you are tired or taking medicine which makes you
drowsy or affects your reactions and concentration.

5. Always ensure your tools and test equipment are kept clean,
appropriate, in good working order.
6. Always discharge capacitors in a circuit. And use correct fire extinguisher.

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9.Accident Proneness:-

1. Un-attentiveness and day-dreaming.

2. Poor eyesight and hearing and lack of stamina.
3. Poor adjustment of work; distaste for the job.
4. Too much sensitivity and tendency to get Emotional.
5. Dislike of the supervisor/foreman, etc.
6. Lack of training, proficiency and skill to do a work.
7. Insufficient intelligence.
8. Unsafe behaviour of the worker (e.g., intentionally not using safety devices
and safe practices).

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 10.Safety Programmes:-

1. Support by top management. By appointing safety director.

2. Engineering a safe plant, processes and operations.

3. Educating all employees to work safely.

4. Studying and analysing the accidents to prevent their occurrence

in future. Enforcing safety rules.

5. Holding safety contests, safety weeks etc., and giving

incentives/prizes to departments having least number of accidents.

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 11.Safety Awareness:-

1. Increasing safety awareness in any organization doesn’t just happen by

accident, nor can you achieve continuous awareness through passive
engagement.
2. Things like safety posters and flyers may be read once or twice before
they start the work.
3. Events like Safety Awareness Week or in-house training sessions can
help to bring top of mind awareness to certain topics, keep employees
engaged.
4. The best way to create effective safety awareness is to build safety into
everything you do within your organization.

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 Preventive Measures while working on Electrical Equipment’s:-

1. Avoid water at all times when working with electricity. It increases the
conductivity of electric current.
2. Never use equipment with frayed cords, damaged insulation or broken plugs.
3. If you are working at your home then always turn off the mains.
4. Always use insulated tools while working.
5. Electrical hazards include exposed energized parts and unguarded electrical
equipment which may become energized unexpectedly. Always be observant of
such signs and follow the safety rules established by the electrical code followed
by the country you’re in.

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Preventive Measures while working on Electrical Equipment’s:-

6. Always use appropriate insulated rubber gloves and goggles while working
on electrical circuit.
7. Never try repairing energized equipment. Always check that it is de-
energized first by using a tester.
8. Never use an aluminum or steel ladder. Use a bamboo, wooden or a
fiberglass ladder.
9. Always use a circuit breaker or fuse with the appropriate current rating.
Circuit breakers and fuses are protection devices that automatically
disconnect the live wire when a condition of short circuit occurs.
10. Working outside with underground cabling can be dangerous. The damp
soil around the cable is a good conductor of electricity and ground faults
are quite common in the case of underground cabling. so it is better to dig
at the cable by hand while wearing insulated gloves.

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Preventive Measures while working on Electrical Equipment’s:-

11. Always put a cap on the hot/live wire while working on an electric board or service
panel as you could end up short circuiting the bare ends of the live wire with the
neutral.
12. Take care while removing a capacitor from a circuit. A capacitor stores energy and if
it’s not properly discharged when removed it can easily cause an electric shock. For
high voltage ones a 12 Volts light bulb can be used.
13. Always take care while soldering your circuit boards. Wear goggles and keep yourself
away from the fumes. Keep the solder iron in its stand when not in use; it can get
extremely hot and can easily cause burns.
14. Always follow safety rules and regulation.

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Summary:-

Common and most important safety Measures

 1. Safe Workplace and Working Condition.

 2. Safe Material Handling.
 3. Prevention of Electric Accidents.
 4. Safe Activities.
 5. Education and Training.
 6. Use of Personal Protective Equipment’s.
 7. Good Housekeeping.
 8. Safe Working Methods.
 9. Accident Prone Areas.
 10. Safety Programmes.
 11. Safety Awareness.
 Example for better understanding.

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 CO4:- Apply Principles of safety
management in activities.

UO3.1:- Explain safe procedural

steps required to prevent
accident.

Written by
Learning Objective :-

► To understand Safe Operating Procedure for preventing accidents.

► To prepare Safe Operating Procedure to prevent accident.

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Contents :-

1. What is SOP? “ Always be responsible for the safety of yourself and

others, Precaution is better than cure.”
2. Need of Safety operating procedure.
3. Benefits of SOP.
4. Steps of SOP.
5. Preparation of SOP.
Atul G.Waghulde

Lecturer in Mechanical Engineering

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What is Safe Operating Procedure ?

A safe operating procedure (SOP) is a written document that

provides step-by-step instructions on how to safely perform a
task or activity which involves some risk to health and safety.

A safe operating procedure is sometimes referred to as

a safe work procedure or safe work method statement.

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Need of Safety Procedure:-

1. Workers doing work activities that have risks, these procedures tell them
"how to do their work activities and remain safe and healthy“.
2. The Supervisors know that; by making sure the workers they supervise
follow those SOPs, they will be helping to keep those workers safe and
healthy.
3. The Manager take reasonable care for the health and safety of workers
and supervisors that the Manager has overall control and responsibility.
4. The Safety Committee and any employees engaged in safety inspection
need SOPs because they are a stable and reliable reference point to make a
safe and healthy workplace.

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Benefits of SOP:-
1.Reduce employee training time.
A written set of guidelines helps ensure that all new hires get the same training, on the same topics and
responsibilities, in the same amount of time.

2.Reduce errors and enhance productivity.

Written SOPs can take the guesswork out of day-to-day operations and help ensure that all of your employees
understand the processes, policies, and procedures associated with their jobs.

3.Meet legal requirements.

Depending on your industry, you may be required to have written SOPs that protect your employees and/or
customers and ensure that you won’t be held legally responsible if something goes wrong.

4.Establish a chain of command.

Everyone in your company should have a clear idea of your company’s leadership structure, and this is especially
important in situations where work products go through multiple stages of review and approval.

5.Transfer work easily.

Most employees take a sick day here and there, but in the case of an extended absence, written SOPs make
it easier to transfer work to another employee.
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Steps of Safe Operating Procedure:-

1. Name or description of the work task.

2. Date of SOP was created and Date it was last reviewed or
revised.
3. Hazards that may cause harm to a worker.
4. Equipment / devices, personal protective equipment (PPE),
or other safety considerations necessary to perform the
task safely.
5. Required training and / or relevant documentation needed
to perform the task safely.
6. Steps to perform the task safely including safe body
positions and / or movements as appropriate.
7. Indication that workers are to be trained on the SOP and
employers must ensure workers follow them.

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 Safety Procedure for preventing the accidents occurred while working on Lathe
Machine.
Department / Area: Approved By: Date Created: Review / Revised date:
Maintenance Maintenance Manager 07/07/2020 30/08/2020
Accident Type/Potential Hazards: Red Indicate Situation Personal protective equipment / Devices required /safety
considerations
-Eye protection, Wear Safety Goggle ,shield.
Awkward / sustained postures – holding tools -Hearing protection
Forceful exertions – pressure holding tools -Safety footwear
Repetitive movements -Disposable Respirator.
Vibration -Dust collection system
Chuck Key attacked on face -Do not wear anything dangling such as hood strings or other dangling clothing
Sharp points / edges :- Hot flying Chips or jewelry. Contain long hair
Pinch points – Jam between stock and tool rest Training / Reference information
Materials falling - Job Fallen on feet -Injury prevention orientation
Surfaces causing -Lift / manual materials handling training
Moving machinery – spinning stock -Operators manual
Chemicals - wood dust -In house training
Biological pathogens
Electrical
Extreme heat / cold
Noise - cutting operation
Combustibles / flammables
Clothing getting caught in machinery

Note: Signs and symptoms of a musculoskeletal injury (MSI) can include pain, burning, swelling, stiffness, numbness/tingling, and/or loss of
movement or strength in a body part. Report these to your supervisor.
Employers must ensure that workers are trained and follow this SAFE Work Procedure,

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 Safety Procedure for preventing the accidents occurred while working on
Lathe Machine.(cont.) :Steps to perform this task safely:

1. Ensure any loose fitting clothing is tucked in appropriately.

2. Long sleeve shirts should be tight at the cuffs, long hair contained, and watches or loose jewelry should
be removed to reduce the risk for jams or entanglement
3. Pre inspect lathe for possible defects before using. Check electrical cords, switches, guards, adjustment
locks, Check wood stock for defects and that glued joints are cured and dry.
4. When lifting materials, try to keep your back straight and keep the load close to reduce stress on your
back, Bend hips and knees rather than bending at the waist. Avoid twisting your back by instead taking
small steps to turn.
5. Load stock into the teeth of the stock holders and ensure it is well secured , Make sure the tool rest is
close to the stock and free from debris / tools .

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Safety Procedure for preventing the accidents occurred while working on Lathe
Machine.(cont.)

6. Turn on lathe. Hold tools firmly with both hands, Do not touch the spinning stock with your hands or
reach around spinning stock.
7. When using V-belt, power should be off and lathe unplugged before changing speeds, Remove tool
rest before sanding and polishing.
8. When an operator has finished working on the lathe, and before leaving the lathe for any reason, the
power must be shut off and the machine must come to a complete stop.
9. When an operator observes an unsafe condition with the lathe or stock being worked, the operator
must report it immediately to the designated person and the lathe shall be taken out of service until
the problem has been corrected.
10. Stop the machine immediately if odd noise or excessive vibration occurs.

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Summary:-

 Meaning of SOP

 Why there is a Need of Safety operating procedure.

 What are the benefits of SOP.

 Step by step points of SOP.

 How to preapare the SOP.

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 CO4:- Apply Principles of safety
management in activities.

UO3.2:- Prepare work permit to

conduct given maintenance
activity.

Written by
Learning Objective :-

► To understand Permit to Work process.

► To prepare work permit for conducting maintenance activity.

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Contents:-

1. What is Work Permit? “Always follow company rules, regulations and

2. Features of Work Permit. procedures.”

3. Elements of Work Permit.

4. Types of Work Permit.
5. Preparation of Work Permit. Atul G. Waghulde
Lecturer in Mechanical
Engineering

Page 44 Maharashtra State Board of Technical Education 16 March 2024

 What is Permit-to-work?

1. A permit-to-work system is a formal written system used to control

certain types of work that are potentially hazardous.

2. A permit-to-work is a document which specifies the work to be done

and the precautions to be taken. Examples work in confined spaces,
work at height, high risk areas, to repair, maintain, or inspect the
electrical installations or to use the large or the complex equipment etc.

3. Permits-to-work form an essential part of safe systems of work for

many maintenance activities.

4. It is also a means of communication between different departments,

plant supervisors, operators, agencies etc.

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Features of permit-to-work systems:-

A Standard Operating Procedure, job or method statement and information

The equipment and tools to be used

A hazard and risk assessment

Required precautions, mitigating actions and control

measures

All PPE requirements

The permit issue, extension and withdrawal details

The names and signatures of those who are responsible for the job

A Tool Box Talk signed by all workmen

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 Elements of Work Permit System:-

 Issue: 1. It means pre job check,

2. Description of work to be carried out
3. Description of plant and location,
4. Assessment of hazards
5. Identification of controls.

 Receipt: 1. It means handover of permit,

2. Competent and authorized person issues permit to workers
3. Work can now start,
4. Workers sign to say the accept control,
5.Plant is now under the control of workers.

 Clearance: 1. It means hand back to permit,

2.Workers sign to say they have left the job site and equipment's can
restart.

 Cancellation: 1. Authorized person accept plant back and can remove isolation,
2. Plant is now returned to the control of the site.
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Types of Work Permit:-

1. Hot work permit: It is any work that could create a source of

ignition that could result in fire or explosion. Examples: Spark
producing tools, hammering in high risk gas areas, explosives,
welding and torch cutting etc.

2. Cold work permit: a cold work permit shall be obtained for all
general work that does not involve activities related to hot work.
Example: Routine maintenance, inspection, hand tools.
Opening of process equipment such as, vessels, towers, pumps,
compressors, heat exchangers, filters, tanks, etc.

3. Electrical Permit: A work permit is required for work on electrical

systems where there is a possibility of contacting energized
electrical conductors.

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Types of Work Permit:-

4. Confined Space Entry Permit: A work permit is required to allow personnel

to enter a confined space such as a tank, vessel, blade, trench, etc.

5. Ground Disturbance Permit: A work permit is required for any excavation or

ground disturbance activity that involves digging, trenching, excavating or
removing soil or ground.

6. Excavation: A process of moving earth, rocks or other materials with tools,

equipment or explosives. It includes earthworks, wall shafts, tunnelling and
underground work, using manual or mechanised methods.
For excavations more than 1.2 meters deep a Confined Space Entry
Authorization is also required.
► Responsible person: A person i.e Issuer, Executor and Field Operator
authorized by manager who will responsible for keeping his area and staff
safe.

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Design of work to Permit:- Sample

Page 50 Maharashtra State Board of Technical Education 16 March 2024

Permit to work Activities for Maintenance of Grinding Machine.

COLD Work Permit for Maintenance Activity

1. Work Details Permits Required :- Yes /No :- Acceptance of Permission /YES
Location of Cold Work: Production Workshop Permit No. :- PW/123
Names of Person/s conducting work: Mr. Anand Bakshi, Maintenance Engineer Employers must ensure that workers are trained and follow this SAFE Work Procedure
Steps to perform this task safely:
Description of Work: Maintenance of Grinding Machine.
Equipment No. 123456.
Prior to permitting the person(s) intending to perform cold work, management are to verify that 1.Only use the grinder in a manner specified by the operational instructions and always ensure the guards are in place
the person(s) are adequately trained. 2.Pre inspect grinder to ensure switches, cords, grinding stone or brush are in good working order.
2. Hazards and Risk Controls If there is damage or excessive wear and tear, do not use the grinder and inform a supervisor
Awkward / sustained postures – holding parts Personal protective equipment / devices required / other safety 3.Ensure the tool rest is not below the horizontal centre line and no more than 3mm from the face of the wheel
Forceful exertions – holding against grinder/brush considerations 4.Hold the part firmly but do not apply excessive force of the tool / part against the grinder
Repetitive movements 5.Do not try to hold parts that are too small so that there is a risk that your fingers may contact the grinding wheel.
Vibration – (hand arm) part against grinder - Gloves
Compression - Safety footwear
6.Attach and secure part to be grinded to another tool / extender such as vice grips
Sharp points / edges – grinder wheels, brush - Eye protection / face shield 7.Do not grind against the side of the wheel
Pinch points - Hearing protection 8.Grinding wheel shape and wear must be maintained as per manufacturer’s specifications
Materials falling - Secure loose clothing, hair, draw strings from hoods etc that 9.For repetitive or long lasting tasks, take micro breaks or change tasks or positions to reduce stress on the same
Surfaces causing falls could become entangled in wheel.
muscles
Moving machinery
Chemicals
Biological pathogens 10.Always turn off the grinder and unplug it / lock it out before performing adjustments, maintenance or repairs
Electrical Safety Checks for compliance
Extreme heat – burns from hot parts Sr.No.
Noise Is Electrical Work Permit Required ? YES
1
Combustibles / flammables
Other _____________________ 2 Is Confined area permit required ?
3 Is Height Work Permit Required ?
4 Is Cold Work Permit Required ? YES
5 Is Excavation work permit required ?

6 Is Process Isolation required ?

If YES, take clearance form process Dept.

Page 51 Maharashtra State Board of Technical Education 16 March 2024

 Permit to work Activities for Maintenance of Grinding Machine. Cont.

3. Verification

All person(s) have received instruction in the Risk Assessment and/or Job Safety Analysis (JSA) for Yes
the work activity.
All person(s) understand the potential risks involved in the work to be carried out. Yes
All person(s) understand the controls to be implemented. Yes

4. Authority

Person Issuing Permit: Person Receiving Permit: Mr.ABC

Mr.XYZ Signature: Signature:
Permit Valid from: Permit Valid to:
Date:07/07/2020 Date7/12/2020
Time: 10 A.M. Time: 5 P.M.
5. Upon Completion of Work

The above work is completed. Man power deployed is removed from the working site.

Waste material has been removed and disposed of safely

6. Authority I accept that the work specified above in this permit has been completed.
Person who Issued Permit: Permit who Received Permit:
Mr.XYZ Signature: Mr.ABC Signature:

Date: 7/7/2020 Date:

Time:10 A.M. 07/07/2020
Time: 11 A.M.
Copy : (1) Production Workshop (2) Safety Office, (3) Office Record ( Retention Period 7 days)

Page 52 Maharashtra State Board of Technical Education 16 March 2024

Summary:-

►Understanding of Work Permit?

►Features of Work Permit.

►Elements of Work Permit.

►Types of Work Permit.

►How to Preapare of Work Permit.

Page 53 Maharashtra State Board of Technical Education 16 March 2024

 CO4:- Apply Principles of safety
management in activities.

UO4:- Explain the causes of

accident in given situation.

Written by
Learning Objective :-

► To understand Types of Accidents.

► To understand Causes of Accidents and Hazards,
► Case Studies, Suggest the Causes of Accidents for a Situation.

Page 55 Maharashtra State Board of Technical Education 16 March 2024

We will Learn About the following Contents :-

1. Definition of Accident.
2. Types of Industrial Accidents.
“Chance takers are accident makers”
3. Causes of Accidents.
4. Types of Hazards.
5. Case Studies.
.

Atul Waghulde
Lecturer in Mechanical Engineering

Page 56 Maharashtra State Board of Technical Education 16 March 2024

 Definition of Accident.:-

An accident is an unplanned and undesired event, which results in to unacceptable and

undesired consequences. The consequences might be injury and / or damage to
equipment, machinery, raw material or finished product or damage to environment and
loss of property, material or human.

Accident is an unfortunate and sudden miss happening which causes

damage or loss of
property, material or human.

Losses Due to accident:-

Direct Losses:

Indirect losses:

Page 57 Maharashtra State Board of Technical Education 16 March 2024

Types of industrial accidents:

1.Machinery accidents- Cause due to inadequate safeguard of machines. These can be reduced by
providing safety guards on belts, gears, etc.
2. Non machinery accidents-Cause due to personal reasons such as age, physical weakness,
inexperience and carelessness or from the plant conditions such as poor ventilation and
illumination.

Page 58 Maharashtra State Board of Technical Education 16 March 2024

Types of industrial accidents:-

3. Based on severity, durability and degree of injury:-

1) Minor accidents :-Preventing employees for the period less than 48 hours from working.
2) Reportable accidents :-Prevent worker for the period of 48 hours working after injury.
3) Fatal accidents :-It result in to death of employee, Reporting to top management, legal
bodies and police.
4) Accidents due to dangerous occurrences:-Explosion, fire leakages are the reasons for this
type of accidents ,Man and property both can be damage.
5) Internal accidents :-Injury without showing external science(e.g. fractured bone)
6) External accidents :- Injury with external signs
7) Major accidents :-Accident causing death/permanent/prolonged disability to injured
employee.
8) Temporary accidents:-Accident which causes disability to worker for a short period (a day/a
week)
9) Permanent accident:-Injury after accident disable the affected worker permanently.

Page 59 Maharashtra State Board of Technical Education 16 March 2024

Types of industrial accidents:-

4. Based on place of accident :-

1) Construction :-Accident occurs at construction sites are often happening

and injuries are serious.

2) Chemical plant accident :-Accident occurs due to hazardous gases, vapours

and fumes.

3) Industrial plant accidents :-Industries accident occurs due to mistakes by

worker, management or situation.

4) Mining accident:-Collapse of soil layer, suffocation, poisons gases.

Page 60 Maharashtra State Board of Technical Education 16 March 2024

Causes of Accidents:-

1. Accidents due to dangerous machines-These accidents occurs from boilers,

pressure
vessels, prime movers, transmission system etc.
2. Unsafe Working conditions-it includes improper guard, improper illumination,
improper Ventilation, unsafe clothing .
3. Moving objects-Sometimes moving objects or foreign objects causes
accident.
4. Personal factors-Lack of knowledge, physical weakness are the personal
factors
which Causes accidents.
5. Unsafe act-These includes working at unsafe speed, loading machine
beyond
capacity, not Using safety devices, adopting unsafe procedure.
6. Electrical causes- Not obeying proper instructions and safety precautions.
Page 61 Maharashtra State Board of Technical Education 16 March 2024
7. Exposure to harmful substances-injuries due to accidents are also caused due
Types of Hazards:-

1) Mechanical hazards: These are responsible for the majority of accidents in work
situations, therefore every workplace and equipment should be properly
examined for identifying mechanical hazards. E.g .Improper use of tools,
Unguarded moving parts, Impropre ventilation, unsafe dress etc.
2) Electrical hazards: These may be due to contact of body with wire, cable, rail and
other
electrical appliances. Immediate effect of this is shock which may be mild or
severe to
cause death depending upon the strength of the current.

Types and causes of electric hazards:

1) By direct contact –while working on electrical circuits , contact with the live
conductor
2) Arc burns-An arc is a result of flash-over. At high voltage flash over can cause
severe burn.
3) Radiation burns-This is a result of short circuit and can cause discomfort to the
person.
Page 62 Maharashtra State Board of Technical Education 16 March 2024
Types of Hazards:-

3) Chemical hazards: A chemical hazard is caused by exposure to chemicals in the

workplace. It can cause acute or long-term detrimental health effects and health
risks. There are many types of hazardous chemicals, including neurotoxins,
immune agents, dermatologic agents, carcinogens, reproductive toxins, systemic
toxins, and sensitizers.

4) Radiation hazard: Radiation hazards in industrial radiography are mainly caused

by external sources, as x-rays and gamma rays are penetrating in nature and can
irradiate organs deep inside the body.
E.g:- Sunlight, Radio waves, x-rays, heat, alpha, beta, gamma ionizing radiation,
and infrared radiation.

5) Fire hazards:-Fire hazard is the most common hazard, which is present in all
areas of life. Fire hazards are workplace hazards that involve the presence of
flame or the risk of an uncontrolled fire. Fire hazards include: Live flames, Sparks,
Hot objects, Flammable chemicals, Chemicals that can aggravate a fire.

Page 63 Maharashtra State Board of Technical Education 16 March 2024

Case Study :- Vizag Gas Leak

1. „Gas leak in chemical factory in Visakhapatnam will immediately remind many

in India and beyond of the 1984 Bhopal disaster, widely considered the world’s
worst industrial disaster.
2. LG Polymers Plant , a gas leak in Visakhapatnam.
3. Investigators probing the leak of styrene from an LG Polymers plant on May 7,
2020 the accident occurred as the plant's cooling system was clogged.
4. A total of 12 people were killed and around 800 hospitalized as a result of the
gas leak. Gas leak was a result of a lack of safety precautions.
5. Clogged cooling system caused Vizag gas leak; staff didn't use warning system’
6. Furthermore, investigators told that the staff at the LG Polymers plant "did
not use a warning system to alert local residents". The accident raises
questions of whether hazardous industries should be situated near urban
centres.

Page 64 Maharashtra State Board of Technical Education 16 March 2024

 Following Precautions to be taken to reduce such type of accident.

1. Check your gas Equipment's regularly.

2. Install fire alarm system.
3. Have your gas lines monitored.
4. Check your gas safety documents.
5. If you detect a gas leak, turn off the gas supply. Do not smoke
6. Open the windows and shut off your electrical devices.

Page 65 Maharashtra State Board of Technical Education 16 March 2024

Case Studies :- Plastic and Chemical Industry:-

Generally in plastics companies accident rates between 2004 and 2015 shows that 3 main areas
of safety contributed to the highest rates of injury to workers.
Machine Safety- About 14% of all reportable accidents happened as a result of contacting
moving machinery. Machine safety resulted in the largest number of enforcement notices served
to plastic companies.
Slips and Trips- About 19% of accidents in plastic companies during the same period were
caused as a result of trips or slips in the workplace.
Work at Height- 12% workers were injured as a result of a fall from height in the workplace.

According to the Bureau of Labour Statistics, in 2019 industrial accidents were the cause of more
than
1.2 million workers in the United States. They point out 4 main causes of accidents in a chemical
plant:
1.Human error,
2.Improper training,
3.Manufacturing defects,
4.Improper maintenance.
Page 66 Maharashtra State Board of Technical Education 16 March 2024
Summary :-

 Meaning of Accident.

 Types of Industrial Accidents.

 Causes of Accidents.

 Types of Hazards.

 Case Studies.

Page 67 Maharashtra State Board of Technical Education 16 March 2024

 CO4:- Apply Principles of safety
management in activities.

UO5:- To know the specifications

of fire extinguisher for the given
type of fire.

Written by
Learning Objective:-

► To understand the types of fires and Fire Extinguishers.

► To Know the specifications of water type extinguisher for class A fire.

Page 69 Maharashtra State Board of Technical Education 16 March 2024

What we will learn today :- Fire Hazards:-

1. What is Fire Hazard? Know fire safety, no pain, no fire safety, know
2. Classification of Fires. pain.

3. Types of Fire Extinguishers.

4. How to use Fire Extinguisher?

5. Fire Emergency Action Plan

6. Specification of Water Type Extinguisher. FI

ATUL WAGHULDE
Lecturer in Mechanical Engineering.

Page 70 Maharashtra State Board of Technical Education 16 March 2024

What is Fire Hazard?

Fire Hazards are conditions that favour Fire Growth. This is The Fire
Triangle. Actually, it's a tetrahedron, because there are four elements that
must be present for a fire to exist.
There must be
oxygen to sustain combustion,
heat to raise the material to its ignition temperature,
fuel to support the combustion and a
chemical reaction between the other three elements.

Remove any one of the four elements to extinguish the fire.

Footnotes

Page 71 Maharashtra State Board of Technical Education 16 March 2024

Classifications of Fires :-

1. Class A fires are fires in ordinary combustibles such as wood,

paper, cloth, rubber, and many plastics.
2. Class B fires are fires in flammable liquids such as gasoline,
petroleum greases, tars, oils, oil-based paints, solvents,
alcohols. Class B fires also include flammable gases such
as propane and butane.
3. Class C fires are fires involving energized electrical
equipment such as computers, servers, motors, transformers,
and appliances.
4. Class D fires are fires in combustible metals such
as magnesium, titanium, zirconium, sodium, lithium, and
potassium.
5. Class K fires are fires in cooking oils and greases such
as animal and vegetable fats.
Page 72 Maharashtra State Board of Technical Education 16 March 2024
Classifications of Fire Extinguishers:-

Fire extinguisher are classified on the types of fires.

1. Class A fires – water gas cartridge, water mist, foam, dry

powder, wet chemical.

2. Class B – water mist, foam, dry powder, CO2, some wet

chemical.

3. Class C – water mist, dry powder,CO2.

4. Class D – specialist dry powder.

5. Class F – water mist, wet chemical.

Page 73 Maharashtra State Board of Technical Education 16 March 2024

How to use Fire Extinguisher?

The following four-step technique can be memorized more easily

with the acronym PASS:-

1. Pull: Pull the pin to break the tamper seal.

2. Aim: Aim low, pointing the nozzle or hose at the base of the
fire. (Do not touch the horn on a CO2 extinguisher since it
becomes very cold and can damage skin).

3. Squeeze: Squeeze the handle to release the extinguishing

agent.

4. Sweep: Sweep from side to side at the base of the fire – the
fuel source – until the fire is extinguished.

If the fire re-ignites, repeat the last 3 steps.

Page 74 Maharashtra State Board of Technical Education 16 March 2024

Fire Emergency Action Plan and Drill:-

1. Assess all possible fire emergencies. Conduct fire drill.

2. Assess resources available in the plant and make a list of them with their locations,
contact phones of fire brigade and in charge persons.
3. Assess resources needed from outside and make a list of them with their places of
availability, contact persons and phone numbers.
4. Prepare a central control room for co-ordination of emergency time activities.
5. Prepare an organized group of key persons who will act to control the emergency.
Everybody should be given their role in writing. Table top exercise and rehearsal
will be carried out to shape their actions. Established an in-house safety committee
6. All communication systems shall be maintained in workable order.
7. Double gates (one for entry, one for exit), unobstructed inner roads and proper
sign boards shall be displayed. Mark fire prone areas on the factory plan.

Page 75 Maharashtra State Board of Technical Education 16 March 2024

Fire Emergency Action Plan and Drill:-

8. Housekeeping shall be regularly checked.

9. Fire water, working order of fixed fire installations and placement of charged portable
extinguishers shall be regularly checked.
10. Alternate power source shall be kept ready.
11. Runners shall be arranged to act in the event of communication failure.
12. Distinctive garments or cap, band etc. shall be given to emergency controllers.
13. Decide assembly points for safe gathering by other people.
14. Keep arrangement for medical, security and transport in readiness to handle the –
emergency.
15. Train firefighting crew, medical staff and other workers for their emergency .
16.Assured before restarting the normal work that fire is fully extinguished,
environment is cooled, debris etc. removed, all-clear signal is given and the plant is
ready for restart.

Page 76 Maharashtra State Board of Technical Education 16 March 2024

Specifications of Water Type Portable Fire Extinguisher (9 Litre capacity):-
Class A

1. Type of Extinguisher Portable Fire Extinguisher, water type (Gas

cartridge)
2. Media of extinguishers Water

3. Quantity 01

4. Capacity 9.0 ± 0.5 litre

5. Shape of the body Cylindrical

6. Outside diameter 175± 5 mm

7. Syphon tube and strainer Syphon tube with strainer shall be fitted at
free end inside the body.

8. Material of construction of body Mild steel with minimum grade D of IS 513

9. Material of construction of Syphon tube Stainless steel tube (IS 6913)

10. Material of construction of Cartridge Stainless steel as per IS 6528

holder, knob, discharge fitting , piercer & plunger.

Page 77 Maharashtra State Board of Technical Education 16 March 2024

Specifications of Water Type Portable Fire Extinguisher (9 Litre capacity):-
Class A
Water Type (Gas Cartridge) Portable Fire Extinguisher(9 Litre capacity)

11. Material of spring Spring steel wire (Grade 1 of IS 4455(part 1)

12. Hose dimension Shall be of not less than 8 mm bore and

length not less than 600mm.
13. Hose quality Braided rubber with minimum bursting
pressure of 40 Kgf/cm2
14. Size of Gas cartridge 60 gm as per IS 4947

15. Carbon di-oxide Shall be moisture free and 99% pure and
shall conform to the requirement of IS 15222
16. Performance requirement of gas cartridge Shall be subjected to internal pressure of 250
Kgf/cm2 for minimum period of 1 minute.
17. Throw Distance Not less than 6 Meter for minimum period of
60 seconds provided that at least 95% of
water is discharged within maximum 120
seconds
18. Colour Fire Red or Post Office Red, conforming to
Shades No. 536 or 538 of IS 5
19. Testing Shall be tested at Hydraulic test pressure of
3.0MN/cm2 (30kgf/cm2) for a period of 2
minutes
20. Marking As per IS:940 (latest amendment)

Page 78 Maharashtra State Board of Technical Education 16 March 2024

Summary:-

 Meaning of Fire Hazard?

 Classification of Fires.

 Types of Fire Extinguishers.

 How to use Fire Extinguisher?

 Fire Emergency Action Plan

 Specification of Water Type Extinguisher.

Page 79 Maharashtra State Board of Technical Education 16 March 2024

 Water Type (Gas Cartridge) Portable Fire Extinguisher(9 Litre capacity)

Page 80 Maharashtra State Board of Technical Education 16 March 2024