INDUSTRIAL SAFETY

Introduction:
Work place of today in Engineering manufacturing and construction presents situations which
are complexed by dangerous operations and use of hazardous materials. It becomes imperative
on the part of engineers and managers to adopt methods and use devices that will reduce the risks
to the physical body and health of the workers.

Safety benefits:

• There are some direct costs/ effects of an accident i.e. medical expenses, compensation to the
injured or their families.
• There are certain indirect costs involved in it also e.g. machine down time, damage to machine,
ideal time of nearby equipment and horror created among workers, loss of time etc.
• Legal implications i.e. As per The Building & other construction Act 1996, Factories Act 1948
and several other related Acts & rules the general duty of the employer is to ensure Health &
Safety of his employee & protect the Environment.

Accident:

Undesirable Event that arises to injury, fatality, ill health, property damage or combination of these.

Causes of Accident:

Unsafe Act & unsafe Condition are basic cause of any Accident. When both conjugate at one
point then accident happened. In other words, Human and mechanical failure are causes of
accident.

➢ Unsafe Act:( Committing mistake by person or Any act that may lead to accident is
known as unsafe act)
▪ Working without wearing safety helmet & safety Shoes
▪ Working at height without wearing full body harness.
▪ Taking Rest in working Areas
▪ working or Taking rest below Hanging Load
▪ Over speeding
▪ Operating equipment without qualification or authorization.
▪ Operating equipment at unsafe speeds
▪ Failure to warn
▪ Bypass or removal of safety devices
▪ Using defective equipment
 ➢ Unsafe condition: Any sources or situation or condition that have potential to create
accident is known as unsafe condition.

➢ Following are example of unsafe Condition:

➢ Damage welding Cable
➢ Mechanical guard not Provided on rotating parts
➢ Defective sling or lifting equipment.
➢ Defective work platform
➢ Floor or platform Opening, Pits
➢ Poor housekeeping
➢ Defective tools, equipment or supplies
➢ Inadequate supports or guards
➢ Congestion in the workplace
➢ Inadequate warning systems
➢ Hazardous atmospheric conditions etc.

Note:

88% Accident occurred due to unsafe act, 10% due to Unsafe Condition & 2% due to natural
calamity.

Accident prevention strategies:

Accident can be prevented to

I) Eliminate hazard or II) Prevent unsafe practices

Hazard control:

❖ Eliminate the hazard

❖ Isolate to hazard
❖ Engineering control
❖ Administrative control
❖ Personnel Protective Equipment
❖ Hazard can be controlled at work place as per hazard control method.

Housekeeping:

Good housekeeping always increases productivity. It prevents injury such as fall, Trip, Slip, fire
etc. Poor Housekeeping is source of Accident. Good housekeeping means materials have stacked
properly & kept separately. All walkways are free from any obstruction.
Benefits of Good Housekeeping:

o Eliminates accident and fire hazards

o Maintains safe, healthy work conditions
o Saves time, money, materials, space, and effort
o Improves productivity and quality.
o Employees Boosts Employees morale.
o Reflects a well-run organization.

Hazard in a Industries:

Different Types of hazard found in an industry as per their Nature.

Following are

Types of Hazard:

▪ Fall of person due to poor workmanship, loss of balance, uneven surface, floor opening,

poor work platform, working at height without using full body harness, Defective ladder

or stair, slippery floor, Loose material in assess etc.

▪ Fall of material due to failure of lifting appliances, Tools & tackles, Loose material

Keeping at edge on height or near floor opening, Poor method of Material lifting &

shifting etc.

▪ Mechanical hazard (entanglement, contact with sharp edge, Ejection like spark and small

particle emitting during grinding job.)

▪ Electrical hazard Like Fire, Electrocution, Burn injury, Fall due to electrical shock.

▪ Fire Hazard due to hot job near flammable material, Inadequate storage of Flammable

material metal storage tank, Smoking,

▪ Physical Hazard like heat, Poor illumination, Cold stress,

▪ Environmental hazard like dust, fumes, Gases, NOx, Sox, Noise

▪ Ergonomically hazard includes repetitive movement, manual handling, workplace/job/task

design, uncomfortable workstation and poor body positioning

▪ Chemical hazard like dust, fumes, gases create central nervous system problem &

respiratory problem due to inhalation and create skin problem when come in its contact.

▪ Vehicle movement may cause of hit to person, hit to object or Collision or topples

Long term exposure of Noise creates Hearing loss & Known as Noise induced hearing

Loss (NIHL). Vibration create vibration induced white finger

Fire:
Fire is a chemical reaction in which combustible material combines with oxygen when external
source of heat is applied.

Causes of Fire:

❖ Hot Job near flammable material.

❖ Flammable material storage near heat source area or live power cable or direct sun light

❖ Loose Electrical Connection

❖ Over load- electrical equipment
❖ Smoking.
❖ Poor Bonding of flammable material
❖ Poor earthing with flammable material storage tank
❖ Static electricity
❖ Poor Housekeeping

COLOR CODES:

Here is a list of the colors used in industrial settings and what they represent:

➢ Red: Identifies fire protection equipment and hazardous areas.

➢ Orange: Identifies dangerous machine and equipment parts.

➢ Yellow: Identifies physical hazards and materials that are potentially hazardous to life

and property.

➢ Green: Identifies first aid equipment, materials, and areas that are nonhazardous to life

and property.
 ➢ Blue: Identifies safety information on bulletin boards and signs.

➢ Purple: Identifies radiation hazards.

➢ Black and white: Identifies trafficked areas.

Factory Act, 1948

Introduction:-

The Factories Act is a social legislation which has been enacted foroccupational safety, health
and welfare of workers at work places.

Applicability:

It applies to factories covered under the Factories Act,1948.

Background:

➢ In India the first Factories Act was passed in 1881. This Act was basically designed to
protect children and to provide few measures for health and safety of the workers. This
law was applicable to only those factories, which employed 100 or more workers.
➢ On the basis of the recommendations of the Factory LabourCommission, more
comprehensive Law was introduced in 1911,which got amended in 1923, 1926 and 1931
➢ With the amendments made by Royal Commission of Labor(1931), Comprehensive
Factory Act, 1934 was introduced.
➢ Following recommendations of the Rage Committee, the Govt. of India enacted
Factories Act, 1948 and came into force w.e.f from1st April 1949.

Objective:

➢ Enacted primarily to protect worker employed in factory against of occupational hazards.

➢ It tries to secure the workers employment conditions conductive to their health & safety.

INSPECTING STAFF:

The act empowers the state government to appoint a chief inspector and inspector for purpose of
administration of its provisions. Every district magistrate is an inspector for his district.
FACTORY ACT PROVISION:

INSPETORE:

➢ Appoint such persons as posses the prescribed qualification.

➢ Appoint as many addition and joint chief inspector.
➢ No person shall be appointed under sub section.
➢ Every district shall be an inspector.
➢ Appoint such public officers.
➢ More inspector than one the government.

HEALTH:

➢ Cleanliness
➢ Disposal of Wastes Effluents
➢ Ventilation & Temperature
➢ Dust & Fumes
➢ Lighting
➢ Drinking Water
➢ Latrine & Urinals

WELFARE:

➢ Washing facilities
➢ Facilities for storing and drying clothing
➢ Facilities for sitting
➢ First-aid appliances

➢ one first aid box not less than one for every150 workers
➢ Canteens when there are 250 or more workers.
➢ Shelters, rest rooms and lunch rooms when there are 150 or more workers.
➢ Creches when there are 30 or more women workers.

➢ Welfare office when there are 500 or more workers.

SAFETY:

➢ Fencing of machinery
 ➢ Work on near machinery in motion.
➢ Employment prohibition of young persons on dangerous machines.

➢ Striking gear and devices for cutting off power.

➢ Fencing of machinery
➢ Work on near machinery in motion.
➢ Employment prohibition of young persons on dangerous machines.
➢ Striking gear and devices for cutting off power.

HOURS OF WORK:

The main restrictive provisions of the Act about the working hours of Adults are:

➢ A worker cannot be employed for more than 48 hours in a week

➢ A holiday must be given in every week

➢ Section 53- Compensatory holidays in case of missing of weekly holiday

➢ A worker can not be employed for more than 9 hours a day

➢ A worker must be given an interval of rest of at least half an hour after 5
hours of work

➢ The total period of work, inclusive of rest interval, must not be spread over
more than 10 ½ hours a day

➢ If a worker works for more than 9 hours a day or more than 48 hours a
week, he shall be paid for overtime @ twice the regular wage

ANNUAL LEAVE WITH WAGES:

➢ A worker shall be allowed in every calendar year, annual leave with wages
@ 1 day for every 20 days of work performed by him during the previous
calendar year

➢ In case of child worker, annual leave with wages @ 1 day for every 15 days
of work performed
➢ Leave can be accumulated up to 30 days in case of an adult or 40days in case
of a child
➢ The leave admissible will be exclusive of all holidays, occurring during, or at
either end of the leave period
➢ Wages for leave allowed shall be paid before the leave begins
➢ In case of a worker who is discharged or dismissed from service, quits or
dies while in service, he or his heir or nominees must be paid wages in lieu of
annual leave
➢ .In such case, the annual leave is to be calculated at the same rate as above
but irrespective of whether the worker has worked for 240 days or not
 MAINTENANCE
Definition of Maintenance:
Maintenance is the routine and recurring process of keeping a particular machine or asset in its
normal operating conditions. So that it can deliver the expected performance or service without
any loss or damage.

Maintenance is defined as:

➢ All actions necessary for retaining an item, or restoring to it, a serviceable condition,
include servicing, repair, modification, overhaul, inspection and condition verification.
➢ Increase availability of a system.
➢ Keep system’s equipment in working order.

Purpose of Maintenance:

➢ Attempt to maximize performance of production equipment efficiently and regularly

➢ Prevent breakdown or failures
➢ Minimize production loss from failures
➢ Increase reliability of the operating systems

Principle Objectives in Maintenance:

➢ To achieve product quality and customer satisfaction through adjusted and serviced
equipment
➢ Maximize useful life of equipment
➢ Keep equipment safe and prevent safety hazards
➢ Minimize frequency and severity of interruptions
➢ Maximize production capacity – through high utilization of facility

Problems in Maintenance:

➢ Lack of management attention to maintenance

➢ Little participation by accounting in analyzing and reporting costs
➢ Difficulties in applying quantitative analysis
➢ Difficulties in obtaining time and cost estimates for maintenance works
➢ Difficulties in measuring performance

Problems Exist Due To:

➢ Failure to develop written objectives and policy

➢ Inadequate budgetary control
➢ Inadequate control procedures for work order, service requests etc.
 ➢ Infrequent use of standards
➢ To control maintenance work
➢ Absence of cost reports to aid maintenance planning and control system

Maintenance Costs:

➢ Cost to replace or repair

➢ Losses of output
➢ Delayed shipment
➢ Scrap and rework

Basic Principles of maintenance planning:

Maintenance Planning:

Effective planning and scheduling contribute significantly to the following:

➢ Reduced maintenance cost.

➢ Improved utilization of the maintenance workforce by reducing delays and interruptions.
➢ Improved quality of maintenance work by adopting the best methods and procedures and
assigning the most qualified workers for the job.

Planning Objectives:

➢ Minimizing the idle time of maintenance workers.

➢ Maximizing the efficient use of work time, material, and equipment.
➢ Maintaining the operating equipment at a responsive level to the need of production in
terms of delivery schedule and quality.

Classification of Maintenance Work According to Planning Purposes:

➢ Routine maintenance: are maintenance operations of a periodic nature. They are

planned and scheduled and in advance. They are covered by blanket orders.
➢ Emergency or breakdown maintenance: interrupt maintenance schedules in order to
be performed. They are planned and scheduled as they happened.
➢ Design modifications: are planned and scheduled and they depend on eliminating the
cause of repeated breakdowns.
➢ Scheduled overhaul and shutdowns of the plant: planned and scheduled in advanced.
➢ Overhaul, general repairs, and replacement: planned and scheduled in advanced.
➢ Preventive maintenance: planned and scheduled in advanced.
➢ An essential part of planning and scheduling is to forecast future work and to balance the
workload between these categories.
➢ The maintenance management system should aim to have over 90% of the maintenance
work planned and scheduled.
Planning Procedures:

➢ Determine the job content.

➢ Develop work plan. This entails the sequence of the activities in the job and establishing
the best methods and procedures to accomplish the job.
➢ Establish crew size for the job.
➢ Plan and order parts and material.
➢ Check if special tools and equipment are needed and obtain them.
➢ Assign workers with appropriate skills.
➢ Review safety procedures.
➢ Set priorities for all maintenance work.
➢ Assign cost accounts.
➢ Complete the work order.
➢ Review the backlog and develop plans for controlling it.
➢ Predict the maintenance load using effective forecasting technique

Basic Levels of Planning Process:

1. Long-rang planning: it covers a period of 3 to 5 years and sets plans for future
activities and long-range improvement.
2. Medium-range planning: it covers a period of 1 month to 1 year.
3. Short-rang planning: it covers a period of 1 day to 1 week. It focuses on the
determination of all the elements required to perform maintenance tasks in
advance.

Long Range Planning:

➢ Sound forecasting techniques to estimate the maintenance load.

➢ Reliable job standards times to estimate staffing requirements.
➢ Aggregate planning tools such as linear programming to determine resource require.

Medium-Range Planning:

➢ Specify how the maintenance workers will operate.

➢ Provide details of major overhauls, construction jobs, preventive maintenance plans, and
plant shutdowns.
➢ Balances the need for staffing over the period covered.
➢ Estimates required spare parts and material acquisition.

Short-Range:

It focuses on the determination of all the elements required to perform maintenance tasks in advance.
Type of Maintenance:

1. Preventive Maintenance
2. Predictive Maintenance
3. Corrective Maintenance
4. Breakdown Maintenance

1.Preventive Maintenance:

It is a method for preventing damage to equipment by periodically replacing parts based on time
of use and carrying out minor maintenance and inspections to find out the current state of the
equipment / machinery.
Example: Cleaning, checking, lubricating, bolt tightening Periodic Inspection Periodic and small
over haul restorations.

2.Predictive Maintenance:
Predictive maintenance is a method for doing maintenance by replacing parts based on
predictions using a tool. The point is if the preventive method is only based on the schedule, then
the predictive method is based on the results of the measurement.
This method can also use the five senses, for example in bearing inspection can be distinguished
from the sound produced. Or checking temperature, by touching it we can feel the difference or
abnormality of the equipment.

3.Corrective Maintenance:

It is a method intended to improve the reliability of equipment/machines by improvising. In

addition to equipment, it is also intended for parts that have a short life cycle (reduce the
frequency of damage) and speed up repair time.
Example: The operator has difficulty checking the oil volume of the generator engine, so
improvisation is done by making a measuring cup equipped with a scale.

4.Breakdown Maintenance:

It is a method where inspection and replacement of parts are not carried out, so with this method
we leave the equipment damaged and then we fix it or replace it.
Usually this method is applied to equipment / machines with consideration:

Equipment is only optional (additional) so that if it is damaged it does not interfere with
production
The cost of repairing / replacing cheap parts
 Insignificant damage
Easy and fast repair

Maintenance economics:
Life-cycle cost analysis (LCCA) is a tool to determine the most cost-effective option among
different competing alternatives to purchase, own, operate, maintain and, finally, dispose of an
object or process, when each is equally appropriate to be implemented on technical grounds. For
example, for a highway pavement, in addition to the initial construction cost, LCCA takes into
account all the user costs, (e.g., reduced capacity at work zones), and agency costs related to
future activities, including future periodic maintenance and rehabilitation. All the costs are
usually discounted and total to a present-day value known as net present value (NPV). This
example can be generalized on any type of material, product, or system.
In order to perform a LCCA scoping is critical - what aspects are to be included and what not? If
the scope becomes too large the tool may become impractical to use and of limited ability to
help in decision-making and consideration of alternatives; if the scope is too small then the
results may be skewed by the choice of factors considered such that the output becomes
unreliable or partisan. Usually the LCCA term implies that energy and environmental costs are
included, whereas the similar Whole Life Costing generally has a reduced scope.
Estimation of economic life of equipment
Consider an investment in a machine with an initial purchase price of $1000. The yearly
operating costs and salvage value of the machine depend on its age as shown in the table below.
We anticipate requiring the use of the machine far into the future. Given that the salvage value is
decreasing and operating costs are increasing, there must be some optimal time to replace it. The
optimal replacement time is called the economic life of the machine.
Investment analysis recognizes that money spent or earned in the future has less value when
viewed from the present. This is called the time value of money principle. We compute the
present value of an amount cn received n years from now as
P = cn/(1 + i)n The quantity i is a percentage expressed as a decimal, and is variously called the
interest rate, discount rate, or minimum acceptable rate of return. The term 1/(1 + i)n, is the
discount factor. When i is a positive quantity the discount factor is less than 1.
"Maintenance costs"
One universal measurement of maintenance performance, and perhaps the measure that matters
most in the end, is the cost of maintenance. Unfortunately, maintenance costs are often used to
compare maintenance performance between companies or between plants within the same
company.
Equally unfortunately, there is no standard for measuring maintenance costs. Each company,
usually each plant within a company and often each department within a plant develop their own
definition of "maintenance costs."
For this reason, maintenance cost comparisons should always be accompanied by a clear
definition of what is included and excluded for each plant included in the comparison.
Fault tree analysis (FTA):

Fault tree analysis (FTA) is a type of failure analysis in which an undesired state of a system is
examined. This analysis method is mainly used in safety engineering and reliability
engineering to understand how systems can fail, to identify the best ways to reduce risk and to
determine (or get a feeling for) event rates of a safety accident or a particular system level
(functional) failure. FTA is used in the aerospace,[1] nuclear power, chemical and
process,[2][3][4] pharmaceutical,[5] petrochemical and other high-hazard industries; but is also used
in fields as diverse as risk factor identification relating to social service system failure.[6] FTA is
also used in software engineering for debugging purposes and is closely related to cause-
elimination technique used to detect bugs.
In aerospace, the more general term "system failure condition" is used for the "undesired state" /
top event of the fault tree. These conditions are classified by the severity of their effects. The
most severe conditions require the most extensive fault tree analysis. These system failure
conditions and their classification are often previously determined in the functional hazard
analysis.

Fault tree analysis can be used to:

• Understand the logic leading to the top event / undesired state.

• Show compliance with the (input) system safety / reliability requirements.
• Prioritize the contributors leading to the top event- creating the critical
equipment/parts/events lists for different importance measures
• Monitor and control the safety performance of the complex system (e.g., is a particular
aircraft safe to fly when fuel valve x malfunctions? For how long is it allowed to fly with the
valve malfunction?).
• Minimize and optimize resources.
• Assist in designing a system. The fta can be used as a design tool that helps to create (output
/ lower level) requirements.
• Function as a diagnostic tool to identify and correct causes of the top event. It can help with
the creation of diagnostic manuals / processes.

Graphic symbols:
The basic symbols used in FTA are grouped as events, gates, and transfer symbols. Minor
variations may be used in FTA software.
Event symbols:
Event symbols are used for primary events and intermediate events. Primary events are not
further developed on the fault tree. Intermediate events are found at the output of a gate. The
event symbols are shown below:

1. Basic event: failure or error in a system component or element (example: switch stuck in open
position)

2. External event - normally expected to occur (not of itself a fault)

3. Undeveloped event - an event about which insufficient information is available, or which is

of no consequence.

4. Conditioning event - conditions that restrict or affect logic gates (example: mode of operation
in effect.

5. Intermediate event- An intermediate event gate can be used immediately above a primary
event to provide more room to type the event description.

Gate symbols:

• OR gate - the output occurs if any input occurs.

• AND gate - the output occurs only if all inputs occur (inputs are independent from the
source).
• Exclusive OR gate - the output occurs if exactly one input occurs.
• Priority AND gate - the output occurs if the inputs occur in a specific sequence specified by
a conditioning event.
• Inhibit gate - the output occurs if the input occurs under an enabling condition specified by
a conditioning event.
 CUTTING TOOL ANALYSIS:

FAILUREOF CUTTING TOOL:

(OR) GATE

• Improper coolant supply

• Improper cutting speed, feed, depth of cut
• Wrong tool selection
• Job material faulty
• Drill holder fail

Improper coolant supply:

(OR) GATE

• Dislocation of pipe
• Leakage
• Coolant pump failure

Coolant pump failure:

(OR) GATE

• No power
• No coolant in tank
• Pump &motor subassembly failure
• Leakage of coolant from tank
Fault tree analysis of water pump:

Internal combustion engine:

Causes Of The Engine Breakdown:

Technical Causes:
Fuel filter was damaged
Air cleaner was absent
Originally it was a diesel engine but was running
in petrol in past.
Change in Compression ratio
No Cooling arrangement
Cylinder Head partially damaged
Valves were not in proper position
Spark Plug used in place of fuel injector
Carburetor used in place of fuel pump
Human factors:
Diesel Engine modified to run with Petrol
Some additional holes were made
Some holes which were necessary for cooling
were made closed
No Cleaning and Servicing done for long time.