7.

1 SAFETY PRECAUTIONS – AIRCRAFT AND WORKSHOP

PURPOSE
-Safety precautions involved in handling and servicing of aircraft on the ground.
-Consult the appropriate manufacturer’s manual.

GENERAL SAFETY PRECAUTION

PERSONAL SAFETY
-Being safety conscious at all times.
-Involves movement (where you are, what you are doing, what others around you are doing).
-Should be aware (limitations, what can go wrong, what actions to take if gone wrong)

PERSONAL SAFETY EQUIPMENT

-Ear protectors – Prolonged exposure to excessive noise can result in permanent damage to
hearing. Interferes ability to work.
-Eye protectors – Goggles, eye shields, face shields. Should be used when working in areas
where high intensity lights like LASER or ARCING, and prevents entry of particles, solids or fluids.
-Masks or breathing equipment – Protect against inhalation of dust, particles, spray or fumes.
-Hardhat – Prevent of minimize injury to head.
-Gloves – Should be worn when carrying hot/cold objects or materials that can react with skin
or absorbed.
-Safety shoes – Reinforced shoe caps to prevent injury to feet. The sole of the shoes prevent
slipperiness by increasing traction and resistance to deterioration from oil/hydraulic fluid.
-Safety harnesses – Attach safety harnesses when walking at high sections.

MANUAL HANDLING
-Lifting or moving objects manually is a major cause for injury.
-Life with the legs, not with the back. Don’t lift too heavy, get help. Before lifting, check if your
path is clear.
Procedure:
-Stand close to the object, feet slightly apart.
-Bend the knees, keep the back straight but not necessarily vertical.
-Position your elbows close to your body, so that the body takes the weight.
-Grip using the palm and the roots of the fingers, not the finger tips.
-Straighten the knees, allow the thigh muscles to the work.

SAFETY WITH MACHINES

1
-Do not misuse, use in a way which they are intended to use.
-Use familiar tools.
-Do not sacrifice safety for convenience. Safety covers and guards might be in the way of
operation but do not remove them.
-Guards are there to prevent you from accidently coming into contact with dangerous moving
parts.
-Cutting and drilling tools are properly sharpened, a dull can require excessive forces, the work
may be grabbed or thrown out of the machine.
-Make sure that the metal is securely clamped to the drill press table/block.
-Use eye protection always when drilling, grinding or sawing.

-Ensure that you know how to stop the machine before set it in motion.
-Maintain your concentration while the machine is in motion.
-Never leave your machine unattended while in motion, do not deactivate dead man handles or
pedals to prevent un-attendant operation.
-Try not to distract other machine operators.
-Never clean a machine while in operation.
-Never use compressed air to clean a machine, it may blow debris into your eyes.
-Never clean away swart with your bare hand, use a suitable rake.
-Keep your hair short or under a cap.
-Avoid loose clothing, do not wear rings or wristwatches.

GENERAL SAFETY PACTICES

-Should only operate with which they are familiar and can operate safely.
-Hand tools should be kept in proper working order.
-Should know the location of the first aid box and emergency equipment.
-Pedestrian lanes and fire lanes should be marked.
-Power cords and air hoses should be straightened, coiled and properly stored.
-Oil, grease and other substances spilled on hangar should be immediately cleaned or covered
and must be prevented to be emptied from floor drains.
-Drip pans should be placed beneath engines and engine parts wherever dripping exists.
-Gasoline spills on the hangar floor must be flushed away with water.
-Always use designated ladders, work stands and maintenance steps and prevent using unstable
piles of boxes or inadequate scaffolding.
-Always work, never run and never hurry.

SAFETY WITH ELECTRICITY

2
-Unique procedures should be followed, and precautions taken before, observed during, and
ensured after, using such a system.

PHYSIOLOGICAL SAFETY
-Primary harm to any living organism from electricity is due to electrocution. Might be fatal
depending on the voltage and duration of exposure.
-Electrical equipment especially faulty equipment can generate a lot of heat energy that can
cause burning if touched.
-An electrical spark or discharge can be a source of ignition increasing fire hazard.
-A small current at high voltage is all what it takes to cause fatalities, if the applied voltage is
high enough, an electrical current can flow through the human body.
-Domestic current 110/230V, affects our nerves in such a way we are unable to turn loose.
-If higher than 3000V, air can ionize and become a conductor.
-Resistance to the flow of electricity through the human body is inversely proportional to the
frequency of the current. The greater the frequency, the dangerous it gets. Aircraft has around
400Hz electrical supply.

WORKSHOP ELECTRICAL SUPPLY

SINGLE PHASE SUPPLY
3 WIRES
1 wire carries power (Live wire)
1 wire is connected to earth ground (Neutral wire)
1 wire connects the housing of the equipment to the earth ground (Earth wire)

SINGLE PHASE WIRE IDENTIFICIATION

Live wire – connected to right-hand connector of the “plug base”
Neutral wire - connected to left-hand connector of the “plug base”
Earth wire - connected to larger sized top center connector of the “plug base”

220V/240V 110V/120V

LIVE RED BROWN BLACK

NEUTRAL BLACK BLUE WHITE
EARTH GREEN GREEN/YELLOW GREEN

THREE PHASE SUPPLY

3
-To operate machinery that requires more power that could be afforded by a single-phase one.
-Is different in design and accept only compatible connectors, but safety concerns are the same.
-Except for a failure in one phase will result in isolation of power for all phases provided that
proper protective equipment (such as circuit breakers) are installed.

ELECTRICAL SAFETY THROUGH DESIGN

-If a 3 conductor cord is present, the return current passes through the earth wire instead of the
human body.
-Circuit breakers are installed to limit the current that is allowed to flow in an electrical circuit.
-The circuit breaker will trip and open the circuit if the current flow is higher than which it is
designed for.

AIRCRAFT ELECTRICAL SYSYEMS

-It is either 115 Volts 400Hz single or 3-phase AC or 28 Volts DC.
-AC supply to equipment will consist of an individual wire for each phase, and an additional wire
to the ground (airframe structure)
-Care should be taken to prevent completing a conductive path between a phase wire and
airframe.

ELECTRICAL SAFETY PRACTICES

Before connecting any electrical equipment, make sure that:
-The user is well versed in the use and hazards involved.
-Wire cords are not frayed or not exposed, and be sure to replace any plugs.
-The operating voltage of the equipment is the same as that of the outlet.
-Power rating of base > Power requirement of the equipment.
-The equipment activation switch is in a deactivated position.
-The electrical outlet in OFF position.
-Electrical equipment connected with 3 wire extension, cords with adequate capacity.

-Do not use electrical equipment in areas where fire hazard risk exists unless authorized.
-At any moment if equipment shows signs of overheating, emits smokes, disconnect.
-During operation, if equipment protection devices such as over current, over temperature,
circuit breakers trip, do not reset.
-Before disconnecting, make sure the equipment is switched off.

4
REPAIR OF ELECTRICAL EQUIPMENT
-To know and obey electrical standard practices.
-To have a good knowledge on the processes involved.
-Before working on any equipment it is necessary to disconnect or isolate the
electrical supply.
-Necessary to perform a tuning operation with covers open and the unit supplied
with power, make sure to follow the procedures stated in the repair manual.

FLIGHT LINE SAFETY

-De-activate electrical system according to AMM.
-If the circuit breakers had tripped or the fuse blown, failure has to be determined before reset.
-Take all precautions and follow the reactivation procedures described in the AMM.

TYPICAL DEACTIVATION PROCEDURE

When deactivating electrical systems the procedure given in the AMM should be followed.

1)DEACTIVATION BY CIRCUIT BREAKER

-If the electrical system is deactivated using a circuit breaker make certain the circuit breaker
will remain open during maintenance work as follows.
Install safety clamp under the open circuit breakers
Tag tripped circuit breakers (Do no close until maintenance is completed)

2)DEACTIVATION BY SWITCH
-Some critical system switches are guarded to prevent inadvertent selection, so the guard must
be removed before placing the switch in a deactivated position.
-A tag should be installed on the switch itself.

3)DEACTIVATION BY FUSE
-Any removed fuses are not reinstalled before maintenance is completed.

NOTE: Some electrical systems may be provided with alternate power sources in case of main
supply failure. These may become active when certain circuit breakers are tripped or switches
selected to open. Therefore ensure those systems are inhibited.

5
TYPICAL REACTIVATION PROCEDURE
-Before reactivation after maintenance make sure that all the controls are in such a position that
inadvertent operation of any component is not possible, always inform other personnel working
on or around aircraft before reactivating the electrical system.
-Follow the reactivation procedure described in the AMM.
-Install appropriate fuses and limiter fuses.
-Energize appropriate electrical system, ensuring external power parameters such as voltage,
frequency are within proper limits.
-Remove any circuit breakers safety clamps.

IN AN EMERGENCY – ELECTRICITY
FIRE – If fire occurs due to an electrical failure or in the vicinity of electrical circuitry always cut
off the power supply, if combustible liquid or gases are present isolate these in the process. If
power cannot be shut-off or unsure, use a CO2 or Halon fire extinguisher. Evacuate the area and
warn others.
PERSONAL – If a person is electrocuted, avoid physical contact with the victim until the electrical
supply is cut off. If the power supply cannot be switched off then try to move the victim clear
using a length of dry cloth, jacket without touching them, and call for medical help.

HAZARDOUS MATERIALS
-Categorized into:
1)Chemical agents
2)Physical hazards
3)Biological hazards

6
1)CHEMICAL AGENTS
Chemicals are categorized into four classes based on their properties

A)Flammable
B)Corrosive
C)Toxic
4)Reactive

-Flammable and reactive chemicals become hazardous primarily after some

outside event, condition, or substance interacts with them.
-Corrosive and toxins on the other hand, act directly on the human body when
exposed. Toxic agents cause poisoning.

A)FLAMMABLE
-Flammable materials that may easily ignite in the presence of a catalyst such as heat, sparks or
flame. They maybe in 3 forms: solid, liquid or gas. Combustible liquids are similar to flammable
liquids but they are not as easy to ignite. Eg: Fuels, Paint-related products, alcohols, some metal
fillings.

-Generally recommended personal safety equipment are:

Fire-retarding clothing and fire extinguisher.

-Handling and storage:

Limit access to open flames, sparks, hot surface.
Containers should be grounded, static electricity may produce sparks.
Limit quantities to a minimum
Store the materials in approved containers
Store flammable toxins and corrosive toxic materials separately.

-Typical emergency procedures:

Turn off electrical equipment or any other potential source of sparks.
Attempt to close shutoff valves.
Remove containers from the area, do not remove with compressed air
For large spills, leave the area and notify.
In case of direct contact with body or eyes, rinse with water.
If toxic substance inhaled, go to a fresh environment
If contact made through clothing, remove clothing and store in a container

7
B)CORROSIVES
-Corrosive materials are materials that can react with metallic surfaces and/or cause bumming
of the skin.
-Frequently found corrosives in aviation industry is acids and bases. Strong acids are normally
found in liquid form, bases tends to come in powdered form.

-Generally recommended personal safety equipment are:

Gloves, aprons, respirator, face shields or goggles and sometimes protective footwear.

-Handling and storage:

Containers must be corrosive resistant.
Goggles and skin protection must be always worn.
Never add water to acid (add acid to water to dilute acid)
Acids and bases should be stored separately
Eye washes and showers should be easily accessible
Flammable toxins and corrosive toxic materials should be stored separately

-Typical emergency procedures:

Remove any corrosives that have come in contact with your eyes or skin with fresh water with
15 mins.
Remove any contaminated clothing.
Go to an area of fresh environment if inhaled.
Ventilate the area.
Check safety equipment before attempting to stop the flow of spillage by creating a darn.
If swallowed do no induce vomiting, drink large amounts of water. Seek medical attention
immediately.

8
C)TOXINS
-Defined as any substance that can cause an illness or injury.
-The effects maybe acute (appear all at once) or chronic (build up over time).
-Some dissipate over time, while other remains in human system even after death.

-Frequently found toxins in aviation industry may be grouped into 8 categories

Solvents and thinners, paints, ketones, adhesives.
Solids such as metal dust or asbestos.
Machine lubricants, cutting fluids, and oils.
Gases such as carbon dioxide and nitrogen.
Polymers, epoxies and plastics. Not normally toxic, but during fabrication it is.
Sensitizers, such as epoxy systems. Although not toxic in their final form, maybe destroy
portions of the body’s immune system.
Carcinogens, can cause changes in the genetic makeup of a human cell, resulting in cancer.
Reproductive hazards, such as carcinogens. rare in aviation. May interfere with reproductive
process, or affect developing process of fetus.

-Generally recommended personal safety equipment are:

Be sure to use the environmental control systems that maybe already in place, such as
ventilation fans and filters.
Gloves, aprons, respirator, face shields or goggles and sometimes protective footwear.

-Handling and storage:

Minimize the release of toxic agents into the environment by capping all the containers, and
storing them in ventilated places. Containers surface areas should be kept to a minimum to
reduce the rate of evaporation into the surrounding.
Flammable toxins and corrosive toxic materials should be stored separately.

-Typical emergency procedures:

If there is any doubt regarding the degree of toxicity of the substance spilled, leave the area and
notify the authorities.
If it is less than 1 gal, it may be cleaned up by wiping with an absorbent material.

9
D)REACTIVE AGENTS
-Reactive materials are those materials that react violently with other materials (no necessarily
solids). May vary from violent explosions to emission of heat.

-Frequently found reactive agents in aviation industry:

Oxidizers, which add oxygen to situation where high levels of heat and burning are present
(Peroxides, Perchloric acid and chromic acid, Halogens)
Water reactive materials, such as lithium, react with water to form hydrogen gases, which are
very explosive.

-Examples of incompatible reactive materials include:

Cyanides (frequently used in plating) and acids
Chloric bleach and ammonia (high toxic chlorine gas)

-Generally recommended personal safety equipment are:

Be sure to use the environmental control systems that maybe already in place, such as
ventilation fans and filters.
Gloves, aprons, respirator, face shields or goggles and sometimes protective footwear.

-Handling and storage:

Store reactive materials in a location separate from other materials. Always review material
safety data sheet (MSDS)
Many reactive agents are both toxic and corrosive

-Typical emergency procedures:

If there is any doubt regarding the degree of reactivity and toxicity of the substance, leave the
area and notify the authorities.

10
SAFETY PRACTICES
-Identify the correct oil/chemical to be used, incorrect or improper may result damage as
certain chemicals when mixed together form highly combustible mixtures.
-Follow manufacturer’s instructions.
-Check for conditions for use as some chemicals may be forbidden to use.
-Use protective equipment.
-After use make sure by-products and leftover materials are disposed according to guidelines set
by manufacturer.
-Most of the oils and chemicals used in aviation are considered to be combustible in the
presence of Oxygen.
-Always keep working area free from spills and clean up as soon as possible if occurs.
-If combustible materials are to be used avoid taking large quantities.

IN AN EMERGERNCY – OIL AND CHEMICALS

-In case of fire with oil or chemicals, the type of chemical will be a factor of hose intense or how
fast the first may spread.
-Most chemicals are likely to give off toxic fumes at elevated temperatures, therefore it is most
advisable to vacate and isolate the area and let emergency services handle situation.
-If material that can react violently are present, vacate the area immediately and move to a safe
location.
-Designated person should perform roll call, to ensure all personnel have evacuated the area
and no one is missing.
-If possible, cut off supply of all other types of fluid and de-energize the electrical system in the
area of emergency.

11
2)PHYSICAL HAZARDS
-Usually caused by the use of some type of equipment not directly controllable by the
technician.
-2 categories:
Hazards that can be detected by the human senses
Hazards that are not detected by the human senses including magnetic waves.

-According to labor rules, it is required that areas where such exposure exists be clearly marked
and that individuals exposed to these hazards are provided with the proper safety equipment.

SAFETY WITH GASES

A)COMPRESSED AIR
B)OXYGEN
C)NITROGEN
D)OTHER GASES

A)COMPRESSED AIR
-Used as a power source for maintenance equipment and tools. Also used for painting as a
pressure source for carrying out leak checks, for purging also.

-Safety measures incudes:

Handle cylinders of compressed gases as you would of high energy sources.
Always use safety eye-shields when handling compressed gases.
If a concentrated steam of compressed air is blown across a cut in the skin, it is possible for air
to enter the bloodstream and cause severe injury. For this reason, air dusting guns are usually
equipped with a restrictor that reduces the pressure discharge rate 30psi or less.
When using compressed air do not blow chips into the face.
Do not use compressed air to clean hands; it can force debris into your skin.
Never use a cylinder that cannot be positively identified.
When storing or moving a cylinder, have the cap securely in place to protect the valve.
When large cylinders are moved, strap them to properly designed wheeled cart to ensure
stability.
Use the appropriate regulator on each gas cylinder.
Release compressed air slowly, rapid release might cause the hose to whip dangerously and may
also build static charges.
Inspect air hoses regularly for breaks and worn spots.
Inline oilers, if installed, should be maintained in operating conditions.
The system should have water sumps/traps installed and these should be drained regularly.
Air hoses should be straightened, coiled, and properly stowed when not in use
12
B)OXYGEN
-Oxygen is available in the compressed form as Industrial Oxygen and Breathing Oxygen.
Industrial Oxygen is used for oxy-acetylene welding. Breathing Oxygen is used for
crew/passenger emergency oxygen system.
-Oxygen is a colorless, tasteless and odorless gas. Gaseous Oxygen is chemically stable and is not
flammable, but combustible materials ignite in oxygen rich areas. Oxygen combines with oil,
petroleum products, greases or bituminous to form an explosive mixture.
-Liquid Oxygen will cause severe “burns’ frostbite if it comes in contact with skin because of its
low temperature.
-Oxygen is often found in aviation shops stored in steel cylinders under a pressure of around
2000 psi.
-Oxygen marked “Aviators Breathing Oxygen” maybe used in aircraft breathing oxygen system,
lower water content.
-Two persons are required. One stationed at the control valves of the servicing equipment and
one man stationed where he can observe the pressure in the aircraft system.
-Oxygen servicing of aircraft should be accomplished outside the hangar.

C)NITROGEN
-Used to inflate aircraft wheel assemblies, pre-charge accumulators, as a pressure source for
testing a certain equipment and as a propellant.
-Nitrogen is colorless, tasteless, odorless gas that is used to pre-charge accumulators,
pneumatic reservoirs and tires and in some cases potable water systems.
-Nitrogen is supplied in compressed gaseous form in steel cylinder pressurized up to 2500 psi.

-Nitrogen is used in place of compressed air mainly due to:

Nitrogen is much cleaner than compressed air as it does not contain moisture or lubricants such
as oil.
Nitrogen is benign to most materials and reduces the fire hazard at high temperatures, which
gives way to be used in wheels.

-Nitrogen tends to displace oxygen in enclosed areas resulting in asphyxiation.

-It also causes frostbites when it comes into contact with skin.

13
D)OTHER GASES
-Gases such as Argon, Acetylene, CO2, etc. have limited application in the aviation industry.
Argon and Acetylene is used in welding, CO2 as a fire extinguisher and as a propellant.
-CO2 is used for inflating passenger life jackets and Slides/Rafts.
-Argon is used as the blanket medium in Tungsten Inert Gas (TIG) welding, Argon is used
because it is an inert gas and does not react even at high temperatures.
-Nitrogen and Argon is not toxic to humans, but may replace Oxygen if released in large
quantities.
-Acetylene gas is a flammable, colorless gas that has a distinctive, disagreeable odor, readily
detectable. Acetylene is used as the fuel that is combined with oxygen in oxyacetylene welding.
Acetylene is stable at low pressure and normal temperature but dangerously unstable when
compressed to a pressure greater than 15psi.
-Acetylene is therefore supplied in cylinders containing asbestos and charcoal that is saturated
with acetone. Since acetone is capable of absorbing 25 times its own value of acetylene gas, this
mixture can be pressurized up to 250psi.
-When working with acetylene gas, proper ventilation must be provided.

14
3)BIOLOGICAL HAZARDS
-Living organisms that may cause illness or disease. Some biological hazards also
have toxic by-products.
-Transmits through air droplets or spores and enter the body through contact.
-In Aviation, Cargo compartment is the main concern for biological hazards.

HAZARD COMMUNICATION
-Full compliance can be achieved by establishing a hazard communication program.
-There are five basic requirements of a hazard-communication program:
1-Invetory – An inventory list for all hazardous materials used.
2-Labeling – All hazardous chemicals shall be properly labeled.
3-Material Safety Data Sheet (MSDS) – MSDS must be obtained for all material stored or used.
4-Training – All employees must be provided training, detecting, handling, labeling.
5-Written Program – Each employer must establish a written program that will comply with the
four points mentioned above.

MATERIAL SAFETY DATA SHEETS

-It is a document provided by the material manufacturer or processor that contains information
related to its hazardousness, handling and disposal procedures.
-Normally, MSDSs are provided with each shipment of a hazardous material.

MATERIAL SAFETY SHEET DATA

-Divided into 9 sections
Section I – Product Identification (Manu name, address, contact no. emergency contact no.,
chemical name, trade name, chemical family, formula)
Section II – Hazardous Ingredients
Section III – Physical Data – BP, Specific gravity, vapor density.
Section IV – Fire and Explosive Data – Based upon the flash point
Section V – Reactivity Data – Ability of the material to react and release energy
Section VI – Health Hazard Information
Section VII – Spill leak and Disposal Procedures
Section VIII – Special Protection
Section IX – Special Precautions

LABELING
-Should have identifying labels and should never be removed.
-First, container should be clearly labeled. Second, once contained is used, it should never be
used for another hazardous material.

15
SAFETY WITH FIRE
NATURE AND CLASSIFICATION OF FIRE
-Fire essentials are:
Fuel – A combustible solid, liquid or gas in the presence of heat combine with oxygen, releasing
more heat.
Oxygen – Element that combines through the process of oxidation.
Heat – A form of energy to raise the temperature of fuel to its ignition, considered as the
catalyst that accelerates the combining of oxygen with fuel

CLASSES OF FIRE
CLASS A (green, triangle) – Solids -
CLASS B (red, square) – Liquids
CLASS C (blue, circle) – Energized or live electrical equipment
CLASS D (yellow, star)– Metals

SPONTANIOUS IGNITION
-Can be caused by lubricants and solvents, such as rags soaked with oil or solvents. These rags
should be disposed of in airtight cans.

PRINCIPLE IN EXTINGUISHING FIRES

-Suppression of fire includes:
1)Cooling the fuel below its kindling point
2)Excluding the oxygen supply
3)Separating the fuel from the oxygen

FIRE EXTINGUISHING AGENTS

CLASS A agents – Water, cool the fuel.
Most effective in Class A, Never use in D & C. Class B and C agents are effective but not equal.

CLASS B agents – CO2, halogenated hydrocarbons (halons), dry chemicals. Displace oxygen.
Foam is effective when used in large amounts. Water is ineffective and spreads more even.

CLASS C agents – Best responds to CO2, must be equipped with non-metallic horn because the
discharge or CO2 through metallic horn can generate static electricity, and might transmit the
current. Halogenated hydrocarbons are very effective too. Dry chemicals are effective but have
the disadvantage of contaminating the local area with powder.

CLASS D agents -.Dry powder, prevents oxidation and the resulting flame.

16
Water CO2 Halons Dry powder
A only B and C B and C B,C and D

INSTRUCTION INCASE OF A FIRE

-In case of an emergency, always sound the alarm first. Give name, location, type, no. of people
involved.
-Vacate the area.
-Isolate electrical and compressed air gas supplies.
-Identify the type of fire and extent before extinguishing.
-Put on protection clothing available.
-Stay low if not wearing any protection.
-Select the appropriate type of fire extinguisher.
-Use the back of the hand against the door to sense the temperature of the door.
-Fire in an enclosed area can be in a state of hibernation, because of the lack of oxygen so the
fire might intensify if the door is opened suddenly, so it is advised to open slowly.
-When using the extinguisher aim at the base of the flames, bottom first, then progress upward
and forward. The discharge nozzle should be moved rapidly with a side-to-side sweeping
motion.
-In case fire on person, never use fire extinguisher on a person, smother the flame with a
blanket.

17
3

141412312312312312zasdasfs af

18