Indira Gandhi

National Open University

MIS-024
School of Engineering & Technology Mechanical and Electrical
Safety Management

Mechanical and Electrical Safety Management

 MIS – 024
Mechanical and Electrical
Indira Gandhi
National Open University
Safety Management
School of Engineering & Technology

Unit Name Page No

BLOCK 1 SAFETY IN MACHINERY 5

UNIT 1 Job Safety Analysis and Machinery Gaurds 9
UNIT 2 Safety in Material Handling 36
UNIT 3 Safety in Design and Safe Working Practices 73
UNIT 4 Case Study and Excercise 108
BLOCK 2 SAFETY IN ELECTRICAL WORKS 123

UNIT 5 Electrical Safety, Fire and its Prevention 127

UNIT 6 Safety of Electrical Equipments 150
UNIT 7 Indian Electricity Rules 183
UNIT 8 First Aid 202
GUIDANCE
Prof. Nageshwar Rao Prof. Satyakam Dr. Ashish Agarwal
Vice-Chancellor, IGNOU PVC, IGNOU Director, SOET, IGNOU
COURSE CURRICULUM DESIGN AND DEVELOPMENT COMMITTEE
Dr. S. Sarkar, Mr. Sudipta Chakarvarty,
GM (Retd.), GAIL, Noida Project Officer, TCS
Prof. Sagar Maji, Prof. Subhasis Maji
Director, GBP Engg. college, Director, School of Engg. & Tech.
New Delhi IGNOU, New Delhi
Mr. G. P. Kumawat, Prof. P Srinivas Kumar
GM, IPGCL, New Delhi Professor in Civil Engineering, School of Engg. &
Tech., IGNOU, New Delhi
Mr. P.K. Varshaneya, Prof. Manoj Kulshrestha
Executive Director, Professor in Civil Engineering, School of Engg. &
Maruti Udyog, Gurugram Tech., IGNOU, New Delhi

Col. P.K. Dutta, Dr. Ashish Agarwal

Ex Director, SOHS, Associate Professor in Mechanical Engineering
IGNOU, New Delhi School of Engg. & Tech., IGNOU, New Delhi
Mr. S.A. Khader, Dr. N Venkateshwarlu
Adviser, WCPD, New Delhi Associate Professor in Mechanical Engineering
School of Engg. & Tech., IGNOU, New Delhi
Mr. Deo Jha, Dr. Sanjay Agrawal
IOCL (Retired), New Delhi Associate Professor in Electrical Engineering,
School of Engg. & Tech., IGNOU, New Delhi
Prof. S. Mukherjee,
Director, KIET Ghazibad
Programme Coordinator Course Coordinator
Dr. Sanjay Agrawal Dr. Sanjay Agrawal
School of Engg. & Tech., School of Engg. & Tech.,
IGNOU, New Delhi IGNOU, New Delhi
BLOCK PREPARATION TEAM
Units Written by Content Editor Language & Format Block Coordinator
Editing
Dr. Shashank Srivastav Block 1 Block 1 Dr. Sanjay Agrawal
(Unit - 1) Mr. Sankari Prasun Dr. Sanjay Agrawal SOET, IGNOU
School of Engg. & Tech., Bhattacharya School of Engg. & New Delhi
IGNOU Retired, Ex. Director Tech., IGNOU
(Engg., R&D)
Mr Pradeep Kumar marri
Hindustan Aeronautics
(Unit - 2)
Ltd., Bangalore,
Kamla Innstitute of
Karnataka
Technology & Science
Singapur, Hyderabaad

Prof. Kamal Sharma

(Unit - 3 & 4)
GLA University, Mathura
Prof. Ashish Gupta Block 2 Block 2 Dr. Sanjay Agrawal
(Unit - 5 & 6) Mr. Bhasker Sharma Dr. Sanjay Agrawal SOET, IGNOU
ITS, Engineering College, Solon India Pvt. Ltd. School of Engg. & Tech, New Delhi
Greater Noida, UP New Delhi IGNOU
Dr. Naqui Anwer, Mr. Prabhakar Sharma
(Unit - 7 & 8) ITS, Engineering College
TERI University, Greater Noida, UP
New Delhi
PRODUCTION
Mr. Y.N. Sharma Mr. Sudhir Kumar
Assistant Registrar (Publication) Section Officer (Publication
MPDD, IGNOU, New Delhi MPDD, IGNOU, New Delhi
March, 2021
©Indira Gandhi National Open University, 2021
All rights reserved No part of this work may be reproduced in any from, by mimeograph or
any other means, without permission is writing from the Indira Gandhi National Open
University.
Further Information on the Indira Gandhi National Open University courses may be
obtained from the University’s office at Maidan Garhi, New Delhi-110068.
Printed and publish on behalf of the Indira Gandhi National Open University by Prof.
Subhasis Maji, Director SOET.
Laser Typesetting by Tessa Media & Computers
Printed at :
SAFETY IN MACHINERY
The job safety and health movement has now become an essential requirement
since the Industrial revolution. Today, there is widespread understanding of the
importance of providing a safe and healthy workplace. There is a saying that an
ounce of prevention is worth a pound of cure. Every hazard that can be
identified should be corrected or at least minimized through the introduction of
appropriate safeguards. The word safety also refers to the precautions people
take to prevent accidents, harm, danger, damage, loss and pollution. Safety
also deals with improvement in working conditions for better health and
improved productivity.
This block covered job safety analysis and all required machines guards,
effective material handling, Safety in design and safe working practices that
should be implemented in the industries to minimize accidents and health
issues in the workers. This block is divided into four units with specified
objectives.
Unit-1 is devoted entirely to the Job Safety analysis leads to improved
productivity, quality and safety. This is a systematic approach to identify the
possibility and probability of risks and taking measures to eliminate or reduce
the risk factors and implement the mechanisms to control the impact on
human, machineries and environment.
Unit-2 describes material handling that involves moving, handling and
storing of materials in an industry or a constructional field. In simple terms, it
is moving, loading and unloading of materials used in the workplace. It
provides an extended flow of products, raw materials and parts for further
operations in a workplace. In this unit all possibilities to effective handling of
material with minimum hazards and maximum safety is discussed.
Unit-3 built on the protective measures taken in form of safeguarding,
operational methodology, storing techniques, handling instructions,
administrative controls etc. However, the most effective and full proof
method for effective management is tackling the unsafe situation through
design. Safety in design and safe working practices is explained with
different related factors and all possibilities.
Unit-4 included some case studies related to accidents that sadly happened
due to ignorance, negligence, casual behaviour against safety norms and
pressure to complete task in the given time frame. Mainly accidents
encountered due to avoidance of safety rules, education and training, site
safety inspection, safety auditing, safety meeting, site safety organization,
personal protective equipments, emergency support and safety measuring
devices, fall protective systems, and safety promotions.
In conclusion, all units discussed various parameters to reduce accidents at
any work place, improve productivity and improve workers health problems.
 BLOCK 1
SAFETY IN MACHINERY
 MIS – 024
Mechanical and Electrical
Indira Gandhi
National Open University Safety Management
School of Engineering & Technology

Block

1
SAFETY IN MACHINERY

UNIT 1
Job Safety Analysis and Machinery Gaurds 9

UNIT 2
Safety in aterial
M andling
H 36

UNIT 3
Safety in Design and Safe Working Practices 73

UNIT 4
Case tudySand xercise
E 108
UNIT 1 JOB SAFETY ANALYSIS AND
MACHINE GUARDS

Structure
1.1 Introduction
Objectives
1.2 Job Safety Analysis
1.2.1 Selecting Jobs for Analysis
1.2.2 Employee Involvement
1.2.3 Division of Steps and Conducting Job Safety Analysis
1.2.4 Analyzing Steps Involved in a Job
1.2.5 Hazard Identification
1.2.6 Modified Recommendations for Safe Procedure and Protection
1.3 Safeguarding
1.3.1 Machine Safeguarding
1.3.2 Machine Operator’s Responsibilities
1.3.3 Employer’s/Owners Responsibilities
1.3.4 Types of Operations and Equipments with their Components
1.3.5 Methods of Safeguarding
1.3.6 Basic Safeguard Areas
1.4 Controls
1.4.1 Engineering Controls
1.4.2 Administrative Controls
1.4.3 Criteria for Safeguarding
1.5 Other Factors in Safeguarding
1.5.1 Location/Distance
1.5.2 Presence Sensing
1.5.3 Potential Feeding and Ejection Methods to Improve Safety for the Operator
1.5.4 Miscellaneous Aids
1.6 Types of Machine Guards
1.7 Safeguarding Devices
1.8 Minimum Requirements of Safeguards
1.8.1 Administrative Requirements
1.8.2 Hazard Evaluation and Control
1.8.3 Training Requirements
1.8.4 Inspection Requirements
1.9 Let Us Sum Up
1.10 Key Words
1.11 Answers to SAQs
1.12 References and Further Readings

1.1 INTRODUCTION
In our day to day life, do we allow little children to switch on an electrical
gadget? No. Why? Because the first thing that appears in our mind is ‘how
safe is the operation and system?’
9
Safety in Machinery Safety is a natural human instinct. The ancient men were looking for safe
places, safe action and safe environment. They found caves for safe shelter,
hidden places for hunting, camouflaging and silence during attack and
arranging fire to prevent animals. These all were safety mechanisms for
survival. So safety is a necessity. With the advancement of civilization, the
safety requirements have also changed.
During the 19th century, with the discovery of electricity and steam engine,
the industrial revolution took place production process became mechanized.
The safety requirement changed drastically. The electrical and mechanical
factories were set up and there were accidents causing death, disability,
machine breakdown and also long term health hazards. These led to making
safety norms and are updated with time and type of industry.
With the enhanced understanding of importance of safety in industry, a
structured methodology became evident to establish the safety norms and
implement the safety mechanism in the industry.
Job safety analysis is the first step in this structured methodology. This is a
systematic approach to identify the possibility and probability of risks
(hazards) and taking measures to eliminate or reduce the risk factors and
implement the mechanisms to control the impact on human, machineries and
environment. The Job Safety Analysis (JSA) finally leads to improved
productivity, quality and safety.
The shop floor is an integral part of an electrical and mechanical industry.
This is the place where a product takes shape from raw form. The shop floor
is a combination of man, machines, material and accessories viz. tools,
documents, handling equipment, energy resources etc. The main objective
JSA is to integrate accepted safety and health principles and practices into a
particular task or job operation in a shop floor. In JSA, each basic step of the
job is to be identified with potential hazards and the safest way to do the job
is recommended.
In this process, machine safeguarding is one of the core areas of shop floor in
any industry as it is responsible for providing risk free environment both to
the personnel and the machines.
Lack of appropriate training of the employees in proper job procedure, job-
related mishaps, injuries lead to fatal situation regularly in the workplace.
The four basic steps that are used for writing a JSA are:
• Selection of the job to be analysed
• Job breakdown into smaller tasks
• Identifying potential hazards
• Determining preventive measures to overcome those hazards
The main advantages of carrying out a JSA are:
1) Safety and health awareness in the shop floor
2) Acceptance and adherence to safe work procedures
3) Promotes teamwork
4) Implementation of JSA recommendation to make the job safe and worthy

10
Objectives Job Saftety Analysis
and Machine Guards
After studying this unit, you will be able to:
• describe the need of job safety analysis and procedures involved in it.
• explain the need of safeguarding and the various methods of providing
safeguard.
• implement job safety analysis and recommendation on a particular shop
floor.

1.2 JOB SAFETY ANALYSIS (JSA)

Establishment of proper job procedures (Process Layout) and training of all
employees in safe and efficient work methods can be a step towards
preventing workplace injuries and damage to machines. Careful study and
recording of each step of a job, identifying existing or potential job hazards
(both safety and health), and reduction or elimination of these hazards form
an essential part of proper job procedures. Improved job methods reduce
costs resulting from employee absenteeism and workers’ compensation, fear
free environment can often lead to increased productivity.
Completion of a task on a job requires certain sequential steps and these steps
extend from the selection of the proper tool, right method of employing the
tool on the job to the use of proper Personnel Protective Equipment(PPE).
Similarly, machines can be unsafe. On most machines, the point-of-operation
is the most vulnerable area since this is the place where the work is
performed and where the machine cuts, shears, punches shapes, bends or
drills different materials. Many hazards exist on all types of machinery that
can lead to serious and debilitating injuries or even death. If the operation of
a machine can injure the operator, or other workers nearby, the hazard must
be controlled and eliminated. Machine safeguarding is the primary way to
control hazards associated with machinery. The personnel are jeopardized
when machines behave improperly and do not comply with applicable
regulations and standards. OSHA (Occupational Safety and Health
Administration), USA requires that any machine part, function, or process
which may cause injury must be safeguarded. In case of injury to the operator
or others in the vicinity, the hazards must either be controlled or eliminated.
All guards should be appropriate for the hazards involved, secured in place
and constructed of substantial strong material, with surfaces devoid of
hazardous projections.
Safeguards on machines are indispensable to prevent workers from injuries
which are often preventable. The most basic safety guidelines for machine
safeguarding are that ‘every machine part, function or process which may
cause injury must be safeguarded.’

1.2.1 Selecting Jobs for Analysis

Job safety analysis is essential for all kinds of jobs whether it be one time,
rare, special or routine job. Even a single step job requiring just switching on
a button, should be analyzed for safety by evaluating, operating, ambient
conditions in conjunction with storage, operating life and built in reliability.
The conditions improve with preventive maintenance and proper failure
mode and criticality analysis. For example, operating an electrical switch in a
11
Safety in Machinery store of gas cylinders may require special precaution, especially if the switch
is defective and gives a spark at a time when there is gas leakage from a
cylinder.
In order to decide which jobs need to be analyzed first, it is very much
necessary to review the job injury and illness reports.
The criteria for selection of job safety analysis are as follows:
• Jobs with maximum number of disabling and life threatening injuries and
illnesses.
• Jobs where accidents or mishaps were just prevented
• Jobs with fast dynamism and moving parts
• Whether single or multi job is on the same floor at a time.
• Jobs with process and procedure changes
• Finally, a job safety analysis needs to be conducted and made available
to employees for all jobs in the workplace.

SAQ 1
a) What is the importance of shop floor?
b) How JSA workout?

1.2.2 Employee Involvement

After selecting a job for analysis, the procedure and purpose of job analysis
need to be discussed with the employees involved directly and indirectly
including those performing the job. One has to take care that the employee
does not feel that his job performance is being evaluated; instead he should
get the message that the job operation and process is being checked. The
employee should be selected considering the average skill level, normal
attitude towards correctness of process, procedure and final result. A very
high skilled employee may not bring out the weaknesses during safety
analysis. Involvement of the employee is must in all phases of the analysis
from reviewing the job steps and procedures to discussing potential hazards
and recommended solutions. The person/group performing the job analysis
should also get the views of workers who have performed the same job. This
helps in getting an exhaustive range of inputs regarding the job. The role of
employee should be explained. The employee should be provided with tools,
documents and conditions as per practice and laid out procedure. The present
process and procedure should be audited and the deliberate or unintentional
deviation from the laid out procedure by the employee should be corrected
first before the analysis.

1.2.3 Division of Steps and Conducting Job Safety Study

Before actually beginning the job safety analysis, carefully go through the
general conditions under which the job is performed at workplace before the
analysis is started, the compliance of laid out process, procedure will be
considered as the Reference standard. The data must be collected to bring the
workplace existing process and procedure to reference standard. In case of
12
non existence of laid out procedure, the existing process and procedure Job Saftety Analysis
and Machine Guards
should be documented to establish the reference standard.
The total process is to be divided in numbers of steps to clearly identify the
chain of actions of the man and machine. These steps are not only specific to
the job, but also specific to the work area. If the work area changes, the steps
may need to change as well. The other associates, logistic support,
movements of material and man, environmental conditions etc are to be taken
into account during this division of steps.
Each step is to be studied thoroughly for safety points of view and the
potential risk areas are to be noted down. Almost every job can be broken
down into job tasks or steps. In the first part of the job safety analysis, enlist
each and every step of the job in the sequence that they occur, while watching
the employee performing his job. The data is then compiled and potential
hazards are to be identified.
During the study, certain enquiries on topics listed below can be raised:
 materials on the shop floor ,
 lightning is adequate or not,
 live electrical hazards at jobsite,
 physical, biological or radiation hazards,
 repair of tools,
 equipment and machines,
 noise,
 job procedures know how and their implementation,
 marking of emergency exits,
 brakes ,
 horns and steering check on moving vehicles like trucks,
 training of operators handling moving vehicles,
 proper protective equipment provided to employees,
 earlier health problems to employees like headache, breathing problems,
dizziness or strong odor,
 ventilation and oxygen depletion in the work area,
 prevention of back and wrist injuries and employee training in case of
fire or explosion award.
This list is by no means complete because each worksite has its own
requirements and environmental conditions. Many more questions can be
added to the list. One also might take photographs of the workplace, if
appropriate, for use in making a more detailed analysis of the work
environment.
The safety analysis checklist is to be filled up during the study. The checklist
should be prepared by a competent person who understands the operation as
well as the regulations related to safety in this specific domain.

1.2.4 Analyzing Steps Involved in a Job

This is the most important step in the safety analysis. The analysis is to be
done with the data and details already captured. The data is related to
material, employee actions, sequence of operation, employee’s reaction time,
13
Safety in Machinery multidisciplinary activities, arrangement of correct tool, dependency on other
operation, multiple works in the same shop floor etc.
One should ensure to record enough information to describe each job action,
but one need not make the breakdown too detailed. Later, go over the job
steps with the employee. Presently, IOT(Internet of Things) is extensively
used for this data collection activity. Sensors and smart camera can be used
for the purpose. The data is subsequently rearranged (data mining) and
possibility of safety failures can be identified. Even the fatigue of the
employee may be a safety concern.
During the Safety analysis, a major requirement is categorizing the criticality
of danger and accordingly safety critical level is to be identified. The
measures are to be taken based on the criticality level. The danger to the life
of people (catastrophe) is considered the highest critical category whereas the
danger to very costly machine may be categorized in next level because this
hampers the operation. However, Criticality level depends on case to case
basis. To determine the criticality level, it is required to carryout ‘Cause and
Effect’ analysis which identifies the impact of any error or deviation in
arrangement, machine performance, operation or human activities. The
probability of failure or breakdown of machine (MTBF - Mean Time between
Failures) also to be considered for safety analysis. This will determine the
preventive measures.
Based on the data captured, operational constraints, environmental condition,
health and chemical hazards the analysis is to be done. The major outcome is
the list of potential hazards and degree of hazard to either human or machine
or environment (criticality level) of each identified hazard.
For Grinding Castings, following job steps are followed as shown in figure
1.1:
1) Reach into metal box to the right of machine, grasp casting, and carry to
wheel.
2) Push casting into wheel to grind off burr.
3) Place finished casting into the box to the left of machine

Figure 1.1: Shows a worker performing the basic job steps for grinding iron castings

14
1.2.5 Hazard Identification Job Saftety Analysis
and Machine Guards

There are various kinds of hazards existing in the work place depending upon
the machine, movements of the worker, types of clothes the workers wear,
working environment causing health hazards etc.
Certain aspects that have to be looked into are as follows:
• whether the job requires personal protective clothing and equipment or
not.
• whether work positions, machinery, pits or holes, and hazardous
operations are adequately guarded or not
• Whether lockout procedures used for machinery deactivation are as per
requirement or not
• Whether the workers wearing clothing or jewelry, or with long hair can
get caught in the machinery thus causing hazard or not.
• Whether fixed objects like sharp edges can cause injury or not.
• Whether interlocking arrangement during operation is required and done
properly or not.
• Whether Special protection of eye is required or not.
• Whether job requires high voltage and electrical grounding protection or
not.
• Whether the system automatically returns to safe condition in case of
partial breakdown or not.
• Checking if depending on the work flow, the movement of the worker is
too rapid or not.
• Whether there is a possibility of worker getting caught in between
moving parts or not.
• Whether there is a possibility of worker getting injured by reaching over
moving machinery parts or materials or not.
• Whether the worker at any time is in an off-balance position or not.
• If there is a possibility of dangerous positioning of the worker with
respect to the machine.
• The worker may be required to make movements that could lead to or
cause hand or foot injuries, or strain from lifting the hazards of repetitive
motions.
• Worker may be struck by an object or lean against or strike a machine
part of object.
• Checking if there is any probability of worker falling from one level to
another.
• Chance of injury to workers from lifting or pulling objects, or from
carrying heavy objects
• Whether environmental hazards (dust, chemicals, radiation, welding
rays, heat, or excessive noise) result from the performance of the job or
not.
• Whether Audio and Visual Warning signals is adequately arranged or
not. 15
Safety in Machinery Example of Hazard identification in grinding job
Repeat the job observation as often as necessary until all hazards have been
identified. Figure 1.2 shows basic job steps for grinding iron castings and any
existing or potential hazards.

Figure 1.2: Grinding Castings: Hazards

Hazards during Grinding Castings are as follows:
1. Strike hand on edge of metal box or casting.
2. Wheel may burst during grinding, not enough of wheel guarded.
3. Strike hand against wheel.
4. Sleeves could get caught.
5. Dust, abrasives, grains and splinters are a common hazard to the eyes in
all dry-grinding operations .

SAQ 2
a) Identify a job for yourself and enlist the hazards associated with it.

b) What are the criteria to identify hazards in the work place?

1.2.6 Modified Recommendations for Safe Procedures and

Protection
After listing potential hazards and reviewing them with the employee
performing the job, the following things have to be determined:

1) Whether the job could be performed in another way to eliminate the

hazards, such as combining steps or changing the sequence.

2) Incorporation of automation to eliminate human error.

16
 Job Saftety Analysis
3) Whether additional safety equipment and precautions are needed to and Machine Guards
control the hazards.

4) Incorporation of warning signal for specific operation.

5) An alternative or additional procedure is to videotape the worker

performing his or her job and analyze the job procedures.

6) If safer and better job steps can be used, list each new step, such as
describing a new method for disposing of material.

7) Exact list of what the worker needs to know to perform the job using a
new method.

8) Whether the recommendations are as specific as possible so that there are

no general statements like “ Be careful”.

9) Improvement in material handling, material carriage and Crane

operations.

10) Periodic checking of safety and warning equipment for a highly

hazardous and inflammable area .

11) Whether to set up a training program using the job safety analysis to
retrain your employees in the new procedures, especially if they are
working with highly toxic substances or in hazardous situations.

12) Whether any physical changes such as redesigning equipment, changing

tools, adding machine guards, personal protective equipment, or
ventilation will eliminate or reduce the danger.

13) Clearances in Gangway and emergency exit routes.

14) Demarcation and fencing around High voltage electrical and high speed
machine area.

15) In case the hazards cannot be controlled, try to reduce the necessity for
performing the job or the frequency of performing it.

16) Also go over the recommendations with all employees performing the
job. Their ideas about the hazards and proposed recommendations may
be valuable. Be sure that they understand what they are required to do
and the reasons for the changes in the job procedures.

17) The output of safety analysis will be qualitative and quantitative. This
also can be expressed in terms of probability, percentage, likelihood of
occurrence, long term and short term health hazards etc. There should
not be judgmental adjectives eg, minimum, least etc. Similarly the
recommendation are in terms of protection, redesign, use of alternate
tools, automation, rearrangement of shop floor, ducting and exhaust for
gas and liquid, adequacy of coolant , operation by certified skilled
persons in specific areas as per norms and regulation etc.
17
Safety in Machinery
18) A training guide for job safety analysis can be prepared.

Figure 1.3 identifies the basic job steps for grinding iron castings and
recommendations for new steps and protective measures.

Figure 1.3: Grinding Castings: New Procedure or Protection

(Courtesy: www.machigan.gor/moisha)

Preventions:
1) Provide gloves
2) Provide larger guard protection over wheel
3) Provide safety goggles.
4) Instruct the worker to wear short or tight fitting sleeves.
A sample table encompassing various aspects of job safety analysis is shown
in Table 1 as an example and can be consulted before taking up the analysis.
However, the table will be tailor made as per the job requirement.

18
 Job Saftety Analysis
and Machine Guards
Table 1: JOB SAFETY ANALYSIS TRAINING GUIDE

Job Title: Page: of JSA No. Date: New Revised

Equipment: Supervisor: Analysis by:

Department: Approved by:

Required Personal Protective Equipment (PPE):

JOB STEPS POTENTIAL HAZARDS RECOMMENDED SAFE JOB PROCEDURES

Break down the job into its basic steps, e.g., what is done first, For each step, ask yourself what accidents could For each potential accident or hazard, ask yourself what safeguards
what is done next, and so on. You can do this by: happen to the employee doing the job. You can get should be provided for the employee and how should the employee do the
the answers by: job step to avoid the potential accident, or what should they do or not do
1. Observing the job to avoid the accident. You can get your answers by:
1. observing the job.
2. Discussing it with the operator 1. observing the job for leads
2. discussing it with the operator
3. Drawing on your knowledge of job 2. discussing precautions with experienced job operators
3. recalling past accidents
4. A combination of the three 3. drawing on your experience
4. a combination of the three
Record the steps in their normal order of occurrence. Describe 4. a combination of the three
what is done, not the details of how it is done. Usually three or Ask yourself; can he/she be struck by or contacted
four words are sufficient to describe each basic job step. by anything; could they strike against or come in Be sure to describe specifically the provided safeguards and precautions
contact with anything; could the employee be an employee must use. Don’t leave out important details. Number each
For example, the first basic job step in using a pressurized caught in, on, or between anything; can they fall; separate recommended precaution with the same number you gave the
water fire extinguisher would be: be over exerted; or be exposed to anything potential accident (see center column) that the precaution seeks to avoid.
1. Remove the extinguisher from the wall bracket. injurious such as gas, radiation, welding rays, etc.? Use simple do or don’t statements to explain recommended precautions as
if you were talking to the employee.
For example, acid burns, fumes.
For example: Lift with your legs, not your back.
Avoid generalities such as, Be careful, Be alert, Take caution, etc.

Trainee’s Name: Training Date:

Trainer’s Name: Trainer’s Signature:

Four-Step Instruction Completed? Prepare the Worker . . . . . . . . . . . . Trainer’s Initials

Present the Operation . . . . . . . . . . Trainer’s Initials
Try Out Performance . . . . . . . . . . .Trainer’s Initials
Follow Up . . . . . . . . . . . . . . . . . . . .Trainer’s Initials

Comments:

19
Safety in Machinery
1.3 SAFEGUARDING
1.3.1 Machine Safeguarding
Protection is required for any person working on or near a machine. A machine
with its various components, each with a specific function and together
performing a particular task applies or utilizes mechanical power which makes
it dangerous. Much of the danger in a machine occurs generally at the point of
operation and the operation may be cutting, shearing, punching, blanking,
bending or drilling. The hazards involved during these processes may lead to
serious injuries or even death.
Machine safeguarding is the primary way to control hazards associated with
the machinery. Dangers include when machines are improperly used or do not
comply with applicable regulations and standards. Occupational Safety and
Health Administration (OSHA) requires that any machine part, function, or
process which may cause injury must be safeguarded. When the operation of a
machine or accidental contact with it can injure the operator or others in the
vicinity, the hazards must either be controlled or eliminated. All guards should
be appropriate for the hazards involved, secured in place, constructed of
substantial material, and have surfaces free of hazardous projections.
It is imperative to employ safeguards on machines so that the operators do not
suffer from injuries. The most basic safety guideline for machine safeguarding
is each machine part, function or process that may cause injury must be
safeguarded. Any operation that may cause injury to the operator or others
working nearby, must be controlled and eliminated.
Machine safeguarding entails various aspects which are enlisted here in detail:
 Who do you think are the two main entities to be held responsible for the
safety of workers?
 Well, the answer is the worker himself and the employer or the owner of
the concerned department.
 What are those responsibilities?

1.3.2 Machine Operator’s Responsibilities

• Should have proper training of his/her work and understanding of the
safety norms.
• Adherence to the laid out procedure for operation, layout and safety
measures is a must.
• Inspection of the machines and safeguards prior to each use and ensures
rectification if necessary.
• Always uses safeguards as required.
• Alerts Employer/Owner Department Management when machines and/or
safeguards need repair/replacement.
• Active participation in safety analysis and finalizing the safety measures.
• If in case machine safeguards cannot be used , then ask the supervisor to
provide administrative controls for safety.

20
 Job Saftety Analysis
1.3.3 Employer’s/Owner’s Responsibility and Machine Guards

• Documented process layout and procedure to be made available.

• Implementation of safety measure as recommended in Safety Analysis.
• Inspect machines on a periodic basis and record the status of machines and safety
measures.
• Repair the machine and safeguards when necessary. Replacement of machines
parts or safety parts with declared life.
• Discard the machine if it cannot be repaired.
• Provide training to all personnel as required.
• Keep and maintain attendance records of all trainings for at least three years.
• Provide alternative methods or administrative control for protection if safeguards
restrict the point of operation.
• Consulting from environmental health and safety (EHS) department about
safeguards and administrative controls before using or allowing the usage of
machine.

1.3.4 Types of Operation and Equipment with their

Components
There are the various kinds of machines that are commonly safeguarded. The
operations and machines require safeguarding .Other machines with exposed
moving parts may be found in different industries or can be employed for a
specific task.
The operations which have safety concerns associated with them are welding,
sawing, crane operation, high voltage testing, chemical mixing, heating and
many more.
Examples of equipment:
Band Saw, Chop Saw, Computer Numerical Control (CNC), Drill Press,
Grinder, Bench Grinder, Belt Grinder, Horizontal Band Saw, Hydraulic Press,
Iron Worker, Jointer, Mechanical Power Presses and Press Brakes, Metal
Lathe, Mill, Miter Saw, Panel Saw, Planer, Radial Arm Saw, Router, Drum
Sander, Oscillating Edge Sander, Combination Sander, Scroll Saw, Shaper,
Shear, Table Saw, Sliding Table Saw, Wood Lathe, Electrical machines, etc,

1.3.5 Methods of Safeguarding

After gaining knowledge about the responsibilities for safety and what to
safeguard, you should now learn about the methods of safeguarding, which are
as follows:
• Guards: A physical barrier that prevents access to hazardous area of a
machine.
• Devices: A safety device may perform one of several functions: It may
stop the machine if a hand or any part of the body is inadvertently placed
in the danger area, restrain or withdraw the operator's hands from the
danger area during operation, require the operator to use both hands on
machine controls, thus keeping both hands and body out of danger,
provide a barrier which is synchronized with the operating cycle of the

21
Safety in Machinery machine in order to prevent entry to the danger area during the hazardous
part of the cycle.
Guards and Safeguarding devices are meant to serve two basic purposes:
one is to protect the operator from moving parts of a machinery and to
offer protection to the people working in the vicinity from flying parts or
material or from getting caught in between moving parts. Examples of
safeguarding devices are shown in Figure 1.4.

Figure 1.4: Examples of Safeguarding Devices

To fulfill the purpose of safeguarding other workers in nearby area, major
safeguard areas need to be defined.

1.3.6 Basic Safeguard Areas

Point of Operation: This is the area where work is performed on the material.
This work includes cutting, shaping, forming and any other job that involved
moving parts.
Power Transmission Apparatus: Components of the mechanical system
which transmit energy to the machine part that is performing the work must be

22
guarded. These components include pulleys, belts, connecting rods, flywheels, Job Saftety Analysis
and Machine Guards
couplings, cams, chains, spindles, cranks and gears.
Other Moving Parts: Any part of the machine that may be in motion must be
guarded. These include rotating and transverse moving parts, reciprocating
parts and feed mechanisms of the machine.
Safeguard for health hazards: The area must be safeguarded for hazards in
health. This includes arc welding causing adverse effect in eye, acid fumes
causes respiratory troubles while cleaning with acid , testing with laser
causing adverse impact on eye, working with radioactive material causing
cancer due to long term use. In these cases the whole area is to be safeguarded.

SAQ 3
a) Discuss the various responsibilities of an employee in ensuring
safeguarding of machines.

b) Enumerate the various areas to be safeguarded.

1.4 CONTROLS
Before discussing the types of safeguard, let us explore up to what extent the
hazards can be eliminated through the controls. There are primarily two types
of controls: Engineering and Administrative controls.

1.4.1 Engineering Controls

The best strategy is to control the hazard at the point from where it emanates.
Engineering controls are the most suitable to handle this. The basic principle
behind engineering controls is that, to the extent feasible, the work
surroundings and the job itself should be designed to eliminate or reduce
exposure to hazards.
These are based on some basic principles enlisted below:
• All efforts should be made to design the facility, equipment or process in
such a manner so as to ensure that the hazard is removed or is substituted
by something that is less hazardous.
• If the hazard still persists, enclose it to prevent exposure in normal
conditions.
• If complete enclosure is not possible, then barriers or local ventilation to
reduce the exposure time is a must.
• Design of material handling scheme is important.

1.4.2 Administrative Controls

OSHA uses the term administrative controls to mean using measures beyond
safe work practices to reduce employee exposure to hazards. These measures
include additional measures like using relief workers, administrating exercise
like breaks and rotating workers, workers trainings etc. These types of controls
are often used in conjunction with other controls that more directly prevent or
control exposure to the hazard.
23
Safety in Machinery The administrative control also ensures that the jobs are done lay personnel
with adequate skills. Skilled and certified persons are to be employed for high
risk operations eg. high voltage, chemical handling, laser and radio active,
explosives etc.
Proper sign boards, warning signals, restriction of general movements, general
awareness about safety, indirect employees are also to be implemented.
When neither Engineering Controls nor Administrative Controls are possible
or they do not provide adequate protection, personal protective equipment
(PPE) must be provided as a supplement. Departments must institute all
feasible engineering and administrative controls to eliminate or reduce hazards
before using PPE to protect employees from injury.

1.4.3 Criteria for Safeguards

• Prevent Contact: The safeguard must prevent hands, arms, and any other
part of a worker’s body from making contact with dangerous moving
parts.
• Secure: Safeguards should not be easy to remove or tamper with and must
be firmly secured to the machine. Guards and safety devices should be
made of durable material that will withstand the conditions of normal use
and higher level of stress during abnormal behavior of machine.
• Protect from Falling Objects: The safeguard should ensure that no
objects could fall into moving parts and become a projectile while the
machine is being operated.
• Create no new Hazards: A safeguard defeats its purpose if it creates a
hazard of its own.
• Any safeguard that impedes a worker from performing the job,
comfortably and safely may soon be overridden or disregarded. A guard
must allow maximum visibility of the point-of-operation.
• Allow Safe Lubrication: Without remaining the safe guards provision
should be made for machines to be safely lubricated.

1.5 OTHER FACTORS IN SAFEGUARDING

1.5.1 Location/Distance
With respect to the design of shop floor layout and storing of inflammable
material, the following precaution must be taken:
• A thorough hazard analysis of each machine and particular situation is
essential before attempting to safeguard.
• The machine or its dangerous moving part has to be positioned in such a
manner that the hazardous areas are not easily accessible to a worker
during the normal operation of the machine.
• The feeding process can be safeguarded by location if a safe distance can
be maintained to protect the worker’s hand.
• The positioning of the operator’s control station provides another potential
approach to safe guarding by location.

24
 Job Saftety Analysis
1.5.2 Presence Sensing and Machine Guards

This is basically implementation of interlocking arrangement, which means the

operation is interlocked with the compliance of certain safety measures.There
are explained below:
a) Photoelectric:- The photoelectric (optical) presence-sensing device uses a
system of light sources and controls which can interrupt the machine’s
operating cycle. If the light field is broken, the machine stops and will not
cycle. This device must only be used on machines which can be stopped
before the worker can reach the danger area.
b) Radio frequency: - In this case of presence of sensing device, a radio
beam that is part of the machine control unit is utilized. When the line of
communication is broken, the machine will stop or will not activate.
Similar to the photoelectric device, this device is only used on machines
which can be stopped before the worker can reach the danger area. This
requires the machine to have a friction clutch or other reliable means for
stopping
c) Electromechanical – The electromechanical sensing device has a probe or
contact bar which descends to a predetermined distance when the operator
initiates the machine cycle. If there is an obstruction preventing it from
descending its full predetermined distance, the control circuit does not
actuate the machine cycle.

1.5.3 Potential Feeding and Ejection Methods to Improve

Safety for the Operator
The following feeding and ejection methods may be implemented to ensure
operator safety:
• Automatic Feed
• Semi-Automatic Feed
• Automatic Ejection
• Semi-automatic ejection
• Robot

1.5.4 Miscellaneous Aids

The following miscellaneous aids may be used:
• Miscellaneous Protective Shields
• Hand-feeding Tools and Holding Fixtures

25
Safety in Machinery
1.6 TYPES OF MACHINE GUARDS
The following types safeguard action, advantages and their limitations are
shown in tabular form:

Type Safeguard Advantages Limitations

Action

Fixed Provides a barrier and is a May be Required

permanent part of machine designed to visibility
suit many for
specific performing
applications. the job may
Can ensure not be
maximum adequate.
protection. Machine
Maintenance adjustment
required is and repair
minimal. often
require
Suitable for removal of
high guard.
Figure 1.6 (a) production,
repetitive
operations

26
 Job Saftety Analysis
Can be Hands may and Machine Guards
constructed to enter
suit many danger
specific area.
applications. Protection
may not be
Can be
adjusted to complete at
admit varying all times.
sizes of stock. May
require
frequent
maintenanc
e or
adjustment.
Operator
may make
guard
ineffective.
May
interfere
with
visibility.

Self- Provides a barrier that moves Does not Maximum

adjusting according to the size of the stock require protection
entering the point of operation. manual is not
Guard is in place when machine adjustments. ensured.
is at rest. Guard pushes away
when worker moves stock into May
point of operation. interfere
with
visibility.
Frequent
maintenanc
e and
adjustment
are
essential.

Figure 1.6 (c)

(Source: Concepts and Techniques of Maachine Safegaurding, U.S. Department of Labour, OSHA and
www.sloipe.org)

27
Safety in Machinery
1.7 SAFEGUARDING DEVICES
The following are the safeguarding devices:
i) Pullback
This type of device is mainly used on machines with a stroking action.
Pullback devices use a series of cables attached to the operator’s hands,
wrists, and/or arms as shown in figure 1.7(a). The operator is allowed
access to the point of operation when the slide/ram is up else a mechanical
linkage automatically assures withdrawal of the hands from the point of
operation when the slide/ram descends.

Figure 1.7 (a): Pullback

(Courtesy: University of California, Santa Barbara)

ii) Restraint
The restraint (holdout) device as shown in figure 1.7 (b) uses cables or
straps that are attached to the operator’s hands and a fixed point. The
cables or straps are adjusted in such a way so as to let the operator’s hands
travel within a predetermined safe area. There is no extending or retracting
action involved.

Figure 1.7 (b): Restraint

(Courtesy: University of California, Santa Barbara)

iii) Gate or Barrier

A gate is a movable barrier as shown in figure 1.7(c ) which protects the
operator at the point of operation before the machine cycle can be started.
Most gates are designed to be operated with each machine cycle. If the
28
 gate is not permitted to descend to the fully closed position, the press will Job Saftety Analysis
and Machine Guards
not function. Another potential application of this type of guard is where
the gate is a component of a perimeter safeguarding system.

Figure 1.7 (c): Gate or Barrier

(Courtesy: University of California, Santa Barbara)

SAQ 4
a) What are the various types of controls that can reduce the extent of
safeguarding?
b) What do you mean by Administrative controls?
c) Name a few types of machine safeguarding devices.

Safety Control
Safety control devices are designed to provide a quick means for deactivating a
machine. Safety control devices include:
• Safety trip control
• Pressure-sensitive body bar
• Safety tripod
• Safety tripwire cable
• Two-hand control
• Two-hand trip
• Mechanical or Electrical Fuse
A fuse is used to protect the machine and operator in case of abnormal
behavior of machine. The drive shaft of a motor is weakened by reducing
localized thickness so that it works like a fuse in case of abnormal behavior of
over speeding or jamming of motor/load. The weak section of the shaft is
29
Safety in Machinery broken and the load is isolated. Similarly, electrical fuse isolates the machine
from the power source in case of abnormal demand of electric power. Speed
governors are widely used to avoid impact of malfunction or abnormal
behavior of machine.

1.8 MINIMUM REQUIREMENTS OF

SAFEGUARDS
1.8.1 Administrative Requirements
• Maintain good and clean environment– avoid crowded, cluttered
conditions.
• Ensure combustible and flammable materials are kept at a safe distance
from spark-producing operations.
• Provide adequate ventilation and air circulation to reduce dust and other
air contaminants.
• Mandatory noise level monitoring and providing hearing protection as per
requirement.
• Identify hazards related to the specific job assigned to the operator.
• Follow the equipment manufacturer’s recommendations.
• Use equipment only for the designated function.
• Tool operation to be conducted at the parameters(eg. speed and tension)
specified by the manufacturer.
• Inspect the equipment visually before use.
• Remove worn out, dilapidated and lifted equipment from service.
• Maintain sharp and clean parts.
• Ensure dust collection system is on and properly functioning.
• Check to see that guards and guides are properly adjusted and functional.
• Make sure hands are kept at a safe distance.
• Follow safe procedures, as outlined in the operator’s manual.
• Always wear eye and face protection and other appropriate personal
protective equipment.
• Loose clothing or long hair should to be avoided.
• Follow proper lockout/tag out procedures during service, repair or during
unusual circumstances.
• Never remove a guard.
• Never reach into areas of the equipment where visibility is poor.
• The operation should be directed away from your body.
• Provide visual signs and warning signal wherever necessary.
• Restrict unauthorized movements in a hazard prone area.

30
 Job Saftety Analysis
1.8.2 Hazard Evaluation and Control and Machine Guards

Hazardous Actions:
The following are categorized as hazardous action:
1) Cutting Actions:-involve rotating motion, reciprocating and transverse
motion. The danger of cutting action exists at the point of operation where
injuries to different body parts of the operator can occur, and where flying
chips or scrap material can strike the eyes or face. Such hazards are
present at the point of operation in cutting wood, metal, or other materials.
Typical examples of mechanisms involving cutting hazards include band-
saws, circular saws, boring or drilling machines, turning machines (lathes),
or milling machines.
2) Punching Actions:-result when power is applied to a slide (ram) for the
purpose of blanking, drawing, or stamping metal or other materials. The
danger of this type of action occurs at the point of operation where the
stock is inserted, held, and withdrawn by hand. Typical machinery used
for punching operations are power presses and iron workers.
.
3) Shearing actions: involve applying power to a slide or knife in order to
trim or shear metal or other materials. A hazard occurs at the point of
operation where the stock is actually inserted, held, and withdrawn.
Typical examples of machinery used for shearing operations are
mechanically, hydraulically, or pneumatically powered shears
4) Bending actions: result when power is applied to a slide in order to draw
or stamp metal or other materials. A hazard occurs at the point of
operation where stock is inserted, held, and withdrawn. Equipment that
uses a bending action includes power presses, press brakes, and tubing
benders.
Hazardous mechanical motions and actions
1) Rotating Motion: Even smooth, slowly rotating shafts can grip clothing,
and through mere skin contact can force an arm or hand into a dangerous
position. Collars, couplings, cams, clutches, flywheels, shaft ends,
spindles, and horizontal or vertical shafting are some examples of common
rotating mechanisms which may be hazardous. There is added danger
when bolts, nicks, abrasions, and projecting keys or set screws are exposed
on rotating parts on machinery.
2) In-Running Nip Point: These are hazardous places on the machine where
parts move toward each other or when one part moves past a stationary
object. Loose clothing or body parts may get caught between or drawn into
the nip point.
3) Reciprocating motions: may be hazardous because of the back-and-forth
or up-and-down motion. A worker may be struck by, or caught between a
moving and a stationary part.
4) Transverse Motion: Mechanical Waves are waves which propagate
through a material medium (solid, liquid, or gas) at a wave speed which
depends on the elastic and inertial properties of that medium.

1.8.3 Training Requirements

It is indispensable that machine operators have to be properly trained in order
to identify hazardous mechanical components and motion related to a
31
Safety in Machinery particular machine. Even the most sophisticated safeguarding system cannot
provide effective protection unless the worker is well acquainted with the
knowledge of its use. Specific and detailed training is therefore a critical part
of any effort to provide safeguarding against machine related hazards. This
kind of safety training is necessary for new operators and maintenance or setup
personnel, when any new or altered safeguards are put in service, or when
workers are assigned to a new machine or operation.
Thorough operator training involves instruction and hands-on training.
Training should include:
• Details of hazards associated with particular machines and how to identify
them.
• The safeguards themselves, how they provide protection, and the hazards
for which they are intended
• Proper operation, adjustment, placement and use of safeguards.
• Removal of safeguards under different circumstances and identifying the
personnel for doing it.
• Deciding future course of action when a safeguard is damaged, lost, or not
functioning properly to provide adequate protection.
• Appropriate personal protective equipment.
• Health hazards associated with using machines (air quality, noise and
vibration).
• Maintenance and care.
• Inspections.
Update Training is necessary for new operators and maintenance or setup
personnel when in cases when:
• There is a safeguard change by opting for a new or altered one.
• Workers are assigned a task on a new machine or a new job in itself is to
be performed.
• Basic Safety Principles Equipment.

1.8.4 Inspection Requirements

Machines with missing guards or in below standard condition should be
immediately removed from service till the time appropriate repairs are made or
guards are affixed.
There should be a periodic inspection and corrective action must be carried out
as detailed in the safety document (Machine Safeguarding manual and
Checklist). Documentation for these inspections must be kept onsite.
Many machines purchased by businesses from various equipment suppliers do
not come equipped with the proper guards and safeguarding devices, and hence
do not comply with the applicable regulations and standards. Machines like
this are very common in factories that utilize machines for wood and metal
work, hence require a varying number of upgrades. High-end machines are
designed and built to comply with the regulations and standards and usually do
not require many upgrades. The Machine Safeguarding Checklist is a good
way to help determine if machines require a more thorough evaluation, and
32
whether or not procedures and policies need to be developed to fulfill Job Saftety Analysis
and Machine Guards
administrative requirements.

SAQ 5
a) Enlist various Hazardous mechanical motions and actions in work
place.
b) Write down the importance of proper training for workers before job
work.
c) What are the main point of worker’s training?
d) Update training is required in what conditions?

1.9 LET US SUM UP

Job safety analysis and safeguarding forms an integral part of any industry, as
safety of the employees is a major concern for the employer and needs to be
addressed in the best possible way.
Job safety analysis encompasses various factors ranging from employee
involvement to working environment. Proper study of the various steps
involved in performing a job along with the hazards associated with it helps the
employee and the management to prioritize the jobs according to the level of
safety required to perform it.
Similarly safeguarding refers to the security measures adopted for a particular
job on a particular machine. It can be done through exercising various types of
controls like engineering, administrative and safety controls, etc. and by
employing different types of guard when the controls are not sufficient. Proper
inspection and training of the workers is indispensable.

1.11 KEY WORDS

JSA: Job safety analysis is the first step in this structured methodology. This is
a systematic approach to identify the possibility and probability of risks
(Hazards) and taking measures to eliminate or reduce the risk factors and
implement the mechanisms to control the impact on human , machineries and
environment.
Shop Floor: The shop floor is an integral part of an electrical and mechanical
industry. This is the place where a product takes shape from raw material. The
shop floor is a combination of man, machines, material and accessories viz.
tools, documents, handling equipment, energy resources etc.
Safeguards: Safeguards on machines are indispensable to prevent workers from
injuries which are often preventable.
Guards: A physical barrier that prevents access to hazardous area of a
machine.
Point of Operation: This is the area where work is performed on the material.
This work includes cutting, shaping, forming and any other job that involved
moving parts.
Photoelectric : The photoelectric (optical) presence-sensing device uses a
system of light sources and controls which can interrupt the machine’s
operating cycle.
33
Safety in Machinery Restraint : The restraint (holdout) device uses cables or straps that are
attached to the operator’s hands and a fixed point.
Pullback: This type of device is mainly used on machines with a strokinacg
tion. Pullback devices use a series of cables attached to the operator’s hands,
wrists, and/or arms.
Gate or Barrier: A gate is a movable barrier which protects the operator at the
point of operation before the machine cycle can be started.

1.11 ANSWERS TO SAQS

SAQ 1
a) The shop floor is an integral part of an electrical and mechanical industry.
This is the place where a product takes shape from raw material. The shop
floor is a combination of man, machines, material and accessories viz.
tools, documents, handling equipment, energy resources etc.
b) The main objective of JSA is to integrate accepted safety and health
principles and practices into a particular task or job operation in a shop
floor. In JSA, each basic step of the job is to be identified with potential
hazards and recommend the safest way to do the job.
SAQ 2
a) Depends on the job selected
b) Hazards depending upon the machine, movements of the worker, types of
cloth the workers wear, working environment causing health hazards etc.
SAQ 3
a) Should have proper training of his work and understanding of the safety
norms. Always uses safeguards as required. Alerts Employer/Owner
Department Management when machines and/or safeguards need
repair/replacement
b) Point of Operation, Power Transmission Apparatus, Moving Parts of the
machines and Safeguard for health hazards
SAQ 4
a) There are primarily two types of controls: Engineering and Administrative
controls
b) Administrative controls include additional measures like using relief
workers, administrating exercise like breaks and rotating workers, workers
trainings etc.
c) Pullback, Restraint and Gate or Barrier
SAQ 5
a) Rotating Motion, In-Running Nip Point, Reciprocating motions and
Transverse Motion.
b) In order to identify hazardous mechanical components and motion related
to a particular machine.
c) Details of hazards associated with particular machines and how to identify
them. Proper operation, adjustment, placement, removal under different
conditions and use of safeguards. Appropriate personal protective

34
 equipment. Health hazards associated with using machines (air quality, Job Saftety Analysis
and Machine Guards
noise and vibration).
d) When safeguard changes, workers are assigned a task on a new machine or
a new job in itself is to be performed and for basic Safety Principles
Equipment.

1.12 REFERENCES AND FURTHER READINGS

[1] Michigan Occupational Safety and Health Administration,Department of
Licensing and Regulatory Affairs
[2] "NFPA 70E", Standard for Electrical Safety in the Workplace 2015 Edition,
2014
[3] https://www.iloencyclopaedia.org/part-xiii-12343/metal-processing-and-metal-
working-industry/item/680-grinding-and-polishing.
[4] https://www.ehstoday.com/blog/5-steps-better-job-safety-analysis
[5] The state of the National Initiative on Prevention through Design, Cincinnati,
OH:Nat. Inst. Occupational Safety Health, Centers Disease Control Prevention,
U.S. Dept. Health Human Services, 2013.
[6] https://www.osha.gov/Publications/osha3075.pdf
[7] "CSA Z462", Workplace Electrical Safety Standard, 2015.
[8]
https://www.lanl.gov/safety/electrical/docs/elec_hazard_awareness_study_guide.pdf
[9] Machine Safeguarding Written Programme University of California Santa
Bara

35
 Safety in Machinery
UNIT 2 SAFETY IN MATERIAL HANDLING
Structure
2.1 Introduction
Objectives
2.2 Material Handling: Concepts and Significance
2.2.1 Principles of Material Handling
2.2.2 Material Handing Equipments
2.2.3 Significance of Materials Handling
2.2.4 Limitations and Drawbacks of Material Handling
2.2.5 Systems Concept of Material Handling
2.2.6 Elements of Materials Handling
2.2.7 Advantages of Correct Materials Handling
2.2.8 Method Oriented Systems of Material Handling
2.2.9 Selection of Material Handling Equipment
2.3 Classification of Material Handling
2.4 Risk Factors Associated with Manual Handling Activities
2.4.1 Controlling Manual Handling Problems
2.4.2 Ways to Reduce the Risk
2.4.3 Methods to Prevent Back Injury in MMH
2.5 Safety Considerations in Manual Material Handling
2.5.1 Safety Tips for Manual Material Handling
2.5.2 Some more Safety Considerations
2.6 Mechanical Material Handling
2.6.1 Mechanical Material Handling Equipment (MMHE)
2.6.2 Classification of MMHE
2.7 Safety in Mechanical Material Handling
2.7.1 Risk Factors in Mechanical Material Handling
2.7.2 Mechanical Material Handling Equipment: Hazards and Its Control
2.8 Safety in Electrical Material Handling
2.9 Let Us Sum Up
2.10 Key Words
2.11 Answers to SAQs
2.12 References and Further Readings

2.1 INTRODUCTION
Material handling is an art that involves moving, handling and storing of
materials in an industry or a constructional field. In simple terms, it is moving,
loading and unloading of materials. It provides an extended flow of products,
raw materials and parts for further operations in a workplace. Different
machineries and equipments are used for handling materials to make it safe
and economic. A simple Mechanical Materials Handling Machine/Equipment
is shown in the Figure 2.1. Material handling is considered as exterior
phenomenon for the product, as it enhances the cost of the product and in most
36 cases it is a qualitative loss too. It doesn’t add any value to the product or
 Job Saftety Analysis
and Machine Guards
good, so it is always preferable to minimize the cost of material handling. In
industries, approximately 40% of production cost is incurred by material
handling and also about 80% of time is wasted in processing, transporting and
waiting.
From the engineering point of view the term material handling refers to an
industrial activity. Whether it may be a big industry or a small manufacturing
unit or it be a construction work, materials need to be handled as large ingots,
semi-finished goods or final products starting from the procurement to the
dispatch. Handling of materials involves various operations such as dumping
of coal with a dumper, moving cartons with a forklift, loading off the bags
from the truck etc. Improper material handling and storage may result in
accidents or injuries. These accidents or injuries may range from back injury
to a catastrophic failure of a dump truck. That’s the reason; in any industry the
safe operation of material handling is vital.

Figure 2.1: Mechanical Material Handling

Aims of Material Handling: The aims of material handling are as follows:
• To economise the cost of material handling.
• To minimize the time intervals and transferring the products with accuracy
in time and position.
• Maximum utilization of material handling equipment and to reduce
manual handling.
• To Increase the efficiency and effectiveness of plants through material
handling unit
• To increase industrial safety in material handling through improvement in
working conditions.
• Prevention of damages to materials and workers in work places
• To lower the maintenance cost of the handling equipment
Objectives
After Studying this unit, you will be able to:
• appreciate safety in material handling.
• differentiate between manual material handling and mechanical
material handling; and
• discuss safety in manual, mechanical and electrical handling.

37
 Safety in Machinery
2.2 MATERIAL HANDLING: CONCEPTS AND
SIGNIFICANCE
2.2.1 Principles of Material Handling
The various principles of material handling are as following
1) Planning: A well chalked out plan should be in place to identify the
material for proper handling equipment, storing and to handle all related
activities.
2) Coordinating the Operations: Ensuring that all the handling activities
are carried out as per sequence and coordinating all operations.
3) Straight Line Layout: Maintaining the straight path as much as possible
to minimize the turning movements.
4) Space Utilization Principle: Plant space utilization should be optimum.
5) Unit Load Principle: Loading should be done based on the load handling
capacity.
6) Gravity Principle: Always prefer gravity to shift the materials where ever
it is possible.
7) Material Flow Principle: Prior planning should be done to sequence of
operation and equipment arrangement to optimize the flow of the material.
8) Simplification Principle: Use the simplest system and reduce/avoid
unnecessary movements of equipment.
9) Safety Principle: Inculcate the safest methods and equipment for material
handling to avoid accidents/injuries.
10) Special safety : Special safety is to be taken for movement of fragile,
inflammable, toxic, liquid or gaseous material.
11) Mechanization Principle: Minimize the manual handling, prefer
automated or mechanized equipment in material handling
12) Standardization Principle: Establish and fix the standard method,
technique, size and type of material handling equipment
13) Flexibility Principle: Opt for flexible methods and equipment to perform
various activities in an industry.
14) Equipment Selection Principle: All aspects regarding the material (load,
size & shape), movement and method are considered while selecting
equipment.
15) Dead Weight Principle: Reduce the ratio of dead weight to pay load in
mobile equipment.
16) Motion Principle: The Equipment designed should be kept in motion for
transporting the material.
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17) Idle Time Principle: Minimize the idle hours and the unproductive hours
of workers and equipment in order to enhance the productivity.
18) Maintenance Principle: To avoid breakdowns, there should be
scheduled, time based or preventive maintenance for all the material
handling equipment.
19) Obsolescence Principle: Replace the outdated methods and equipment
with the advance methods and equipment to improve the efficiency.
20) Capacity Principle: Choose handling equipment to carry the loads with
full capacity. This will reduce the repetitive movement of equipment.
21) Control Principle: Improve inventory control, production control and
other handling by using material handling equipment and techniques.
22) Performance Principle: The primary criterion in Material handling is to
calculate its performance efficiency. This should be in terms of cost per
unit handled.

2.2.2 Material Handing Equipments

Broadly material handling equipments can be classified into two categories,
namely:
a) Fixed path equipments,
b) Variable path equipments.
a) Fixed Path Equipment
In fixed path, equipment travels along a specified path. Mostly conveyors,
monorail devices, chutes and pulley drive equipment are belonging to this
category. A slight variation is provided in this area by the overhead crane,
which though restricted, by virtue of its design, can move materials in any
manner within a restricted area. Overhead cranes have a very good range
in terms of hauling tonnage and are used at the time of palletizing for
handling bulky raw materials and stacking.
b) Variable Path Equipment
The path of travel of this equipment is not restricted for the movement.
But the equipment size is the major factor which is to be considered
majorly. Trucks, forklifts, mobile cranes and industrial tractors belong to
this category. All this equipment is available in many ranges, they are
maneuverable and various attachments are provided to increase their
versatility. Table 2.1 shows the difference between Fixed Path and
Variable Path Equipments.

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 Safety in Machinery Table 2.1: Difference between Fixed Path and Variable Path Equipments

Fixed Path Equipments Variable Path Equipments

1 These equipments move in a fixed These don’t have any restriction in

path. movement and direction. They can
move wherever sufficient space is
available

2 Modification is required in handling No modification is required in the

system if there is any change in the handling equipment when the plant
plant layout layout is redesigned.

3 Example: conveyors, pulley drives Example: Forklifts, trucks

2.2.3 Significance of Material Handling

The most significant aspect of material handling is that it enhances both the
productivity and profitability and improves the safety. Improper material
handling techniques and practices lead to low productivity and the enterprises
may have to shut down their firms it they won’t follow proper techniques and
practices. The safety practices must be ensured as per safety rules. Otherwise
due to violation and negligence of safety, the government authorities may
cancel the license. The volume of material handled may vary from small
cartons to large castings. Industries like steel manufacturing, mining,
construction, aircraft etc., involve huge and bulk materials and these industries
cannot function without a proper material handling system. Further, in order to
sustain in the present competitive business world, industries have to improvise
the old and conventional equipment with the latest and advanced material
handling equipment. Proper and well-designed handling equipment are used to
achieve the following:
• Delivery of material and right quantity, place and time.
• Reduction in labor cost.
• Eliminating damages during storage or delivery of the product.
• Minimizing inventory cost and to maximizing space utilization.
• Following safety norms to avoid accident, human injury and sudden
damages.
• Minimization of overall cost in the plant.
• Enhancing efficiency and production yields and plant handling systems.

2.2.4 Limitations of Material Handling

The limitations of material handling are given below:
• Apart from general equipment cost, investment is needed in material
handling equipments.
• Further, flexibilities and improvisations cannot be done greatly once the
system is installed.
• With an integrated material handling system, any failure/stoppage leads to
increased downtime of the production system.
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• Material handling system needs periodic maintenance; hence additional
cost may incur for it.

2.2.5 Systems Concept of Material Handling

Material handling is an integration of all the systems to make a complex body.
The word “system” in this backdrop can be defined as a complex unit
composed of many sub parts that are used to serve a common purpose. The
subsystems which are called parts should function properly for the efficient
usage of the system which indirectly enhances the handling efficiency. If an
industry is considered, material handling is a part of the manufacturing
process.
The system concept involves different handling equipment needed at various
locations in an industry by considering associated customers and suppliers end.
An engineer, who works for material handling, should have a brief idea to
maintain a plant in order to optimize the conditions which are faced in a plant.
His solutions should be economic and effective in handling the materials. The
solutions should not only be useful for a particular plant, but also be feasible
for further research.

2.2.6 Elements of Materials Handling

The elements of material handling are as follows:
• Movement – This is the actual transportation of material from one point
to another.
• Quantity – This Ensures the type of material handling equipment to be
used the cost per unit.
• Time – Time taken for material to be shifted to the work point and also
materials queue to be processed and space that the materials can be stored.
• Control – tracking of the material, selection of proper material handling
units, handling required quantity to avoid the shortage and time dependent
issues to be considered to increase the profits.
• Safety - Improve the safety of man and material.
• Analyze – the drawbacks in material handling system should be rectified
and analyzed (if any) by proper decision making, which will help in
various aspect.

2.2.7 Advantages of Correct Materials Handling

The following are advantages of correct material handling:
 Proper utilization of space to store the goods
 Better inventory control
 Enhancing the working abilities
 Qualitative goods
 Reduction in risk factors
 Time management
 Cost reduction
 Idle time reduction
 Safe transportation

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2.2.8 Method Oriented Systems of Material Handling
In production methodology the material handling methods of systems can be:
• Manual Handling Systems
• Mechanized Systems
• Automated Handling Systems
• Function Oriented Systems
• Job-shop Handling Systems
• Mass-production Handling Systems
The systems can be defined according to the material handling functions like:
• Transportation Systems
• Conveying Systems
• Transferring Systems
• Elevating Systems

2.2.9 Selection of Material Handling Equipment

The following factors should be considered while selecting material handling
equipments:
1) Material
a. Material Type
b. Properties
c. Chemical Actions
2) Plant
a. Plant Layout
b. Building Orientation
3) Nature of Operation
a. Operation Sequence
b. Volume of Production
c. Flow ( i.e, Intermittent or Continuous)
d. Distance to be Handled
e. Travel Path
f. Type and Extent of Movement
4) Safety
a. Safe transportation of material
b. Safety of humans against accidents
c. Safety provision of handling equipment.
d. Safe from pollution point of view
The following are additional factors that should be should be considered while
selecting material handling equipments:
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a. Adaptability: the equipment should be fit for the material handling
problems like load carrying without any damage to the product.
b. Flexibility: the equipment must be flexible to handle variety of sizes and
goods.
c. Load capacity: material handling equipment should have the capability
to carry bulk and heavy loads within the rated cost.
d. Power: Enough power to do appropriate work
e. Speed: Suitable material handling is selected for quick response of the
product movement to the work points within the work space.
f. Supervision Required: In the selection of material handling units, an
automatic design as per requirement and ease of maintenance at a rated
cost should be considered.
g. Environment: Selection of equipment should be eco friendly as per our
environment regulations.
h. Cost: The selection should be based on how much is the cost and how
much is the worth of it.
i. Safety: The handling equipment must be safe for human and material for
handling fragile, toxic, inflammable, liquid or gaseous materials

SAQ 1
a) Define material handling.
b) List some principle of material handling.
c) Distinguish between fixed path and variable path equipment.
d) What are the advantages of material handling?
e) List some factors affecting the selection of material handling
equipment.

2.3 CLASSIFICATION OF MATERIAL

HANDLING
The process of material handling can be done either by man or by using some
specially designed equipment/machine. In most cases material handling is done
by using some machinery for the purpose of safety. Some of the equipment
used for material handling is palter jacks, forklifts, conveyors, cranes etc.,
which make the job easier and more efficient for the employees working in
warehouses, factories, distribution centers etc., but when not utilized properly,
this heavy machinery can also put the safety of material handling in jeopardy.
Based on the medium/agency in which the material is moved, material
handling system is majorly classified into two categories:
i. Manual material handling
ii. Mechanical material handling

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 Safety in Machinery Manual Material Handling
Manual material handling activities are defined as unaided human acts of
pulling, pushing, lowering, lifting, carrying, holding or releasing an object. In
simple terms, it is defined as unaided motions of objects combined with
twisting and awkward postures. Some of the activities that are associated with
manual material handling are moving trolleys, packing stock, stacking shelves,
lifting and lowering the load are as shown in Figure 2.2. The main driving
source of doing such jobs manually is the muscular force exerted by a person.
Mostly it is assumed that manual material handling is the best option as no
extra investment is needed. But most of them are not aware about the risk
associated with manual material handling operations. The direct cost is low in
manual material handling but the workers have to pay more if they sustain an
injury. Due to the human elements involved, the Manual Material Handling
(MMH) can lead to various hazards. The hazards are due to improper handling
methods like slipping, falling or dropping of loads which may lead to injuries.
MMH has been recognized as a major source of hazard to workers by many
authorities on occupational health and safety.

Figure 2.2: Manual Material Handling

• Manual Material Handling Hazards

The hazards associated with improper manual material handling include
a) Being struck by a load,
b) Losing control of load,
c) Physically overexerting oneself, and
d) Exceeding equipment capacities.
The above hazards may lead to accidents or injuries. Strains and sprains may
occur due to improper lifting or carrying of loads which are too heavy. If the
worker is struck by the load, then the worker may suffer from fracture or
bruises. Also, cuts and bruises may be caused due to the falling of material
which is stored improperly. Some of the common injuries that occur due to
manual material handling are as follows:
a) Strains and sprains
b) Neck and back injury
c) Slips, falls and crush incidents
d) Cuts, bruises and acid burns
44 e) Hernia and broken bones
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f) Occupational overuse syndrome (OOS)
The injury doesn’t happen for the lifting of only heavy loads. In some cases
infrequent lifting may also result in injuries. Manual handling injuries make it
very inconvenient for employees to perform lot of work due to improper health
conditions. Apart from the above stated injuries, MMH operations may also
lead to musculoskeletal disorders (MSD).
• Effect of Manual Materials Handling
The effect of manual material handling can be seen more on aged workers
working in an industry than the young ones. The probability of getting
injuries for young and old worker may be same. But if a young worker
sustains injury, he may be able to cope with the strains and sprains and
recover faster as he is young. At this stage, younger workers working with
manual material handling system will get affected less if they sustain an
injury. Continual pains or muscular aches may indicate that there is an
excessive physical stress in aged workers.

2.4 RISK FACTORS ASSOCIATED WITH

MANUAL HANDLING ACTIVITIES
The associated risk factors with the activities of manual handling may increase
the likelihood of the worker getting injury. These factors may also make
manual handling of loads hazardous and enhance the risk of musculoskeletal
injury. The factors that contribute to the manual handling injuries are grouped
into five categories. They are as follows:
1. The load
2. The task
3. The work environment
4. Organizational and psychological factors
5. Individual and lifestyle factors
Risk factor 1: The load
In MMH, the load is the primary risk factor as carrying huge and bulky loads is
very difficult for the worker. It may slip from the hands of the worker and may
cause injury and also damage the material. It may also make an unstable
movement which may cause damage to other workers. Also, carrying the loads
with sharp edges and which is hot, toxic may also cause the injury to the
workers.
The following points are to be noted while considering load as a risk factor.
• Do not carry huge, bulky loads
• Avoid loads which are difficult to grasp
• Don’t carry the loads which makes an unstable movement
• Avoid the load which causes harm, e.g. sharp, hot objects
• Avoid the loads which are too large for the handler to see over or around.
Risk factor 2: The task:
Handling a material and moving it from one place to another is a task/activity.
Most of the workers working in an industry may make mistakes while
performing the task. They try to carry the load holding near to the body and
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 Safety in Machinery some may make awkward postures. Some others may carry the load for long
distances which is not preferable as far as safety is concerned.
The following points are to be noted while considering this factor.
• Always hold the loads away from the body;
• Hold the load with proper protection and tools
• Do not make awkward and static postures, e.g., working with hands above
shoulder level, sitting;
• Don’t apply high forces, e.g., lifting, carrying, pulling, pushing and using
tools;
• Don’t carry the load for long distances;
• In case of more persons are engaged, the proper selection and posture of
people is required for balanced loading on each person.
Risk factor 3: The work environment:
The ambience of the working area is also an important factor when safety is
considered. The primary factor is the space. If the space of the working area is
limited, then the chances of getting stuck by the load are more and it also make
the movement inconvenient. The neatness of the floor and the lighting
condition are also vital to avoid the accidents/injuries. If the substances like oil
and grease are thrown on the floor, then the workers may slip and injur
themselves. So, the floor of the working area should be kept neat.
The following points are to be noted while considering this factor.
• Avoid cold or excessive heat.
• Always make sure that the space for the movement is not limited and
allow for free movement.
• Avoid vibrations and its intensity.
• Perform the activity on the platform or the floor which is neat and non-
slippery.
• Don’t perform the activity in poor lighting conditions.
• Make the workplaces non-noisy.
• Prevent the workplaces from gusts of wind or other strong air movements.
Risk factor 4: Organizational and Psychosocial factors:
The organizational and psychosocial factors are also important for safety. The
management and co-employees behavior may also impact safe working.
Employees may lose their concentration while working due to improper
behavior of management. This may make the worker dissatisfied and enhance
the chances of error which is dangerous. Also an employee’s psychological
wellbeing has a great impact on the safety. The management must ensure
proper supervision, tools and protection through the use of kits, gloves etc. to
ensure safety which gives a psychological boost up to the employees
The following points are to be noted while considering this factor.
• Have a high level of control over the works to be performed
• Ensure job satisfaction.
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• Try to avoid repetitive works
• Maintain friendly relations with colleagues and managers.
• Don’t perform the work continuously for a long time.
Risk factor-5: Individual and lifestyle factors:
The above said factors are majorly related to the organization and its system.
But this factor is no way related to the organization. Every employee has his
own background, in terms of health, finance, family, habits etc., these may also
have a significant impact on the safety.
The following points are to be noted while considering this factor.
• Maintain good health.
• Avoid smoking.
• Be trained before you handle the jobs.
• Enhance your physical capabilities.
• If you are a female, take a long leave during pregnancy.
• Handle the works as per your age.
• Stay free of agony as much as possible.

2.4.1 Controlling Manual Handling Problems

a) Minimize the weight and size of packing
Generally, cement is available in 50 kg bag. If this could be reduced to a
smaller one weighing 25kg, then it can be handled and lifted more easily
than the 50 kg bag.
b) Reduce multiple handling
Minimize the number of times an object/good is handled. If possible try to
see that the stock is displayed immediate after the delivery.
c) Maintain correct height at work
Always use sturdy, stable and step stools to make access goods which are
kept at heights.
d) Minimize push/pull forces
Workers should limit the number of shopping trolleys to be collected at
one time by employees.
e) Training and Education.
Training, guidelines and supervision should be given to the young and
newly joined workers to prevent manual handling injuries. Workers should
be trained and educated in the following:
i) Manual handling hazards
ii) Safe methods of manual handling
iii) Procedures for safe working
iv) Using manual handling aids
v) Right to ask for help

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 Safety in Machinery f) Safe working procedures
Employers have to draft the procedures for safe working by taking help
and feedback of the experienced staff in order to take care of
inexperienced and newly joined workers.
g) Keep informing
If an employee is new to his job, he has the responsibility to keep
informing to his higher authorities if they feel that the job is hectic,
difficult and unsafe or causing too much strain.

2.4.2 Ways to Reduce the Risk

The following are the ways of reducing risk at work:
a) Lighten loads (break loads in to smaller quantities);
b) Reduce bending, twisting, reaching movements and heights
c) Prevent muscle strain and fatigue. This includes warming up before
working, allocating time for rest breaks, and allocating time to gradually
get used to a new job.
d) Use of proper tools and aids
e) Proper layout of release point, delivery point, storage and movement path.

2.4.3 Methods to Prevent Back Injury in MMH

The implementation of the following methods can keep back injuries at bay:
• Always prefer diagonal foot position.
• Keep the load close as to you as possible.
• It is easy to move the load which are at waist height
• Stacking pallets to raises the height of the load is an ergonomic solution.
• Use scissor lift, which raise the load mechanically to a comfortable lifting
level.
• Avoid repetitive lifting of load from the floor.
• When standing up with a load, hold the load close to your body.
• One can take the additional support of knee when lifting a load with
handle. Also use diagonal foot position
• One should try to keep the loads as close to the center of gravity (C.G) as
possible.
• In case of longer materials, one should carry the loads on one’s shoulder,
which keeps one safe. For example, lifting construction poles and long
bars.
• It is easy to carry loads by both the hands having same weight. This will
balance the load, but the weight of the load should be reasonable.
• While climbing up on a ladder with a load, always maintain a “three-
point” contact. That is, both feet and a hand or two hands and a foot
should be in contact with the ladder.
• Most manual material handling is done by pushing or pulling the load.
Pushing is preferable than pulling makes the back easy and light.
• When there is a need to push a load, one should use arms and legs. This
will provide the leverage to start the push.
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• It becomes easier to push, if the handle is ideally above the waist.
• If the load is to be pulled, keep the handle of the cart at your side. This
will minimize the twisting of lower back.
• One must not try to lift or push or pull the load with jerk or imbalanced
hold.

SAQ 2
a) What are the risk factors associated with manual material handling?
b) List out some methods to prevent back injury in MMH.
c) Write down the different ways to control manual material handling
problems.

2.5 SAFETY CONSIDERATIONS IN MANUAL

MATERIAL HANDLING
Many jobs require frequent lifting, carrying, pushing, pulling, lowering and
raising materials by hand. These job tasks are often referred to as manual
material handling. Staff who lift or perform other materials handling tasks may
be at risk of back or other injuries. These injuries may be prevented by
redesigning jobs and practicing safe handling techniques. The layout of the
work area and the load handling geometry are two main considerations in
manual handling. These are discussed below:
i) Layout of work area
The layout of work area plays a prominent role in safety. The layout of
work area is said to be perfect, if it is arranged in such a way that, it should
prevent postures such as twisting, bending and overreaching. The height of
the working platform should be at a waist height or it can be adjustable for
preventing bending. The space around the work area should be sufficient
for easy moving and turning around and to prevent twisting. Storing of
materials directly on the floor that are to be lifted manually will cause
back injury. For this reason, racks should be provided at faceable height in
the work area for storing of materials to prevent back injury.
ii) The power zone
For the safe and effective lifting, the load has to be carried in a certain
boundary. The region within the boundary is known as power zone. This
zone is between the mid chest and mid-thigh and is generally very near to
the body. The region above the power zone boundary can be termed as
danger zone. The power zone and danger zone are as shown in Figure 2.3.
Most loads can be lifted by the arms and back in power zone with less
effort.

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Figure 2.3: Power Zone and Danger Zone

2.5.1 Safety Tips for Manual Material Handling

a) Check the Load before you Lift it
i) Always check the load or the material (object or carton) before lifting
it (Figure 2.4). This will help you to find the damages if any.
ii) After checking, push the load slightly by the hand to see whether it
moves easily or not. This will help you to know how heavy the load
is.
iii) One has to note that, a small object does not mean it’s a lighter load.

Figure 2.4: Checking Load

b) Ensure that the Load is Packed Correctly

i) Workers packing the boxes have to make sure that the weight of the
load in the boxes should be balanced and properly tightened so that
it will not move around.
ii) If the box consists of loose pieces, it makes the box unbalanced and
can cause accidents.
iii) The fragile materials eg. glass items or electronic goods are to be
packed with proper package material eg. Bubble sheet and packing
box and marked “handle with care”.
iv) Proper marking is to be made on the packing box if the material is to
be kept in particular orientation
The proper way of packing is as shown in Figure 2.5.
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Figure 2.5: Proper way of Packing

c) Ensure that the Object is Easy to Reach

It is preferable to use step stools and ladders as shown in Figure 2.6 when
you are lifting the load above you height. In some cases, workers will arch
back to lift the loads. This will result in the back injury.

Figure 2.6: Step Stool and Ladder

d) Test the Load
To ensure whether the load is too heavy or light, it is better to test the load
before lifting it. If you feel that the load is too heavy, then you may ask the
co-workers for their assistance as shown in Figure 2.7.

Figure 2.7: Test the Load and Take Help

e) Plan Your Lift
Improper lifting may cause joint pains. So before lifting the load, the
worker has to plan for the lift as shown in Figure 2.8.
i) Initially the worker has to look into the weight of the material being
lifted, shape and size of the object and the space where the load has to
be moved.
ii) Also worker should have an idea about the hazards (if any) that occur
during the travel. Further, workers should discuss and analyze them to
eliminate them.
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 Safety in Machinery iii) Know the route that your travel. Check if there are any stairs,
obstacles or doors in between.

Figure 2.8: Plan Your Lift

f) Lifting Properly

Stand very near to the load with your feet

Step One spread about shoulder width apart. Keep One
foot slightly in front than the other foot, for
proper balance.

Bend the knees (not the waist), and sit down.

Step Two Hold the load. Keep your back as vertical as
possible.

Step Before you lift the object, hold it tightly with a

Three firm grip

Slowly begin, lift the load with your legs by

Step Four straightening them. Never twist your body
during this step!

Once lift is complete, keep object as close to

your body as possible. As the load's center of
Step Five gravity moves away from the body, there is a
dramatic increase in stress to the lumbar region
of the back.
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g) Team Lifting
When two or more persons are involved in lifting a load, then it is said to
be team lifting is as shown in Figure 2.9. Choosing a team lifting
technique is the better option if there is no appropriate solution for
handling a material. It is said that the total team strength is lower than the
sum of individual worker strength. Team lifting is chosen if
• There is a heavy load
• There is a irregularly, bulky loads
• Worker feels uncomfortable in lifting the load
In team lifting, the team members should be of same height. If there is a
difference in the height, then taller people have to be at back side. It is
advantageous to nominate a lift leader. The lift leader should plan and
organize the lift, give simple and clear directions and ensure that all
members lift and lower the object at a time. Also the lift leader must
ensure that it is convenient for the team to lift the load. If it is not so, then
the team members should lower the load carefully.

Figure 2.9: Team Lifting

h) Caution during Team Lifting

Team lifting should be carried out with utmost caution, as there are more
chances of getting injured due to falling, slipping, tripping and dropping.
The team members should confer the plan of lift before they begin the
process. They may communicate verbally to give the instructions, which
will be helpful in initiating the actions and also warning of hazards if any.
2.5.1.1 Planning Ahead
i) Before you move the load from one place to another, it is better to plan the
route. This allows you to analyze the route safety, limitations, hazards etc.,
ii) Also analyze the shape and weight of the load and ensure that the
movement of load is smooth and continuous.
iii) Before you move or lift the load, analyze the following questions
• Do you need any assistance?
• Is the shape/weight/size within your limits?
• Are you able to see the route?
• Do you require any safety measures?

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 Safety in Machinery One has to plan the following two factors before moving a load
i. The route
ii. The drop off Point
2.5.1.2 The Route
Plan the route in which you move the load. Unexpected interruptions while
moving the load may result in property damage or injuries.
Considerations for planning the route:
- Check whether there are any steps, closed doors or congested
passageways.
- Check if there are any steep corners or wet floors.
- Know the traffic situation.
2.5.1.3 The Drop off Point
See that the load will not block the traffic when it is placed. Check whether the
place is sufficient or not to place the load. Ensure that the load will not create
any hazards when it is placed.
i) Lowering the Object
Important considerations to remember while lowering an object is to avoid
bending at the waist. Instead bend at the knees. Also avoid twisting
movement when lowering the load down. If you want to turn when
lowering a load, don’t twist your back. Rather adjust your feet.
The following Figure 2.10 illustrates how not to put a load down.

Figure 2.10: How not to put a load down

2.5.2 Some more Safety Considerations

The following are a few more safety consideration to adhere to:
1) Stacking
While stacking, ensure that the base is neat and clean, and is straight.
Don’t stack the load above the height limit and never crush it.
2) Drums
Use a lift truck to move the drums, even for a short distance. When
moving empty drums individually don’t roll on the rim, instead, roll on the
side.
3) Cylinders
Valves must be protected by a proper safety cap. Use a special hand truck
to move individual cylinders, and “walk” them only short distances to
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align them. Cylinders must be stored in designated areas and secured with
safety chains or bars as shown in Figure 2.11.

Figure 2.11: Cylinders Safety System

4) Mechanical Aids
Often the best way to move loads is with a mechanical aid, like a hand
truck or rolling cart. Choose the right aid for the job and inspect it before
use. Place the heaviest items on the bottom, with the weight concentrated
between the wheels. Keep your hands away from the edges so they won’t
be scraped or crushed in the doorways.

SAQ 3
a) What do you mean by team lifting?
b) What consideration should be followed for safe handling of material
manually?

2.6 MECHANICAL MATERIAL HANDLING

As discussed earlier, materials can be handled either manually or
mechanically. If the amount of material to be carried is small and easy, then it
is preferable to carry them manually. But some materials are huge and bulky
and carrying them manually is an impossible task. In such cases, materials are
handled using some mechanical means. In mechanical handling, material
movements are done by using some specific equipment/machines to lift or
transfer/move the materials. A variety of equipment are available for handling
materials mechanically and these equipment vary depending on the type of
material to be handled and the type of field where the equipment is used. At an
outset, mechanical material handling can be defined as,
“Mechanical material handling is the movement of the products or
materials or things by using the mechanical equipment’s such as trucks,
hoists and conveyors etc.”

2.6.1 Mechanical Material Handling Equipment (MMHE)

In most of the industries and construction sites, MMHE forms the basis for
majority of the tasks performed. These industries use variety of equipment like
hydraulic excavators, dozers, bulldozers, tippers, cranes, vibratory compacters,
dump trucks, graders, forklifts, drills , rope shovels, pavers, asphalt mix
plants, wheel loaders etc. Hence safety management is the main criteria to run
the industry or plant. MMHE at work performs transporting, lifting,
loading/unloading or other associated activities which should be performed
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 Safety in Machinery with utmost care. Any negligence or mistake may lead to accidents or injuries
or damages.

2.6.2 Classification of MMHE

Depending on the movement of the equipment, load carrying capacity,
automation, shape and size and type of material to carry, the material handling
equipment is broadly classified into five major categories. They are-
i) Conveyors
ii) Industrial trucks
iii) Cranes and hoists
iv) Containers and
v) Robots
i) Conveyors
Conveyor is a device that transports some sort of material from one place
to other. The different conveyor systems used for different materials
transportation are shown in Figure 2.12. These are useful for transferring
the materials continuously or intermittently in between two work areas. In
general they are mostly used for continuous or mass production operations
especially for the operations where the flow is more steady. Different
kinds of conveyors are avasequential operation properly.

Figure 2.12: Conveyors for Hanlding Different Materials

ii) Industrial Trucks
Industrial trucks are not permanently fixed in one place and they can travel
between various workstations. An Industrial Forklift and a Dumper
Vehicle are at work for handling different materials are shown in Figure
2.13. Industrial trucks are more flexible in use as compared to conveyor.
Because of this reason, industrial trucks are most suitable for intermittent
production and for handling various sizes and shapes of material. These
trucks may be driven by means of fuel, electric power, hand power etc.
The materials may be overflown during the truck movement. Hence proper
caution is to be taken that overflow of material does not happen.

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Figure 2.13: Industrial Forklift and Dumper at Mining

iii) Cranes and Hoists : Cranes and Hoists are the equipments that carry
heavy materials through the overhead space are as shown in Figure 2.14.
But, the space of its movement is limited. Based on the loading capacities,
cranes and hoists can be classified into several types. Cranes and hoists
can be used both for intermittent and also for continuous production. Lot
of safety precaution eg. Adequate Crane movement. path, proper holding
of too bulky material etc is to be taken as there are scope of accident in
this type of material handling.

Figure 2.14: Cranes and Hoits at Industrial and Contructional Site Containers
iv) Containers
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 Safety in Machinery These are either dead containers are shown in Figure 2.15 (e.g. Cartons,
barrels, skids, pallets) which do not move themselves and just hold the
materials and to be get transported, or liver containers (e.g. wagons,
wheelbarrows or computer self-driven containers) and is usually operated
manually. This equipment can both contain the materials and move it
further.

Figure 2.15: Containers

v) Robots
There are many types of robots with different sizes, different in
functioning and maneuverability. Robots can be used for material handling
and to transport the products and also it can perform machining, welding
and spray painting operations. The main advantage of the robots is that
they can perform the work in any hostile environment and can easily carry
repetitive and heavy works with the speed and accuracy.

Figure 2.16: Robots in Material Handling

2.7 SAFETY IN MECHANICAL MATERIAL

HANDLING
Safety in mechanical material handling forms an important necessity in an
industry. The equipment used in industry for handling materials can be
categorized as heavy duty and light duty based on their load carrying capacity.
Every equipment has several built in features of safety which differs from one
manufacturing agency to the other. Due to the lack of awareness and
knowledge, irregular maintenance policies and operation errors the violations
in safety procedures are increasing. Further, human elements also play a
prominent role in causing damages and injuries/accidents while handling
material mechanically. The damages or the injuries that are caused by
mechanical material handling are more sever when compare to the damages
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caused by handling materials manually. So there is high necessity to know the
hazards and its methods of prevention for safe handling of materials.

2.7.1 Risk Factors in Mechanical Material Handling

Handling of materials by means of mechanical equipment involves lots of risk
factors. These risk factors lead to hazards which are to be considered for the
safe handling. Safety in mechanical handling is much more important that
manual handling because of the involvement of heavy machines, trucks etc.
Due to the lack of skilled man power and experience, the equipment operation
would be high complicated task that results in the breakdowns or in some cases
it may lead to accidents in the field. For this reason, the management and
employees must be focused towards the safe handling of the materials and
equipment. There are four risk factors associated with mechanical material
handling. They are
i) Equipment
ii) Load
iii) Workplace
iv) Employees
Equipment
• It has to handle the loads either in lifting or shifting in terms of its
capacity.
• In order to avoid breakdowns or failures, it should be maintained properly
and inspected on regular basis.
• Equipment should not collide other machines or workers.
• The movement of equipment should be as per planned or designed route. It
should not travel into the restricted areas.
• Some heavy equipment consists large number of moving parts like gears,
pulleys, belts, etc., the chances of getting trapped between the moving
parts is more.
• Sudden failure in Electrical or hydraulic power may lead to severe
accident.
Load
• To eliminate the possibilities of accidents, the load carried by MMHE
should be limited.
• Depending upon nature of load, required caution must be mentioned.eg:
flammable substances, explosives or health hazardous chemicals etc.
• The load should be properly arranged and fit in the equipment for its
stability, so that it will not slide down.
The workplace
• The workplace area should be spacious for the easy movement of
equipment and workers.

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 Safety in Machinery • Maintain the maximum free space to avoid collision between persons to
machineries and with the moving loads.
• Should be designed so that if situation arises the workers and loads are
kept apart.
The employees
• Proper skillful employees must be appointed to operate the heavy handling
equipment.
• Any mistake in the operation of the equipment may lead to accidents. Also
any faults made by the workers or operator may damage the equipment or
may be lead to damage of entire unit. To avoid such possibilities, the
operators should be properly trained.
2.7.2 Mechanical Material Handling Equipment: Hazards and Its
Control
A. CRANES
Cranes are used for the intermittent flow to transfer the loads over the
horizontal and vertical paths within a specified area. These equipments
are highly flexible in the movement when compare to conveyors and on
the other hand less flexible when compare to trucks. Any loads of
different shape, size and weight can be handled with the cranes. Most of
the cranes use hoists for vertical alignments.
Reason of Cranes Failures
Over turning
Over turning will occur due to weak support, striking the obstructions and
strong winds. Also operating the cranes more than its capabilities will also
result in overturning.
Overloading
This is occurring when the cranes are equipped with the loads beyond its
operated limit or safety limit.
Collisions
This occur when crane collides with other equipment, cables and transformer
power units or electric poles.
Support or floor failures
When the cranes are moved on or parked on the weak floors or weak solid
ground floor, this failure occurs. The failure of structural components in crane
will result in support failures.
Operating errors
Errors due to physical disability of operator like poor eyesight or inadequate
training of operator will result in such failures. Different types of Crain
Failures are shown in Figure 2.17.

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Figure 2.17: Different Types of Crane Failures at Workplace

Control of Hazards
• Every crane must be tested and certified by clearly marking of safe load
limit etc., generally it is done at the time of equipment manufacturing. But
the selection or identification of equipment will be based on required
working condition.
• Proper maintenance has to be carried out on regular basis. If any faults are
identified, repair must to be done immediately and has to maintain the
statistical data for further analysis.
• A number of safety measures should be incorporated for the safe operation
of the crane.
• Operating areas has to be checked to avoid the possibilities of collisions
with overhead tanks, electric poles, power supply units and with the other
equipment or structural components.

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 Safety in Machinery • Crane operator has to be strong and fit by means of physicality and
mentality. He must be well trained and follow safety mode conditions and
should have clear visibility in running the crane when loaded.
B. HOISTS
Hoists are the mechanical linkage that holds and supports the load within
the confined space. These are referred as end of device tools that connect
the load to the device. Hoists are not preferred when the load has to be
shifted for load distances or when the workplace is fully occupied with the
devices or workers. Hoists types include balancing hoists, triaxial
manipulators and overhead trolley suspension hoists.
Reason of Hoists Failures Striking Obstructions
Improperly projecting of hoist’s platform/cage into the space will result such
failures
Structural failure
If the hoist operates beyond its capabilities, these failures will result.
Overloading
By exceeding the operating capacity or by failure of safety devices this type of
failure occurs
Loss of load
Loss of load occurs if there is an excessive bumping of hoist platform
Collisions
These occur when hoist collides with overhead cables and electrically loaded
platforms
Operating errors
Errors due to physical disability of operator like poor eyesight or inadequate
training of operator will result in such failures. Different types of Hoist failures
are shown in Figure 2.18.

Figure 2.18: Hoists Failures

Control of Hazards
• It is advantageous to maintain records of maintenance and inspections for
future analysis.
• Solid supports should be placed under the ground level hoistway and
62 approach areas
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• Training should be provided for the safe operation of the particular
equipment
• A number of safety measures should be incorporated for the safe operation
of the hoist.
C. FORKLIFT
Forklift is a material handling truck having large metal forks at the front
end which is used for carrying and raising the loads. Most of the forklifts
operate on rear wheel steering mechanism to increase the maneuverability
in tight cornering situations.
Reason of Forklift Trucks Failures
Overturning
Overturning occurs when driving at too high speed, driving down the ramp
with the load or by sudden breaking
Overloading
If the truck exceeds maximum lifting capacity, overloading arises
Dangerous stacking
This failure will destabilize a complete racking column
Floor failure
An uneven floor or ground will result floor failure. This may also occur by
exceeding the load capacity of the floor. Different failures of forklift trucks are
shown in Figure 2.19.

Figure 2.19: Forklift Failures

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 Safety in Machinery Physical Hazards Related to the use of Forklift Trucks
• Noise factor is due to poor silencing of the engine unit
• Exhaust fumes problem occurs when maintenance is poor
• Vibration problems is mainly due to uneven surfaces and badly inflated
tyres and a weak structural design
• Ergonomic hazards such as musculoskeletal injuries caused by the bad
road surface, holes or cracks on the path.
Control of Hazards
• Training should be provided for operators in the safe operation of their
equipment, followed by certification.
• Warning lights and/or sounds while reversing of vehicle should fitted
wherever possible.
• Make sure that fuel filling and battery charging areas should be well
ventilated and lit with no smoking.
• Regular maintenance has to be carried.
D. CONVEYORS
Conveyors transport the material from one workstation to another.
Conveyor works either by gravity or electrical power. Conveyors won’t
perform the lifting or lowering operations and hence require workers to
perform such operations. In some cases, conveyors may combine with the
lift cables or hoists to facilitate lifting and carrying operations. The
following are some hazards related to conveyors are shown in Figure 2.20
Power Transmission Hazards
Conveyor consist many moving and rotating parts that includes pulley belts,
couplings, sprockets, chains and shafts. Power transmission hazards are
associated with the parts between the motor and drum. Crushing, dragging or
entanglement with rotating part may result in severe injuries.
Other conveyor moving part hazards
These hazards are associated with in-running nips and moving conveyor belt.
This may result in dragging into in-running nips or being struck by ruptured
belt.
Confinement zone hazards
These hazards results in crushing and shearing between the load and a fixed
object
Moving load hazards
When the hands of the workers come in contact with the moving load, these
kinds of hazards may arise. This results in crushing and shearing between the
fixed walls and the load.
Moving sub-assembly hazards
This occurs when the conveyor re-orients or changes the direction of loads.

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Figure 2.20: Hazards Related to Conveyors

Control of Hazards
• Provide trip devices and nip guards
• Avoid wearing loose cloths while working near the conveyors
• Arrange fixed caps or guards on either side of the elevator and also around
the power drive.
• Provide bump caps wherever necessary.
• Remove the sharp edges.

SAQ 4
a) What is mechanical material handling?
b) What are the risk factors associated with mechanical handling?

2.8 SAFETY IN ELECTRICAL HANDLING

It is very important to take safety measures while handling with the electrical
equipment. A safe work environment is always important to the control all
hazards. Everyone must be very cautious while working with electrical
equipments. Safety precautions help in controlling your & other risk of injury
or death from electrical hazards. Safety must not be compromised and some
golden safety rules are to be followed.
Electrical safety is regulated by work place health & safety regulations which
state that every employer is responsible for ensuring employees are safe from
injuries and risk. No one could overstate importance of electrical safety
knowledge. It is imperative to know how to work safely with or within vicinity
of electricity. The basic guide lines must be followed to have safe & healthy
life.
The basic guide lines regarding safety measures in electrical handling are
discussed below.
1) Avoid Contact with Energized Electrical Circuits
Treat all electrical devices as if they are live or energized. Don’t try to
repair energized equipments, check whether it is de energized or not
before you handle them. It can be tested with the help of tester. The
electrical hazards include both unguarded equipment along with the
energized equipment, and sometimes unguarded equipment may become
energized. So never touch the energized circuit before testing. These carry
some of the warnings like “Shock Risk”, “Avoid Contact”.

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 Safety in Machinery 2) Away from Water
Most of the electrical accidents in and around the industries or residences
happen when people use electricity near water. When working with
electricity, try to avoid water at every instant. Never handle electrical
equipment when hands, feet or body are wet or perspiring or when
standing on a wet floor. Due to wetness in the body, the conductivity
characteristics will increases and conduction takes place. This may lead to
flow of electrical current. To prevent such electrical hazards, never touch
or repair any equipment with wet hands/feet, better use gloves instead.
3) Ensure Proper Insulation and Grounding
Proper insulation and grounding play a major role in safety measures
while dealing with electricity. In electrical wiring, insulation plays major
task for safety. The following instructions come under this group.
a) Don’t plug a bunch of wires into one outlet/extension cord.
b) Don’t use equipment with broken plugs and with frayed cords (worn
at end or edge).
c) Never use damaged insulation equipment.
d) Don’t yank an electrical cord from the wall.
e) Do make sure that all the cords are tucked away, neat and tidy
f) The equipment body and parts must be grounded properly so that the
operator or anybody touching the equipment do not get electric shock.
g) There should be no exposed electrical point.
h) Proper senior guidance must be needed for un-insulated parts.
i) Keep safety caps on all unused electrical outlets/cords

4) Check for the Mains Supply

Always ensure/check whether the main supply is turned off/not. If you are
working with any equipment in the industry or house hold activities,
always turn off the mains. If an individual comes in contact with a live
electrical conductor, do not touch the equipment, cord or person.
Disconnect power source from the circuit breaker or pull out the plug
using a leather belt. While working with electricity always turn off the
mains. If someone ON accidently it may leads to damage, hence it is very
important to put a sign on the service panel so that no one turns ON the
switch by accidently. There should be emergency stop switch on the
equipment

5) Appropriate Ratings of an Equipments

Proper ratings of circuit breakers, fuse or relays must be maintained.
Switch gear protection includes protection of circuit breakers, relays,
fuses, and these disconnect automatically when fault occurs i.e., when
situation of short circuit currents/over current occurs.
Hence, the appropriate fuse rating must be maintained. Normally for
protection of again short circuit/fault condition, fuse rating of 150% of
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 Job Saftety Analysis
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normal current circuit is selected. Current ratings plays major role in
protection of the circuit & designing becomes little lesser. Circuit with
10Amp current, 15Amp fuse will protect against short circuit.

6) Avoid Electrical Shock

Drain the capacitors before working near the circuit and keep the short
circuit on the terminals during the work to prevent electrical shock. Proper
grounding/earthing should be needed to avoid the electrical shock. Never
touch another person’s equipment unless, instructed to do so. Enclose all
the electrical contacts & conductors so that no one can accidentally come
into contact with them, this avoid shocks. Disconnect power source before
servicing or repairing electrical equipment to handle in safe way.

7) Wear Non-Conductive/Insulated Gadgets

When it is necessary to handle equipment that is plugged in, be sure that
the hands are dry and if possible, wear non conductive gloves, protective
cloths & shoes with insulated soles. Always use insulated tools while
working with electricity. Appropriate usage of goggles & rubber, non
conductive gloves while working on any branch is absolutely vital. Use
only tools & equipments with non conducting handles when working with
other devices.

8) Fiber/Wooden Ladders
Do look up and look out for power lines before climbing a tree. There may
be chances of passing high tension power cables through the tree branches.
Always use a bamboo, wooden or fibre glass ladders working on any
receptacle at heights in industries or residencies. Avoid usage of aluminum
or steel ladder or wet one.
9) Proper Soldering
Proper soldering must be taken into consideration while dealing with the
circuit boards. The solder iron must be handled carefully and after use,
keep the solder iron in its stand. It prevents from burns & other attacks.
Solder iron gets extremely hot and cause damage. Wear goggles and
gloves while soldering to avoid from fumes and sparks. It is better to
maintain non conductive gloves, and jacket for the protection while
soldering electrical equipment.
10) Usage of Storage Element Capacitor
Capacitor is an energy storage element in the form of electric field. While
removing a capacitor from circuit, it stores energy & it may not be
discharged properly and cause shock. The usage of tip of two insulated
screw drivers on capacitors terminals helps in easy way to discharge low
voltage capacitor. A 12V bulb can be used for high voltage capacitor, and
bulb will glow using lost of stored energy.
11) Avoid over Current/Short Circuit Faults
A GFCI (ground fault circuit interrupter) is a residual current device
(RCD). Always check all the connections of GFCI’s once a month. These
are used to help from avoiding shock hazards. It is designed to disconnect
quickly enough to avoid injury caused by over current/short circuit fault.

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 Safety in Machinery Over current conditions occurs when there is current rating above the set
up value of rated current.

12) Proper Underground Cable Connections

The ground faults are very common in underground cabling connections.
Through underground cable connections are very safe but it is a costly
affair. If any fault occurs in underground cabling, it becomes difficult to
find out the faulty region. Working with such cables are very dangerous &
harmful because the damp soil, which is around the cable, is not only
protective case but it is a good conductor of electricity. Use hand for
digging at the cable by wearing gloves. Do not dig by using spade. If so,
the wires get disconnected and the entire connection will be damaged.
Proper guidance must be needed while dealing with the underground
cables.

13) Avoid Metallic Tools

Never use the metallic pencils or rulers or metal watch bands and wear
rings when working with the electrical equipment. It is to be noted that
never show some of the electrical part pointing with metallic pencil. Use
only tools with non conducting devices/handles.
14) Basic Safety Measures
It is very safe to do work with only one hand, keeping the other hand at
your side or in a pocket, away from all conductive materials. This
precaution reduces the likelihood of accidents that result in current passing
through chest cavity. Enclose all contacts so that no one can accidentally
come into the contact with them. When it is necessary to touch electrical
equipment (over heated motors) use back of hand, thus, if shock were to
cause muscular contraction, you would not freeze to conductor.
15) Avoid Cold & Flammable Gases
Do not store highly flammable gases/liquids near the electrical equipment.
Minimize the use of electrical equipment in cold rooms or other areas
where condensation is likely. If it is used in such areas, mount the
equipment on a wall/vertical wall.
16) Avoid Loose Clothing
Do not wear loose clothing or ties near electrical equipment. Never handle
equipment with wet feet/body/cloths.

2.9 LET US SUM UP

Material handling is loading, moving and unloading of materials. Handling of
materials involves various operations such as dumping of coal with a dumper,
moving cartons with a forklift, loading off the bags from the truck etc.,
Improper material handling and storage may result in accidents or injuries and
material damage. That’s the reason; in any industry the safe operation of
material handling is vital. The main objective of safety in material handling is
to avoid the injuries or accidents while loading, unloading or transporting the
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materials from one place to another. Some of the equipments used for
materials handling are palter jacks, forklifts, conveyors, cranes etc.,
Based on the medium/agency in which the material is moved, material
handling system majorly classified into two categories, manual material
handling and mechanical material handling. Manual material handling is
defined as unaided moving of objects combined with twisting and awkward
postures. Due to the human elements involved, the Manual Material Handling
(MMH) can lead to various hazards. The hazards associated with improper
manual material handling includes being struck by a load, losing control of
load, physically overexerting oneself and exceeding equipment capacities.
Manual material handling problem can be controlled by reducing weight and
multiple handling of the load, maintaining proper height at work, training and
education the workers. The major problem in MMH is back injury and injury
due to imbalance. On the other hand mechanical material handling is the
movement of the materials by using the mechanical equipment’s such as
trucks, hoists and conveyors etc. Every equipment has several built in features
of safety. Due to the lack of skilled man power and experience, the equipment
operation would be high complicated task that results in the breakdowns or in
some cases it may lead to accidents in the field. Hence safety in mechanical
material handling is much prior than the manual handling. . Proper
maintenance has to be carried and every equipment must be tested and certified
by clearly marking of safe load limit. Training should be provided for the
employees for the safe operation of the particular equipment.
Apart from material handling, it is also very important to take safety measures
while handling with the electrical equipment. When working with electricity,
try to avoid water at every instant. Proper insulation is provided at the every
joint and openings. Always ensure/check whether the main supply is turned
off/not. Never use the metallic pencils or rulers or metal watch bands and wear
rings when working with the electrical equipment.

2.10 KEY WORDS

Musculoskeletal Disorders (MSD) - Musculoskeletal disorders (MSDs) are
injuries or pain in the human musculoskeletal system, including the joints,
ligaments, muscles, nerves, tendons, and structures that support limbs, neck
and back.
Adaptability: the equipment should be fit for the material handling problems
like load carrying without any damage to the product.
Flexibility: the equipment must be flexible to handle variety of sizes and
goods.
Power zone: The region within the boundary is known as power zone. This
zone is between the mid chest and mid-thigh and is generally very near to the
body.
Mechanical material handling: Mechanical material handling is the
movement of the products or materials or things by using the mechanical
equipment’s such as trucks, hoists and conveyors etc.
Conveyors: Conveyor is a device that transports some sort of material from
one place to other.
Cranes and Hoists: Cranes and Hoists are the equipments that carry heavy
materials through the overhead space.
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 Safety in Machinery Mechanical Material Handling Equipment (MMHE): industries use variety
of equipments like hydraulic excavators, dozers, bulldozers, tippers, cranes,
vibratory compacters, dump trucks, graders, forklifts, drills , rope shovels,
pavers, asphalt mix plants, wheel loaders etc.
Over turning: Over turning will occur due to weak support, striking the
obstructions and strong winds. Also operating the cranes more than its
capabilities will also result in overturning.
Overloading: This is occurring when the cranes are equipped with the loads
beyond its operated limit or safety limit.
Collisions: This occur when crane collides with other equipment, cables and
transformer power units or electric poles.

2.11 ANSWERS TO SAQS

SAQ 1
a) Material handling is an art that involves moving, handling and storing of
materials in an industry or a constructional field. In simple terms, it is
moving, loading and unloading of materials.
b)
i) Planned Principle
ii) Co-ordinate the Operations
iii) Straight Line Layout
iv) Space Utilization Principle
v) Material Flow Principle
vi) Simplification Principle
c)

Fixed Path Equipments Variable Path Equipments

1 These equipments move in a fixed These don’t have any restriction in

path the movement and direction
wherever sufficient space is
available

2 Modification is required in No modification is required in the

handling system if there is any handling equipment when the
change in the plant layout plant layout is redesigned.

3 Example: conveyors, pulley Example: Forklifts, trucks

drives

d) Advantages of Correct Materials Handling

• Proper utilization of space to store the goods
• Reduction in risk factors
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• Cost reduction
• Idle time reduction
• Safe transportation
e) Factors that affect the material handling equipments are as follows:
i) Adaptability
ii) Flexibility
iii) Load capacity
iv) Power
v) Speed
vi) Supervision Required
SAQ 2
a) The factors that contribute to the manual handling injuries are grouped
into five categories. They are
1. The load
2. The task
3. The work environment
4. Organizational and psychological factors
5. Individual and lifestyle factors
b)
• Always prefer diagonal foot position.
• Keep the load close to you as possible.
• It is easy to move the load which are at waist height
• Stacking pallets to raise the height of the load is an ergonomic
solution.
c)
i) Minimize the weight and size of packing
ii) Reduce multiple handling
iii) Maintain correct height at work
iv) Minimize push/pull forces
v) Training and Education.
vi) Safe working procedures
SAQ 3
a) When two or more persons are involved in lifting a load, then it is said to
be team lifting.
b)
i) Check the Load before you Lift it
ii) Ensure that the Load is Packed Correctly
iii) Ensure that the Object is Easy to Reach
iv) Plan Your Lift
SAQ 4 71
 Safety in Machinery a) “Mechanical material handling is the movement of the products or
materials or things by using the mechanical equipment’s such as trucks,
hoists and conveyors etc.”
b) There are four risk factors associated with mechanical material handling.
They are
i) Equipment
ii) Load
iii) Workplace
iv) Employees

2.12 REFERENCES AND FURTHER READINGS

[1] Material Handling Safelty, https://www.mccue.com/content/material-
handling-safety?utm_source=le_footer
[2] Chen.W, Zhang.G, “Safety management on hazardous material
transportation”,, 2014 International Conference on Connected Vehicles and
Expo (ICCVE)
[3] T. Xia, Z. He, "Design and implementation of supervisory system for
transportation of hazardous chemicals" in Electronic Measurements Technology,
Chinese, vol. 34, pp. 85-89, 2011.
[4] K Häkkinen, “Safety in materials handling”, Article in Scandinavian
Journal of Work, Environment & Health 7 Suppl 4, page no. 109-14 · February
1981
[5] https://www.osha.gov/Publications/OSHA2236/osha2236.html
[6] https://mn.gov/bms-stat/assets/cd_safe_materials_handling.pdf[7]
https://www.slideshare.net/mehulomgupta/material-handling-industry
[8] https://quizlet.com/203139238/iet-327-exam-2-study-guide-flash-cards/
[9] https://www.mccue.com/content/material-handling-
safety?utm_source=le_footer
[10] https://www.safetyinfo.com/material-handling-and-storage-safety-index/
[11] https://kdcconstruction.com/wp-content/uploads/2016/01/510_General-
Material-Handling.pdf
[12]
https://www.wrha.mb.ca/professionals/safety/files/SafePatientHandling/MMH
M.pdf

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 Job Saftety Analysis
and Machine Guards
UNIT 3 SAFETY IN DESIGN AND SAFE
WORKING PRACTICES
Structure
3.1 Introduction
Objectives
3.2 Safety in Design
3.2.1 Defining Design and Fault
3.2.2 Fault Management in Design
3.2.3 Fault Avoidance Techniques
3.2.4 Reliability
3.3 Safe Working Practices
3.4 Safties in Abrasive Wheels
3.4.1 Characterstics in Abrasive Wheels
3.4.2 Training
3.4.3 Wheel Breakage
3.4.4 Handling and Storage of Abrasive Wheels
3.5 Safety in Wood Working Machine
3.6 Casing of new Machinery
3.7 Safety in Lifting Equipment
3.7.1 Importance of Safety in Lifting Equipment
3.7.2 Preventing Access to Dangerous Parts
3.7.3 Consider of other Factors
3.7.4 Do’s and don’ts of Equipment Safety
3.7.5 Do’s and don’ts of Lifting Safety
3.8 Safety in Casting and Foundry Practices
3.8.1 General Safety for Foundries
3.8.2 Rules in our Foundry
3.9 Safety in Welding Machines
3.10 Personal Protective Equipment (PPE)
3.11 Working at Height
3.12 Let Us Sum Up
3.13 Answers to SAQs
3.14 References and Further Readings

3.1 INTRODUCTION
Safety is a necessity in everyday work whether domestic or industry. The
Industrial product or operation can develop situations of creating safety
hazards. Different mechanisms are implemented to improve the situation.
These mechanisms are extended during storage, operation, handing over,
transportation or general use. Protective measures are taken in form of
safeguarding, operational methodology, storing techniques, handling
instructions, administrative controls etc. However, the most effective method is
tackling the unsafe situation is through design. The result of ‘safety built-in
design’ is most long standing solution to the problem.
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 Safety in Machinery A sharp knife may cause injury. Hence, the blade is kept under cover or the
blade can be folded and is made safe. Hence the folding mechanism is
designed to introduce safety during non-use. While in use, the working practice
and skill takes care of safety.
This unit covers the scope of design for safety and safe working practices.
Objectives
After studying this unit, you will be able to:
• explain the concept of safety in Design
• describe safe working practices
• discuss safety in wood working machines
• explain the safety practices in casing of new machinery and lifting
equipment
• explain safety practices in casting and foundry practices

3.2 SAFETY IN DESIGN

3.2.1 Defining Design and Fault
Design is a process from out of which a product takes shape to meet the user
requirement to the best possible extent. The process is a culmination of human
thought converted into a physical product. The user requirement extends from
functional, operational, environmental and safety. Safety requirement is one of
the most important requirement and cannot be compromised. The design
process starts with the understanding of requirements and identifying the
essentials followed by reducing the object into a number of simpler, smaller
parts and analysis of interactions, interfaces and structures, modularization
then operation of detailing and adding features. Finally the strategies are
decided. The strategy is a culmination of different solution for each
requirement and optimization in a manner that the product becomes user
friendly and affordable.
The design process starts with the functional requirements and will normally
also fulfil certain non-functional requirements which might include such
factors as size, weight. cost and power consumption. To meet the operational
requirement, the product should be easy to operate and obviously safe to
operate. The operation must meet the safety norms and regulations, free from
hazards. The operations should also not cause health hazards. All these aspects
are to be taken care during design. Finally these safety requirements,
functionality and other requirement will define what the system developer is
going to achieve.

3.2.2 Fault Management in Design

To do a proper fault management, a major requirement is to categorize the
criticality of fault and accordingly safety critical level is to be identified. Fault
management measures are to be taken considering the criticality level. The
levels may be categorized as CAT-A, CAT-B, CAT-C and CAT-D. The failure
causing danger to the life of people (catastrophe) is CAT-A (Safety Critical). It
is considered the highest critical category whereas the fault causing breakdown
of a machine may be categorized in CAT-B (Operation Critical) because this
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hampers the operation. The failure which mightnot stop the operation but
causes an impact disturbing the flow of operation will be categorized as CAT-
C failure. The failure which is not affecting the operation but is still a failure is
categorized as CAT-D (Non-Critical) failure. However, Criticality level varies
fromcase to case . To determine the criticality level, it is required to carryout
‘Cause and Effect’ analysis which identifies the impact of any error or
deviation in arrangement, machine performance, operation or human error. The
probability of failure or breakdown of machine is (MTBF- Mean Time
between Failures) also to be considered for Failure Management so that the
preventive measures can be taken during design. Based on the data captured,
operational constraints, environmental condition, health and chemical hazards
the analysis is to be done.
Fault management techniques are introduced in design to eliminate or
minimize the impact of operation in safety. The impacts are analysed in
FMECA (Failure Mode Estimation and Criticality Analysis). Considering the
estimation of fault and criticality of impact, the techniques are employed. The
techniques are divided into four groups Viz. Fault avoidance, Fault removal,
Fault detection and Fault tolerance. In a system , failure has to occur and no
system can be designed or made with NIL failure. So the failure in a system is
always accounted in terms of probability and being measured in MTBF (Mean
Time Between Failure).

3.2.3 Fault Avoidance Techniques

Fault avoidance techniques aim to prevent the generation of faults during
normal operation of the system. The failure of hardware components are
restricted by using high reliable component fit for the normal and highly
stressed operational conditions. Use of a high quality switch will obviously
reduce the probability of failure. Design with interlocking methods reduces the
probability of occurrence of fault in system. A thorough ‘verification and
validation’ activity will bring out the hidden weakness in design both in
hardware and software. The possible failures are surfaced during simulation
and actual operational conditions which may be in normal, emergency and
abnormal conditions of operations. The rectifications to be undertaken in
design before induction to service.
Fault Removal Design
This is a technique to isolate a particular fault before affecting the whole
system operation. Itis also a design criteria to isolate the system before it enters
service. In a house or factory, the circuit breaker is provided separately for
each room or each load. In case of short circuit in a particular machine or
room, the corresponding circuit breaker trips and the machine is isolated before
the main circuit breaker trips. Hence the faulty system is removed from the
system.
Fault Detection
Fault detection is a very important stage in safety. As the system is in operation
and if the fault is not detected in the initial stages, it may lead to accident.
Hence, early detection of fault is necessary. If a nut is loosened in a dynamic or
rotating machine and not detected at the initial stage with continued operation,
there may be disastrous effect after sometime. Hence fault detection techniques
like monitoring of high impact safety parameters eg, speed, temperature,
pressure, coolant reserve, alignment etc be displayed on instruments and the
arrangement be implemented during design of machine and operational
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 Safety in Machinery system. There should be regular checks and corrective actions during periodic
preventive maintenance should be incorporated as part of operational guidance.
Fault Tolerance
Fault tolerance allows a system to operate correctly even in the presence of
faults. The system is designed in a manner that redundancy is built-in system
operation. This means that in case of failure of one system there may be
automatic or manual changeover to redundant system and operation continues.
Both hardware and software methods are used and implemented in design
itself.
None of these approaches provide total solution to the problems of fault
management and hence combination of techniques are used during design
considering the criticality category, performance standard, operational
complexities and other associated factors.
When design aspects of a project is considered the system architecture has an
enormous effect on the ability of a system to tolerate faults within it. It can
provide protection against random component failures as well as some
systematic failures.
Types of Failed Systems:
The systems are designed to withstand multiple failures through redundant
hardware or software (computer programs) managed by fail-operational/fail-
safe capability.
a) Fail operational
Fail-operational performance means that, after one failure in a system,
another redundant system continues the operation. In a fail-operational
system, a clear safe state is not identified. The system remains
operational and a performance in output is guaranteed. An airplane can
complete the mission even if onealternator fails but the other alternator
provides power to all the loads.
b) Fail safe
Fail-safe means that after a failure, the system will be capable of returning
to a safe mode without any danger to man or machine. If a system can
enter a “safe” state when failure occurs, the system is fail-safe. Eg: 1)
Railway signaling system failure: a safe state is to turn all lights red
leading to stoppage of train by driver. 2) Failure in anesthesia machine
should stop the flow of liquid to the patient.
c) Fail-passive
A system that looses partly or completely its functionality (e.g. to actively
motion compensate) in case of control system single failure but the system
can still be manually controlled is called Fail passive.

3.2.4 Reliability
Reliability is the probability of an item in performing its function in a specified
way in a given time period and under specific conditions. Reliability
engineering is a specialized science invariably applied to any complex systems,
encompassing system safety, reliability and maintainability.
The reliability engineering takes into account the contribution of the
component failure over to the system, the available redundancy in the system,
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the post-failure behavior of the rest of the system, the statistical correlation
between failure events and the progressive degradation of components.
A system is said to be critical if its failure leads to catastrophes (Safety
critical), mission abortion (operational critical) or degradation. A system is
called complex if its design is complex, it has multiple functions or / and it has
more number of units in it. Maintenance factor depends on the ease with which
the system can be maintained. The objectives of reliability engineering is to
apply engineering knowledge and specialist techniques to prevent or reduce the
likelihood of frequency of failures (Reliability based design),to identify the
causes of failures and fix the design, despite the efforts to prevent them
(Repair/Rehabilitate/Retrofit),to determine ways of coping with failures, if
their causes have not been eliminated (Risk management),to apply methods for
estimating the likely reliability of new designs, and to analyze reliability from
operational data (Reliability assessment).
Reliability engineering in general deals with two types of failure analysis, viz.
qualitative failure analysis and quantitative failure analysis. Failure modes and
effects analysis (FMEA) is a qualitative technique for understanding the
behavior of components in an engineered system. The objective is to determine
the influence of primary component failure on other secondary failure, and on
the system as a whole. Accordingly the system failures are categorized
qualitatively using levels or categories. e.g., ranging from safe to catastrophic.
FMEA uses a scale of likelihood with respect to failure mode occurrence, so
that together with the effect on system can be derived as relative risk for each
failure mode.
Reliability Prediction
Failure Rate - The number of failures per unit of gross operating period in
terms of time, events, cycles. This is termed as λ
Mean Time Between Failures (MTBF) - MTBF is a basic measure of
reliability and can be described as the time elapsed before a component,
assembly, or system fails. For constant failure rate systems it is given by,
MTBF= 1/λ

SAQ 1
a) What are the 3 major reasons of fault occurrence?
b) What are the different category of failures and basis of
categorisation?
c) Explain Fault management Techniques and define FMEA
d) What are different types of Failed system?
e) What is Reliability and MTBF?

3.3 SAFE WORKING PRACTICES

In an industry, safety plays an important role for a long term sustainability. Lot
of actions are taken in design, layout, dress, safeguards to minimize the safety
hazards, However, the people involved in operation, management and other
logistics must take seriously the safety concerns and implement the working
practices and administrative rules in the working and associated places. Each
one of us must practice the act of safe working in industries as well as in daily 77
 Safety in Machinery life. Though, these practices are closely related to the different types of
manufacturing, processing and testing industries but equally applicable in the
daily life of all human beings. Moreover, the discussion made through the text
written here has a wide coverage of safe working practices with regards to
mechanical and electrical industries.
The main aims of constructing safety laws are to prevent the worker from
injuries. However, unsafe working practices followed by workers must be
reported to the superintendents or supervisors or any other person responsible
to handle such unethical acts. Henceforth, violation of safety norms and
regulations must be as minimum as possible to avoid drastic injuries or
machine damage. The company professionals must always be vigilant about
the proper implementation of such safety guidelines, which further leads to
decrease in number of non-compliances as per safety rules and practices made
by the injured workers. On the other hand, in order to minimize such non-
compliances, the employers should organize awareness programs from time to
time.
i) The regular training must be imparted to the workers in periodically
especially engaged in construction, high voltage, chemical industries, so
that they may get trained to handle heavy on site machineries, chemical or
electrical hazards without any mishap. Thus, the practical trainings
through mock drills etc are very much essential for safe working practices
in an industry.
ii) Keeping in view the safety related issues, the employer has to keep a close
eye on overhauling, preventative maintenance and replacement of faulty
machineries and equipment. The remedial actions further leads togood
quality production without any worker safety issues. We should provide
machine guards, spectacles, protective clothing and many more to the
workers for addressing safety related issues. Furthermore, at work places
the unwanted crowding, pulling and pushing should be avoided and a
special care has to be taken at the places of bulk transmission through lifts
and cranes.
iii) A proper attention is to be given to the footwear of workers especially
working on the shop floors or at work site. Throwing of materials,
different unused parts, tools and other lying about structures has to be as
minimum as possible. Therefore, housekeeping is very important for
keeping floor area neat, clean and tidy. Henceforth, workers must be
trained in such a way that they automatically follow these ethical safety
practices. In case of any hazard is seen that can be corrected by the
worker, go ahead and perform the work or report it to someone who can
correct it.
iv) Personal protective equipment should be used when handling chemicals or
hazardous substances. Please follow the instructions written over the label
for ease of use and handling. washing of the hands or skin after using
hazardous chemicals and No gasoline is to be used for any type of
cleansing purpose.
v) Care and precaution should be taken while handling ladder at work or job
site. Please ensure that the ladder extends at least three feet above the
landing area. Inspection of a ladder and its condition prior to usage is a
very important task.
vi) Please report to your immediate supervisor in case of injury.
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vii) Ignition sources near a tank or vessel or any inflammable article must be
avoided, special care has to be taken in case of welding of joints or
openings. Operators using welding equipment must always be cautious of
nearby materials and self about the initial spark or flash occurs at the time
of welding. Welding operation around the combustible or inflammable
material should be avoided but on the other hand, if it is necessary then
arrangements in the form of fire extinguishers must be done.
viii) Tools and equipment used for the different operations have to maintain in
good serviceable conditions. A damaged tool should be kept in different
shelf and tagged “defective”. Appropriate tools for specific jobs are to be
used such as screwdriver has to be used for loosening the screw not to be
used as chisel. Portable electric tools are not to be pulled through their
electric or power chords, they should be simply lifted to get transport from
one place to other. A power chord of all the electric equipments has to
properly checked and replace chopped wire if any. Before, the use of
electrical tools, they must be inspected to make sure the power cord and
plugs are in good condition. You cannot simply wrap electrical tape over a
cut or frayed cord.
ix) Machineries should be operated by only authorized persons, who are
properly trained to perform the relevant operations in the machine. Safety
precautions have to be followed by the operator. Before starting the
machine, the instructions displayed near the machines to be followed. It
should be checked that whether any warning message is displayed in order
to have any possible injury. The machine starting and stopping operation
must be done as per laid out sequence. Emergency stoppage should not be
used other than in emergency condition. Electrical ‘Power On’ should be
the last operation for switching on the machine and Electrical ‘Power Off’
should be the first operation for switching off the machine. Periodical
checking of installation should be carried out for heavy vibration
generating machines.
x) While working in the shop floor, it should be properly observed the
movement of vehicle and other movable items to prevent any danger.
Since such areas are having noisy atmosphere due to running of machine,
therefore it is the responsibility of the person to check properly. Any
excavations in the working area should be properly inspected before
starting the work in particular area. Overturning of heavy tractors,
bulldozers, scarpers may be dangerous in such areas.
There are much more safety precautions which should be strictly followed
while working with machines which are discussed in detail in following
sections. However safety is a common sense and good judgment of the
situations. In case of injury due to ignorance or of any reason, then proper first
aid must be taken. Thus in order to avoid such situation safety precautions
must be observed very seriously.

SAQ 2
a) What is meant by Safe Working Practices?
b) What is Safety Laws and the role of Supervisor and training in
industrial Safety?
c) What are the main areas of concern in operation and shop floor for
safe practices?
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 Safety in Machinery
3.4 SAFETIES IN ABRASIVE WHEELS
The abrasive wheel is manufactured with small or unconnected particles which
are discrete in nature, as a result these particles are susceptible to breakage,
after an excessive or after definite duration of use. Therefore, attention has to
be given to bonding of abrasive particles during its design and manufacturing.
The wheel must be designed and manufactured with the bonding material
suitable for climate and the friction force applicable during the operation. The
design must define the storage and handling conditions also.
Apart from the flaws in design and manufacturing of abrasive wheels there
may be other factors such as absence of skilled operator, proper mounting of
wheel, faulty circuits and poor environmental conditions responsible for any
accident during machining operation. The following factors related to abrasive
wheels must be kept in consideration:

3.4.1 Characteristics Abrasive Wheel

This usually defined as a wheel shape, which mainly consists of abrasive
particles distributed and bonded together with the help of various adhesives.
The proper distribution of these small abrasive particles provides a better life
to the abrasive wheels even in cyclic loading conditions. These may be
classified as inorganic and organic.
Inorganic - The manufacturing process of inorganic type abrasive wheels
mainly involves processing through a furnace with an optimum temperature for
stiff bonding between abrasive particles and adhesive, however such process
makes the wheel brittle in nature. Such abrasive wheels are extensively used
for grinding application, which is due to their rigid nature; however, it requires
time-to-time dressing after a long span of grinding operations.
Organic - organic types of abrasive wheels are made usually at low
temperatures as compare to inorganic type abrasive wheels. The formations of
bonds in such wheels are as follows:
• Vitrified (V)
• Bakelite or resinoid (B)
• Silicate (S)
• Shellac (E)
• Rubber (R)
These wheels are best suited for non-precise rough applications because of
their toughness, ability to withstand shocks, automatic dressing property etc.
The following terms are used with respect to manufacturing of abrasive
wheels:
a) Abrasive means the type of abrasive used in wheel construction;
b) Wheels are graded with “soft and “hard” represents the tenacity of the
abrasive wheels with which the bonding material holds the abrasive grain
in a wheel. The hardness of grinding wheel is very soft (A to G), soft (H to
K), medium (L to O), hard (P to S) and very hard (T to Z).
c) Grain/grit size means the particle size of abrasive grains. The range is
expressed by number (very coarse 4 to very fine 1200);
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d) Structure means the level of porosity in the wheel. The higher the
number, the greater the level of porosity;
Bond type means the bonding material used in the wheel construction.

3.4.2 Training
There is no replacement of intensive practical training covering all aspects of
the mounting and use of abrasive wheels. Henceforth, all training programs
should cover at least the following:
a) Guideline or precautions about the hazards and risks that may arise during
the operation of abrasive wheels are to be observed in advance;
b) Abrasive wheel designation with their type, size and maximum operating
speed;
c) Methods of storage, handling and transport of abrasive wheels;
d) An exact identification of damage that has occured on the surface of
abrasive wheels;
e) The functions of sub components of abrasive wheel such as blotters,
flanges, bushes, nuts etc;
f) Knowledge must be imparted about the assembly, mounting with proper
alignment (with well define limits, fits and tolerances) of abrasive wheel
on the shaft.
g) Dressing of abrasive wheels (to make the surface even by removing all
such materials which come out in the form of abrasive particles because of
excessive use of abrasive wheels);
h) The correct adjustment of the work rest on pedestal or bench grinding
machines;
i) The use of suitable personal protective equipment, for example eye
protection.
j) Selection criteria of correct wheel for correct operation, initial setting,
starting and stopping procedure
The supervisors of an employer are advised to keep a record of such training
along with date of commencement, the detail of participants and the resource
person from the concern field. More information about the conduction of such
programs and the resource persons can be obtained from British Abrasives
Federation (BAF).

3.4.3 Wheel Breakage

Abrasive wheel manufacturers take all reasonable precautions, including speed
tests, to supply sound wheels, and various methods are used in their
construction to reduce the risk of breakage. These include:
a) Fibre reinforcement: Glass fiber woven in the form of mat normally coated
with resins are used in organic type of abrasive wheels, which often used
for heavy-duty grinding and machining process. Such resin-coated fiber
provides more strength to abrasive particles (fragments) and helps these
particles to keep bonded themselves;
b) Steel rings: These have been inserted into the wheel very close to the bore
for retaining small fragments in wheels after an extensive machining
81
 Safety in Machinery operation. These rings also protect and prevent excessive wear and tear of
the wheel especially at high speeds;
c) Safety inserts: These are threaded nuts which act as a locking arrangement
for teeth along with forming part of a plate, which finally results in
strengthening the base of a cup wheel. Such locking arrangements can be
merely an additional safety device and not the replacement of the guard;
d) Tape winding: The main use of tape winding is during the event of
breakage of abrasive particles due to continuous use of wheel at high
speeds, they support to hold the small fragments together. Generally,
adhesive tape, glass-fibre or metallic wires were used to strengthen thin-
walled cup and cylinder wheels.
e) Fine grit centre or similar: This grit centre is an integrated part of wheel
molded together, usually placed around the bore to provide strength to
vitrified grinding wheel. In order to provide more strength an epoxy resin
may also be filled in the bore area around the wheel.
Though, a lot of precautions for the prevention of breakage were considered
but subsequent mishandling or misuse by the operator leads to an obstructed
service. Improper storage, inappropriate mounting, improper balancing of
rotating masses, wrong selection of wheel for a particular application,
malfunctioned grinding operations are some of the important factors
responsible for the occurrence of breakage in the wheels. Therefore, a careful
investigation is always required during the machining operations especially
with the variations in speed.

3.4.4 Handling and Storage of Abrasive Wheels

There are always possibilities of damage in wheels during their shipment, so
unpacking of this wheel play a vital role, when they got unpacked they should
be well cleaned with soft brush and be deeply examined. Therefore, the tools
used in unpacking of such wheels should be carefully chosen so that it does not
harm the wheel inside it. Further, a “Ring” test can be performed to check the
soundness of wheels by tapping their surfaces with a light. One major
precaution in terms of cleanness and dryness of dust contained by the surface
of wheels has to be taken during this test otherwise signal in the form of sound
will be consumed by such dust particles. Ring test as shown in Figure 3.1 can
be performed on both heavy and light wheels. Heavy wheels are supposed to
be supported on the neat and clean floor while light wheels are used to suspend
them from their hole on a small pin. If any crack is found during this entire
process, no sound can be produced and such wheel will either require
maintenance or has to be returned back, finally they cannot be used for
machining purposes.

Figure 3.1: Process for Conducting the “Ring test”.

Before starting the use of any wheel, its comparison with other wheels will
help in identifying problems, if any. In the event of any mismatch
82 manufacturer has to be informed. Because of their shape and size following
 Job Saftety Analysis
and Machine Guards
types of wheels do not have practicable rings which require extra care and
vigilance.
• Wheels having diameter less than100 mm
• Wheels which are mounted
• plate-mounted wheels
• Inserted nut disc and cylinder wheels.
Handling
Due to the manufacturing process involved in making abrasive wheels they are
relatively brittle in nature. Therefore, due care has to be taken during handling
of such wheels and rough handling should always be avoided. In order to save
them from any type of cracking or breakage following rules must be followed:
a. Supervisors should instruct the lower labour involved in unloading the
wheels about dropping and bumping of the wheels. Rolling of abrasive
wheels should also to be avoided. If it is unavoidable due to larger size of
the wheel than unloading should be done on soft and resilient surface
(floor).
b. Giant wheels that cannot be carried with hands must be transported by
choosing suitable conveyors with proper support as shown in Figure 3.2.

Figure: 3.2 Handling of Large Wheels

(Source :Health and safety executive :safety in the use of abrasive wheels Pdf )

Storage
Special purpose racks, bins or drawers are to be provided to place the different
types of wheels. Following are the few suggestionsto help in designing the
facilities for storing different kind of wheels:
The exact process of laying down abrasive wheels has been illustrated in
Figure 3.3.The best and comfortable solution of storing the abrasive wheels is
to keep them in vertical position and inserted between two parallel wooden
beams as shown in Figure 3.3.
These abovementioned racks shall make up of steel or wood structure
separated with linings of wood or rubber or any other soft material. The height
of all the stacks must be proper which could not damage the edges of different
kinds of abrasive wheels otherwise; it hampers the performance of wheel
during grinding operations. An extra care has to be taken especially those
wheels, which placed at the bottom of stack.
83
 Safety in Machinery The same rules has to be followed at the time of handling different grinding
wheels within the vicinity of production shops along with their working stands.
Wheels should not be dropped and are to be handled carefully from impact
each other or hard objects.

Figure 3.3: Example of Rack Construction for Storage of Different Kinds of Abrasive
Wheels (Source: andreabrasive.com)

Position of wheel and racks must be compatible with each other. Its
transportation is performed in trucks which are having rubber wheels. Further
it can be rolled on the floor if proper covering is provided for protection.
Plain and tapered types of wheels are best supported on their edges or on a
central support, however a support in the form of cradle should be provided to
prevent the rolling of wheels. To prevent wrapping of organic bonded wheels
used for cutting purpose it should be kept away from heat and moisture and
should beput ona horizontal surface. Flatness of wheels must be checked and
maintained.
Speed
Speed is an extremely important parameter to be examined in the case of
abrasive wheel. Centrifugal force (the only fatal cause of wheel bursts)
increases as the square of the speed of abrasive wheel. Therefore, the
maximum operating speed of an abrasive wheel must be clearly mentioned on
each and every wheel.The following are two ways of marking the speed:
The maximum operating speed is marked on every wheel in two ways:
a. The peripheral surface speed (m/s);
b. The rotational speed (rpm).
Wear and tear occurs in the wheels because of their continuous use at constant
rotational speeds. This may result in gradual reduction in the peripheral speed
of abrasive wheel which may result in reduced grinding efficiency. To
counteract this, the spindle speed has to set to an optimum value. Rotation of
wheels should be strictly performed with specified limits of speeds. Over
speeding causes wheel breakage.
SAQ 3
a) What Training should be covered for worker on Abrasive Wheel?
b) What are the main possible failures in a abrasive wheel?
c) How the abrasive wheels are transported and Stored?
d) What is the role of speed in use of Abrasive Wheel?
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3.5 SAFETY IN WOOD WORKING MACHINE
3.5.1 Wood Products Manufacturing Plant
Wood products manufacturing plant includes wood cutting machines, safety
equipment, inventory shades and also the equipment or appliances to enhance
the performance of employees to complete their tasks with quality within the
given time frame. The complexity of wood products manufacturing plant
depends on the variety and the production of different parts of wood.
A person or a worker operating in woodworking plant is often applying
different types of cutting blades at high speed for giant timber blocks. Wood
manufacturing transformation processes includes head rig, edging, trimming,
rough lumber sorting, stickering, drying, planning and grading. Wood cutting
plants mostly depend on batch production rather than mass production. They
often involve in low volume production instead of high volume production.
Such customer based requirements force to modify wood cutting plant in a
very short span of time.
A rigorous training about the safety is the prime concern of woodcutting
plants. In most of the cases, the supervisor has to keep a close eye on the
workers who are directly involved in cutting wooden pieces from heavy duty
blades. Employers must ensure that exposed blades are properly guarded and
that the worker can prevent himself from the direct contact of such life
threatening machines. Employers must ensure risk controls to reduce the risk
of injuries or does not introduce other hazards or risks into a system of work.
For example;
• In woodcutting plants there is always need of a forklift for the traffic
management from giant blocks of timber to the cluster of small wooden
pieces.
• For load shifting bulky mechanical equipments such as powered pallet
jacks, the supervisor shall have to train their subordinates about the safe
working. This could be achieving by using proper safety aids throughout
the working in the wood cutting plant.
• When a worker is using lifting gears or other equipment for transferring
big or small cabinets, carcasses, one must ensure that loads carried are
within safe working load (SWL) limits provided by the manufacturer’s
guideline. Therefore, the supervisor can implement a program to monitor
damage to shackles, slings etc.
• Changes to equipment will require a plant risk assessment to be conducted
to ensure employees are not injured by newly introduced hazards such as
trapping points or in-running nip points and that controls are put in place if
risk is present.

3.5.2 Training and Supervision

Employees, working in the close proximity of plant involved in operating,
maintaining are required to be trained and supervised during the entire
operation of that plant. The inexperience of employees is a potential hazard
and employers should ensure new or inexperienced employees are not left to
training. Following points may also include avoiding or controlling the risk
during different operations performed in wood cutting plants:

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 Safety in Machinery • The worker has to ensure that they are using the right kind of machine for
accomplishing the right purpose.
• Production capacity of the plant should be defined at the beginning of the
set up because such prior decisions always control the overuse of bulky
machine equipment and finally ensure the safety of the workers and the
plant.
• At the time of training the worker, they must be segregated through a
proper grading system; additionally this could help the supervisor in
allotting the right kind of work to the right worker.

3.5.3 Push Pads and Push Sticks

Push pads and push sticks are used as instruments which help in smooth
working with woods. Push pads are used for easy disengagement of operators
hand from the cutting blade as shown in Figure 3.4 and 3.5. Push sticks are
often used to push timber through a rip saw. Following guidelines must also be
followed during use of these instruments:
Push sticks should never be used to:
• Remove off cuts from a running machine.
• Heat up a blade by applying a friction force.

Figure 3.4: Pushup Pads Made up of a Foam Grout Float

(Source: finewoodworking.com)

(a) (b)
Figure 3.5: Woodworker’s Safety Push Stick (a) Flat Traction Tread, (v) “V” Traction
Tread
(Source:tablesawpushstick.com)
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3.5.4 Kick Back
‘Kick back’ action is a common problem associated during the manufacturing
of timber products especially when worker performing their respective jobs by
using rotating plant and machinery. Generally, “Kick back” action occurs with
sawmill at the time of timber cutting operations. There are many considerable
serious safety issues within sawmills. In order to save the workers from
hazards “anti kick back” are devices installed on sawmills. An example of anti
kick devices is on circular saws to prevent jammed or rusted lumber being
ejected from the machine after sudden use of the machine. Few considerable
occupational safety and health hazards can be seen through Table 3.1
(http://www.ilocis.org/)
Table 3.1: Occupational safety and health hazards
Process area Safety hazards Physical hazards
Open area and water Mobile, conveyor belts Noise,
filled area temperature
Debarking Walking at elevated sites, Noise
conveyor belts, flying
debris, failure of machinery
Sawing, Planting and unsecure logs, flying Noise, repetitive
Chipping and related debris, failure of machinery injury
operations
Kiln drying Mobile equipment Temperature
extremes
GUARDING
Guarding of dangerous exposed parts of machinery is very important to save
the lives of working peoples. There are many kinds of guarding systems
available in the market especially for those parts of machine, which has offset
or an elevation from the main casing of the machinery.
Guarding has to be done for:
• Physical barriers which are permanently fixed.
• Physical barriers which are interlocked
• Physical barriers equipped with sensing system
Permanently fixed physical barrier
Permanently fixed physical barriers as shown in Figure 3.6, ensures that there
should not be anyone who have either complete or partial access to dangerous
areas during operation, maintenance or cleaning of the plant.

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 Safety in Machinery

Figure 3.6: Permanently Fixed Physical Barrier

3.5.5 Interlocked Physical Barrier

An interlocked physical barrier as shown in Figure 3.7 has a moveable part. In
such type of barrier system, the guard directly interacts with the movable parts
of the machinery to prevent their motion when the guard will be in open
situation. Due care has to be taken while designing of such guard systems
because if at the time of working, guard is defeated then it could make the
situation dangerous for the worker performing his task. The step-down time
needs to be taken into account so that access is only available when sufficient
time has lapsed for the motion of the dangerous parts that have gone out of
order at that time.

Figure 3.7: Interlocked Fixed Barrier

3.5.6 Physical Barrier (fixed guard)

A physical barrier (fixed guard-with no moving parts) fixed in a particular
position by means of fasteners, which ensures that the guard cannot be altered
or removed without using a tool or a key as shown in Figure 3.8.
Standard barrier
These are meant for providing the protection when the guard is in correct
position.
Stationary guards may be:
• The standard barriers cannot completely enclose the hazard but it always
helps in reducing to the access of danger point.

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 Job Saftety Analysis
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• Fence guards completely enclose the exposed part of the machine, which
further prevents any occurrence of the hazards with worker.
• Adjustable guards always provide an opening to the machine to serve the
purpose of feeding the material when it gets finished.

Figure 3.8: Fixed Barrier

Presence sensing system
The installation of Presence sensing systems (PSS) in heavy machinery plants
can be viable solution for providing the safety and hence to increase the overall
efficiency of the plant. PSS (Figure 3.9) has a proactive device based on
optoelectronic technology and installed in the close proximity to the point of
operation. These devices are categorized as special purpose devices because
they start reacting when an object especially any body part such as hand, finger
of operator struck in an invisible plane or barrier. The designs of these systems
are based on high reliability and are “fail safe” especially when the machine is
operating at its full swing.

Figure 3.9: Presence Sensing System

Manual Handling and Musculoskeletal Disorders
Manual handling
A wide range of hand activities such as wood handling before and after it get
finished, tool handling, wood taken in and out from machinery, delivery
followed by on-site installation etc especially in wood products
manufacturing industry have to be performed by concern workers/operators.
In most of the tasks stated above, there are many chances to get
musculoskeletal disorders because of overload fatigue, impact load disorder
and localized excess loading. Furthermore, following are the possible
hazardous characteristics to refer to during manual handling:
• The force or load applied is of repetitive nature;
• Weak posture of worker or position of work piece fixture;
• Continuous movement of worker;
• Sudden application of heavy load;
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 Safety in Machinery •Occurrence of more vibrations;
•Improper balancing of reciprocating and rotating masses leads to
generate more vibrations and finally originates fatigue and disorder in
various body parts of the operator.
Musculoskeletal disorders
A musculoskeletal disorder (MSD) always causes “sprains and strains” in the
body of workers when subjected to continuous work in the plant. Sprains
broadly related to tearing or stretching of ligaments, which may further explain
as tough bands used to connect two bonds together in a human body. Ankle is
the most common part of the body where sprain generally originates which
may be attributed to wrong posture of worker during cutting operation or other
tasks. Following are the risk Factors:
• Environmental conditions. Uneven or slippery surfaces always cause an
injury to the workers. Wooden dust in Humid conditions causes
pulmonary problems.
• Fatigue. Exhaustive workload leads to tired muscles which may not be
able to provide sufficient support to the joint of worker, consequently
causing an irreparable injury.
• Poor equipment. Poor equipment can lead to a sprain in the body.
Repetitive strain injury (RSI), occupational overuse syndrome (OOS),
cumulative trauma disorder (CTD) and work-related musculoskeletal disorder
(WRMSD) are some of the common injuries occurred in the body of worker
due to excessive workload.
Manual Handling
While performing manual handling (Figure 3.9) of job suitable postures,
movements and forces should be made to eliminate the unnecessary labor
associated with it. Possible arrangements made for this are enumerated below:
• Physical change in workplace design must be made to facilitate the
movement of job.
• Workplace must be adjusted to accommodate performance of different
tasks and workers.
• Avoid working on movement of job above the shoulder height and below
the knee level.
• Keep the movement of job close to the body.
• Avoid extreme and complicated postures with high forces.
• Reduce vibrations from power tools by selecting proper tools.
• For handling of heavy items, helmet and proper shoes should be used.

90 Figure 3.10: Manual Handling

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SAQ 4
a) What is a wood manufacturing plant? What are the main
precautions worker should follow in a wood plant?
b) Why Push Back and Anti Kick back systems are required.
Explain in brief?
c) What are Guarding and Barrier systems and how these
are implemented?
d) What is Musculoskeletal disorders and how these can be
minimized?

3.6 CASING OF NEW MACHINERY

1) The power driven machineries installed in any plant must have the
following in accordance with the common- cement factory Act:-
• Every type of fasteners such as set bolt or key, screw, splines, rotating
shaft, short shafts or spindle, gear wheel or pinion shall be encased or
sophisticatedly guarded to prevent danger causes to the operator or
worker;
• Heavy torque or power transmission media like spur, worm and other
toothed or friction gearing devices in which frequent adjustment of
assembly is not needed shall be completely guarded or encased.
2) The sellers, their agents, hirer involved in the procurement of the power
driven machinery for use in factory or plant must follow the act or the
provisions made by the government. Otherwise the accused will be
subjected to imposition of either an extendable imprisonment or fine or
both.
3) Apart from the central governments, state governments are also free to
make amendments in the rules which areobviously in favor of operator,
workers or any other person for their safeguards from any dangerous part
of any particular machine.

3.7 Safety in lifting equipments

3.7.1 Importance of Safety in Lifting Equipment
At the time of using lifting equipment, it’s always necessary to stay vigilant
and take all the precautions prescribed in factory act. Any type of negligence
will cause damage to the workers/operators; few of them are as follows:
The supervisor has to ensure that the stow cranes can move and exit properly.
Elevation or offset of sharp edges always causes damage in terms of cuts and
severe injuries.
No body should stand or move underneath a heavy load especially when the
load is moving by crane or otherwise. The malfunctioned equipment, rusted
parts can shear off consequently causing a heavy damage.

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 Safety in Machinery A fabricated extremely heated part from the machine outlet or inlet of hot
water or steam has sufficient reason to cause burns or scalds. Apart from this
open electrical points or wires, can cause moderate to heavy resulting in
burning or even death.
A supervisor should ensure that the worker is trained and updated. The
employer should arrange for training programs to update their knowledge and
skills.

3.7.2 Preventing Access to Dangerous Parts

In order to make the use of dangerous equipment safe, the following points one
has to remember the following:
• Fixed guards with well fastened screws, nuts and boltsshould be used to
envelop the dangerous parts. Good material such as mild steel for fasteners
and enclosing materials should be used in case these are experiencing
excessive use and are damaged. If the materials are prone to rusting, care
should be taken for their cleaning. The guards or wire mesh should not
have projections.
• If it is not possible, install fixed guards then other methods such as
interlocking of the guard should be done. In that case the equipment
cannot be started before interlocking of the guard gets unlocked. Apart
from such interlocking system the designer can use some special
preventive systems such as pressure sensitive devices, photoelectric
devices and servo driven automatic guards to make the system fail safe.
• The supervisor can organize training program to communicate necessary
information to the operator/ worker that always be helpful in avoiding
hazardous risks.

3.7.3 Consideration of Other Factor

It is always advisable to ensure that all types of control switches are clearly
marked to show their operation. Major controls must be supported with
emergency switches such as mushroom head push buttons as shown in Figure
3.11.The emergency STOP switch must be visible from distance with ‘Hat’
headed where as the START button should be ‘Flash’ headed. This is to ensure
an intentional start. The location of STOP emergency should be such that
easily accessible.Fuse or Circuit Breaker are used extensively for safety
purposes. In case of jamming or misalignment of drive and load or sudden
overloading of machine or short circuiting, the fuse or circuit breakers operate
and isolate the abnormal machine from electrical power before major damage
or accident occurs.
Through an orientation, course and adequate training, supervisor can ensure
their workers skills, necessary level of knowledge and physical fitness for
performing a particular task. Worker should ensure about the cleanness around
the working area of the equipment, free from obstructions or slips and trips
hazards.

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Figure 3.11: Mushroom Head Push Button Type Emergency Switch

(Source www.schneider.com)

3.7.4 Do’s and Don’ts of Equipment Safety

Supervisor should make sure that all workers must use lifting equipment and
understand and follow these dos and don’ts:
Do…
1. Do the preliminary checking, maintenance and fitment of all equipment;
2. Make sure all parts, including attachments, can accommodate the load
weight;
3. Use the equipment properly and in accordance with the manufacturer’s
instructions;
4. Make sure employees are wearing the appropriate protective clothing and
equipment, required for that machine, such as safety glasses, head
protection and safety shoes.
Don’t…
• Don’t Use equipment that has a danger sign or tag attached to it. An
authorized person who is satisfied should only remove danger signs
that the equipment or process is now safe;
• Don’t Remove any safeguards, even if their presence seems to make
the job more difficult;
• Don’t Wear dangling chains, loose clothing, rings or have loose long
hair that could get caught up in moving parts; distract people who are
using equipment.
3.7.5 Do’s and Don’ts of Lifting Safely
Do’s…
The following points are to be remembered:
• It is always advisable to use only certified power lifting equipment.
These equipment are marked with safe working load value and certain
overload with duration. Please avoid to work with all equipment under
examination condition. If it cannot be avoided then that particular
equipment should be labeled with a tag of under maintenance.

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 Safety in Machinery • Supervisor must keep all the reports, declarations of conformity or test
certificates, calibration certificate generated after thorough examination
of equipments.
• Please ensure that load, which has to be lifted is properly attached,take
necessary precautions about slipping or falling of the load.
• From mechanics point of view, thedesigner should calculate the center
of gravity of unbalanced load, before lifting. Sudden lift or rise should
be avoided because this kind of act always creates jerks, which
consequently leads in sudden fall of that lifted load.
• Proper packaging of goods should be made such that sharp edges of the
goods are not protracted during transportation and when subjected to
sudden loadings. Handling instructions should be provided on the
packaging to give instructions to the person responsible for performing
movement of job with jib cranes or any other medium. Various
instruments like slings and outriggers can be used for minimizing
losses to job by facilitating transportation.
Don’t…
• Never use equipment which are not properly serviced because
equipments that aredamaged, like badly worn chains, rotted fiber ropes
can lead to accidents.
• Do not deviate from marked working specification for the equipments.
Sometimes a small increase in load has manifold effect due to even
small angular applications.
• Don’t avoid lifting a load from inadequate equipment. Make
appropriate selection of equipments for lifting a load.
Golden Rule 6 – Mechanical Lifting
General guidelines which must be followed while lifting are given below:
• Make sure that the equipment is approved and certified from the
competent agency.
• Operator is authorized for lifting loads and working by the competent
supervisor.
• Capacity of the equipment must be strictly followed.
• Regularly check the working of equipments.
• Strictly follow the safety rules.
Following precautions should also take:
• People must not stand in the way when the load is moving (Figure
3.12).
• Position yourself below the suspended load.
• Operate equipment onlyif you are trained and authorized for it.
• Don’t use the equipment which are not marked the certification of
safety.
• Never exceed the capacity of lifting machine. Calculate the safe
working load of the lifting equipment.
• Do not ignore the overload warning.

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Figure 3.12: Mechanical Lifting

(Source: Health and safety executive, Lifting equipment at work )
Things to check when inspecting lifting equipment
• In order to prevent the snapping of chains, the chains must be checked to
ensure that elongation remains within specified limit. If the chains are
stretched then calculate the maximum permissible stretch limit.
• Wear in the chains can severely affect the strength of chains, hence if the
chain has worn out,it should immediately be quarantined.
• Any distortion in chains and hooks (Figure 3.13) must be removed before
using it.
• Webbing slings must be arranged to remove because it can cause abrasion,
cuts and tears which will create damage in the operations.
• Further to prevent injury, the lifting instruments (Figure 3.14) must be
intended for that specific purpose only and should be attached to the
suitable lifting point.

Figure 3.13: Chain Hoist

(Source: Health and safety executive, Lifting equipment at work )

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 Safety in Machinery

Moused Hook

Hook with Spring-Loaded Safety Catch ‘C’ Hook with link

Choker Sling Cradle Sling

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Double Wrap Sling Grips the Load and Helps Prevent it from Slipping Sidewyas
Figure 3.13: Lifting Equipments
(Source: Health and safety executive, Lifting equipment at work )

SAQ 5
a) Which parts of the machines must be encased?
b) What is lifting operation? Why safety is important in lifting
operation ?
c) What are the Do’s and Don’ts in manual lifting operations?
d) What are the Do’s and Don’ts in machine lifting operations?
e) What are things should be checked during inspection of lifting
equipment?

3.8 SAFETY IN CASTING AND FOUNDRY

PRACTICES
3.8.1 General Safety for Foundries
Safety procedures and precautions are important ashot metal flow is involved
in the casting and foundry operation. Therefore, it is essentila to be aware of all
these safety precautions before starting the metal casting process. General
safety precautions which should be kept in mind are:
• Mixing of moisture and molten metal must be avoided since it can cause
steam explosion. Steam explosion accounts for biggest reason for death in
foundries.
• Avoid pouring water in metal to prevent huge explosions.
• Dry piles of sand and shovel should always be kept ready to control fire
and metal spills.
• Sand bed must be made in all areas which must be at least three inches
thick to avoid metal spills and protect flooring.
• Avoid contact of molten metal with concrete to prevent explosion.
• Fresh clean metal must be used as feedstock. Use of residuals can be toxic.
• Area must be well ventilated. Fumes and dust are toxic which must be let
out from working area.
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 Safety in Machinery • Dust mask must be used by workers to prevent sand, particles,dust and
chemicals from entering the body.
• Safety glasses must always be used to minimize mishaps.
• Never use broken or leaking crucibles to avoid leakage of hot molten
metal.
• Avoid contact of hot crucibles with cold surfaces to avoid explosion and
haze.
• Movement of spilling molten metal must be prevented.
• Operator must be aware of essential requirements on shop floor.

3.8.2 Rules in Foundry

In order to maintain the safety of workers working in the foundry, some
precautionary measures must be followed by framing certain rules. This must
be done to prevent the injury or death of workers. Other than the precautions
mentioned above , some of the rules to be followed are :
• Always read, understand and follow the instructions provided in the shop
floor.
• Wear leather shoes and fireproof apron
• Wear foot and leg protection
• Use gloves and wire mesh face shield
• Always wear safety glasses
• Wear cotton baseball hat and long sleeve cotton shirt made up of cotton or
natural fibers. Avoid synthetics as it can melt and stick to the skin.
• Pour hot molten metal properly without gettinginvolved in other activities.
• Pour only one at a time without moving nearpouringarea.
• Avoid unnecessary movement in the foundry area.

SAQ 6
a) What is a foundry plant and what are the general precautions should
be taken in casting and foundry plant for safety?
b) What are the safety rules to be framed and be followed strictly in a
foundry?

3.9 SAFETY IN WELDING MACHINES

Part 1: Welding hazards
Performing welding process requires great attention. Some of the accidentsthat
may occur due to ignorance of safety precautions are fire, fumes, burns and
explosions.

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Burns
Temperature of welding area increases up-to the melting point, which causes
items to become hot creating a risk of burns and fires due to hot metal and
welding spatter.
Fumes
Fumes are generated due to chemical reactions taking place during welding
process. These fumes create negative effect on health. When left for long
duration the impact of these can be dangerous. Proper ventilation equipment
must me installed to prevent fumes.
Electric shock
Welding processes operate with electricity, therefore there is a risk of electric
shock that can be fatal. Standard precautions required to prevent from electric
shocks should be followed.
Compressed gases
Compressed gases in the cylinders are present at prescribed pressure. This
pressure limit has to be maintained, otherwise it can create blast or leakage.
Hazardous substances
Some specialized processes require hazardous substances such as extremely
toxic gases and chemicals that have to be dealt with wisely to prevent any mis-
happening. Some of the dangerous gases are:
• Hydrofluoric acid
• Acetylene, ozone, nitrogen oxides, carbon monoxide
• Epoxy resins, degreasing agents, paint
• Phosgene or phosphine
Suffocation
Welding generates heat and presence of inert gases and lower the oxygen level
in surrounding area which creates suffocation. To avoid suffocation, proper
ventilation and exhaust must be provided in the welding area.
Radiation
Radiations are generated during welding which are dangerous for eye and skin.
To prevent from radiations, various preventive measures should be used such
as reflecting surfaces, spacious area etc.
Heat stress
Prolonged work in hot environments can lead to distress and fatal heat stroke.
An expert advice must be taken from medical professional for welders working
in such environment. The welding area layout must be designed with safety
and should have environmental clearance.
Noise and vibration
Certain level of noise and vibration is associated with the welding process. If
the intensity of noise and vibration increases beyond critical levels, then
appropriate hearing protection should be worn.

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 Safety in Machinery Part 2: Training, qualifications and competency
General
Welding process involves wide range of specifications to be maintained in
variety of working conditions. This requires high skills and competency level
in the welding operator to avoid any mis-happening. The welding operator
must be appropriately trained and certified to be able to work by following:
• Correct process to be performed,
• Identify Hazards associated with the work,
• Methods to minimize hazards
• Precautionary safety measures to be maintained.
The welding operator’s competence should be certified by training instituted
under regulatory bodies industry training organization (ITO) and National
Qualifications Framework. Operation of essential equipment like fire
extinguishers and hot work must be known to the worker. Operators must also
strictly follow the laid down standards.
The value of experience
From the above literature it can be well understood that welding process
requires critical safety levels, prerequisite knowledge and experience as a
precautionary measure of all aspects of health and safety.
Theoretical knowledge is not enough to attain the required welding expertise,
hence experience, skill and practice are essential for performing safe working
practices.
Therefore in order to strictly follow the welding safety, regular training and
updating of knowledge is essential. This should be performed by an
appropriate team headed by a team leader.
Other general health and safety requirements in welding include:
• Good housekeeping with essential clean working atmosphere,
• Analysis of chemical gas generated during welding process should be
known to the operator to warn in due time.
• Protection of eye should be made from arcs, flashes and heat.
• Hot surfaces must be marked, preferably each part engaged in welding
must be considered hot.
First aid
Though all precautions are maintained and the workers/ operators are trained,
yet first aid must always be available at welding shop. Workers assigned for
applying the first aid must be trained to understand when first aid is required.

SAQ 7
a) Explain in brief the various safety hazards in welding operation?
b) What are the training required for the welding workers?
c) Explain value of experience.

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3.10 PERSONAL PROTECTIVE EQUIPMENT
(PPE)
During performing welding process, due to risk involved proper precautions
needsto be made[14]. For this standard personal protective equipment (PPE)
are used. The PPE (Figure 3.15 - 3.19) consists of:
• Welding helmet incorporated with suitable arc flash filter (with not less
than shade 10)
• Eye protection
• Use of dark clothing to avoid ultraviolet (UV) rays
• Gloves (Occupational protective gloves)
• Apron
• Respiratory protection

Figure 3.15: Full PPE Figure 3.16 :Respirator

(Source :Department of labour, health safety in (Source :Department of labour, health safety in
welding pdf) welding pdf)

Figure 3.17: Eye Protection Figure 3.18: Hearing Protection

(Source:Department of labour, health safety in (Source :Department of labour,health safety in
welding pdf) welding pdf)

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Figure 3.19: Welder with PPE

(Source :Department of labour,health safety in welding pdf)

SAQ 8
a) What is meant by Personal Protective Equipment ?
b) What are body parts should be protected and what are the PPE
for protection?

3.11 WORKING AT HEIGHT

3.11.1 Definition of Working at Heights
When a person is working at some elevation as compared to the surface then
the risk of working at height originates. In such situations precautionary
measure should be adopted to prevent from harms (Figure 3.20 - 3.22).

Figure 3.20: Working at Height

(Source :Health authority, Height aware working safely at height pdf)

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Figure 3.21: Risks of Working at Height

(Source :Health authority, Height aware working safely at height pdf)

External factors such as wind, heat stress, structural instability and worker
factors should all be considered along with control requirements as they can
be the cause of falls leading to injury.

Figure 3.22: External Factors While Working at Height

(Source: Health authority, Height aware working safely at height pdf)

SAQ 9
a) What is meaning of operation from height?
b) What are the risks in operation from height?
c) Give examples of external factors while working from height.?

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3.12 LET US SUM UP
To summarise, this unit has helped you appreciate the need of implementing
safe practices in design and how fault management in design is helpful. It
has also emphasised the need for safety practices in abrasive wheel and wood
working machine. The unit has also stressed on the importance of casing of
new machinery and how it helps in increasing the longevity of machines.
Safety in lifting equipment and casting and foundry equipment was also
discussed in detail to help the learner get an idea of how each of it is
important in the long run to prevent damage to the machine as well as ensure
that workers are safe and do not face any injury, fatal or otherwise.

3.13 ANSWERS TO SAQS

SAQ 1
a) Failure of hardware components, use of low quality switches and failure
of software.
b) Intermittent failures, transient failure and wear out failures and basis of
categorization is the time period.
c) Fault management techniques are detecting ,isolating and correcting
malfunctions in a given system. FMEA is failure mode and effect
analysis which tells us about ways or modes in which something like
equipment may fail and consequences of those failures.
d) Fail operational, fail safe and fail passive.
e) Reliability is defined as the probability that a product, system, or service
will perform its intended function adequately for a specified period of
time, or will operate in a defined environment without failure.. Mean
time between failures (MTBF) is the predicted elapsed time between
inherent failures of a mechanical or electronic system, during normal
system operation.
SAQ 2
a) Definition: Safe work practices are generally written methods outlining
how to perform a task with minimum risk to people, equipment,
materials, environment, and processes.
b) The laws related to safety like health and safety work regulations is
known as safety law and role of supervisor is to enforce various safety
regulations and disciplinary measures
c)
1. Establish effective shop floor training programs.
2. Develop reciprocal communication channels.
3. Identify emerging safety issues via audits.
4. Streamline systems to mitigate human errors.
5. Effectively manage safety-related risks.
SAQ 3
a) Guideline or precautions about the hazards and risks that may arise
104 during the operation of abrasive wheels are to be observed in advance;
 Abrasive wheel designation with their type, size and maximum operating Job Saftety Analysis
and Machine Guards
speed;should be known to workers.
b) The workpiece get burnt,wheel loading and glazing ,wheel chatter and
poor surface finish.
c) Supervisors should instruct the lower labour involved in unloading the
wheels and about dropping and bumping of the wheels.
d) Centrifugal force (the only fatal cause of wheel bursts) increases as the
square of the speed of abrasive wheel. The spindle speed has to set to an
optimum value
SAQ 4
a) A wood manufacturing plant is where the carpenter or work with wood is
done with the help of machines and wood working lathes . The main
precautions that a novice must follow is to wear face shield, goggles
and mask in a wood working plant.
b) Push pad and push sticks are used for smooth working with wood.
Generally, “Kick back” action occurs with sawmill at the time of timber
cutting operations. There are many considerable serious safety issues
within sawmills. In order to save the workers from hazards “anti kick
back” are devices installed on sawmills.
c) An interlocked physical barrier has a moveable part. In such type of
barrier system, the guard directly interacts with the movable parts of the
machinery to prevent their motion when the guard will be in open
situation. Barriers are meant for providing the protection when the guard
is in correct position.
d) A musculoskeletal disorder (MSD) always causes “sprains and strains”
in the body of workers when subjected to continuous work in the plant .
These can be minimized by correct posture of worker during cutting
operation or other tasks.
SAQ 5
a) Every set screw, bolt or key on any revolving shaft, spindle, wheel or
pinion shall be so sunk, encased or otherwise effectively guarded as to
prevent danger.
b) When an object is moved against the gravity by machines or equipments
it is called lifting operation . If any part of machines or equipment falls
down then the condition of workers or other machines in the vicinity will
get effected and that's why one should be safe while lifting operation.
c) To ensure activities which don’t cause injury, we recommend
you DO:Share lifting equally between employee,Reduce moving
distances wherever possible Donts DON’T:Lift loads that you struggle to
manage.Move loads up or down stairs.
d) Do's use only certified lifting equipment, marked with its safe working
load, which is not overdue for examination;keep the reports of thorough
examination as well as any declarations of conformity or test certificates;
Don't use unsuitable equipment, eg makeshift, damaged, badly worn
chains shortened with knots, kinked or twisted wire ropes, frayed or
rotted fiber ropes.

105
 Safety in Machinery e) In order to prevent the snapping of chains, the chains must be checked
to ensure that elongation remains within specified limit. If the chains
are stretched then calculate the maximum permissible stretch
limit.Wear in the chains can severely affect the strength of chains,
hence if the chain has worn out,it should immediately be quarantined.
SAQ 6
a) A foundry is a factory that produces metal castings. Metals are cast
into shapes by melting them into a liquid, pouring the metal into a
mold, and removing the mold material after the metal has solidified as
it cools. Workers should wear full face shields
and safety glasses to reduce or eliminate the risk of eye or face injury.
b) Rules in Foundry

• Always read, understand and follow the instructions provided in

the shop floor.
• Wear leather shoes and fireproof apron
• Wear foot and leg protection
• Use gloves and wire mesh face shield
• Always wear safety glasses
SAQ 7
a) Burns ,fumes which are hazardous to health and electric shocks which
can make a person dead in minutes.
b) Welding process involves wide range of specifications to be maintained
in variety of working conditions. This requires high skills and
competency level in the welding operator to avoid any mis-happening.
The welding operator must be appropriately trained and certified to be
able to work by following:
Correct process to be performed,
Identify Hazards associated with the work,
Methods to minimize hazards
c) Theoretical knowledge is not enough to attain the required welding
expertise, hence experience, skill and practice are essential for
performing safe working practices.

SAQ 8
a) During performing welding process, due to risk involved proper
precautions needs to be made. For this standard personal protective
equipment (PPE) are used.
b) Welding helmet incorporated with suitable arc flash filter (with not less
than shade 10)
• Eye protection
• Use of dark clothing to avoid ultraviolet (UV) rays
• Gloves (Occupational protective gloves)
• Apron
• Respiratory protection
106
SAQ 9 Job Saftety Analysis
and Machine Guards
a) The operation from heights means working at any distance above the
ground level. When a person is working at some elevation as compared
to the surface then the risk of working at height originates.
b) The hazards and factors affecting the risk from working at height include
vertical distance of a fall, fragile roofs, roof lights, voids, sloping roofs,
deteriorating materials, unprotected edges, unstable or poorly maintained
access equipment and adverse weather conditions.
c) External factors such as wind, heat stress, structural instability and
worker factors should all be considered along with control requirements
as they can be the cause of falls leading to injury.few examples are
blowing of sand which causes poor visibility and wind which can make
materials to fly as well as problems to the operator working at height .

3.12 REFERENCES AND FURTHER READINGS

[1] Material Handling Safelty, https://www.mccue.com/content/material-
handling-safety?utm_source=le_footer
[2] Chen.W, Zhang.G, “Safety management on hazardous material transportation”,,
2014 International Conference on Connected Vehicles and Expo (ICCVE)
[3] T. Xia, Z. He, "Design and implementation of supervisory system for
transportation of hazardous chemicals" in Electronic Measurements Technology,
Chinese, vol. 34, pp. 85-89, 2011.
[4] K Häkkinen, “Safety in materials handling”, Article in Scandinavian Journal
of Work, Environment & Health 7 Suppl 4, page no. 109-14 · February 1981
[5] https://www.osha.gov/Publications/OSHA2236/osha2236.html
[6] https://mn.gov/bms-stat/assets/cd_safe_materials_handling.pdf[7]
https://www.slideshare.net/mehulomgupta/material-handling-industry
[8] https://quizlet.com/203139238/iet-327-exam-2-study-guide-flash-cards/
[9] https://www.mccue.com/content/material-handling-safety?utm_source=le_footer
[10] https://www.safetyinfo.com/material-handling-and-storage-safety-index/
[11] https://kdcconstruction.com/wp-content/uploads/2016/01/510_General-
Material-Handling.pdf
[12]
https://www.wrha.mb.ca/professionals/safety/files/SafePatientHandling/MM
HM.pdf
[13] https://www.safequarry.com/toolbox/Safeuseofliftingequipment.pdf.pdf
[14] https://m.lincolnelectric.com/assets/US/EN/interactive/welding-
safety/data/FACT-33.pdf
[15] https://www.hsa.ie/eng/Topics/Work_at_Height/

107
 Safety in Machinery
UNIT 4 CASE STUDY AND EXERCISE
Structure
4.1 Introduction
Objectives
4.2 Case 1: Study of The Bhopal Gas Incident
4.2.1 Union Carbide in Bhopal
4.2.2 The Gas Disaster
4.2.3 The International Medical Commission (Imc)
4.2.4 Immediate Effects of The Disaster
4.2.5 Toxicity of MIC
4.2.6 Epidemiological Study
4.2.7 Attribution of Harmful Disease Due To Gas Exposure
4.2.8 Safety Failures:
4.3 Case 2: Vizag Gas Leak Case
4.3.1 The Leak
4.3.2 Facilities and Leakage
4.3.3 Steps for Damage Control
4.3.4 Safety Failures
4.4 Some More Case Studies
4.5 Let Us Sum Up
4.6 Keywords
4.7 Answers to SAQs
4.8 References and Further Readings

4.1 INTRODUCTION
Safety is an important aspect for any industry, as accident free work
environment boosts the moral of the team members working in any hazardous
situation. Recognizing these facts industries involving various hazards and
risks industries prepare their own safety policy, safety manual and have a
separate department/section for safety so as to create proper awareness and
provide the know-how-about the safety.
Adherence to the useful information, rules, and mandatory requirements
governing the safety and guidelines will help prevent occupational injuries
and accidents which constitute an unavoidable and needless waste of human
and material resources.
Safety means continuing and healthful living without injury. Safety is
freedom from harm or the danger of harm. The word safety also refers to the
precautions people take to prevent accidents, harm, danger, damage, loss and
pollution. Safety also deals with improvement in working conditions for
better health. Management is responsible to provide safe working condition
and individual’s safety.
All undesired events in a workplace which can give rise to death, ill health,
injury, damage or other loss need to be thoroughly investigated, people are
trained to safeguard against them, and need to be eliminated. Similarly, all
108
hazards, i.e., source/situation capable of injury or ill health, damage to Case Study and
Excercise
property or workplace environment etc. should be identified and action plan
drawn for safeguard against them.
It is not only sufficient to care for safety but other two inter-related aspects,
viz.; health (well-being of employees) and environment. All these three
elements i.e., safety, health and environment (also known as SHE) are inter-
related and affect each other. For instance, if health of an employee is not
given due consideration, it may lead to accidents. Each industry, therefore,
has certain obligations towards keeping good environment and also towards
health of people.
Cases of construction site accidents often happen. To reduce accidents at any
work place, we have to determine the current safety practices at the
concerned sites, to identify the safety practices related problems, and to
identify the strategies to reduce the safety practices related problems. Among
the practices are safety policy, education and training, site safety inspection,
safety auditing, safety meeting, site safety organization, personal protective
equipment, emergency support and safety measuring devices, fall protective
systems, and safety promotions.

Nevertheless, several problems are encountered in the safety practices; the

problems are ignorance of workers on work procedures, lack of financial
allocation for safety management, lack of awareness among workers, and
language barrier between supervisors and workers. Several strategies have
been suggested to overcome the problems, the strategies are to provide
effective safety training, allocation of budget for safety management, full
commitment from the top management, and to provide safety booklets in
various languages as the strategies to reduce problems in safety practices.
The suggestion cover three aspects for the implementation of safety
practices, i.e. awareness of workers, commitment of top management and the
allocation of resources.

Objectives

After studying this unit, you will be able to

• explain the losses due to aaccidents in industries
• enumerate the ccauses of aaccidents in industries
• list down the factors responsible for accidents in industries
• explain the measures for preventing accidents in industries
• analyze the causes of mishaps through different cases.

4.2 CASE-1: STUDY OF THE BHOPAL GAS

INCIDENT
Even after 25 years of massive gas leakage disaster in Bhopal, a chronic
respiratory disease continues in the body of local residents due to toxicity of
air. This section of case study explains the health hazards faced by people
due to gas leakage in Bhopal. The case study also brings out the failure of
safety considerations.

109
 Safety in Machinery 4.2.1 Union Carbide in Bhopal
Bhopal, the capital of Madhya Pradesh is geographically located at the center
of the Indian map. There is a housing society located in the north and central
part of the Bhopal, named as shanty ('kucha') which accomodated a
population of around one million. A picture of the aforementioned society
has been shown in Figure 4.1.

Figure 4.1: Houses near UCIL factory in Bhopal.

Union Carbide India Limited (UCIL) which is a subsidiary of the US based
Dow Chemical Company, set up a plant (Figure 4.2) in Bhopal. It produced
pesticides, batteries, carbon product and industrial chemicals. The company
was set up originally to import, mix and package pesticides manufactured in
the United States. In 1979, methyl isocyanate (MIC) production unit was
installed, for the production of pesticide with the name 'Sevin'. Leak of this
deadly MIC gas from UCIL plant on midnight of 2-3 December 1984
resulted in Bhopal gas disaster (1984).

Figure 4.2. UCIL factory in Bhopal.

MIC is manufactured with combination of (mono) methylamine and
phosgene. The mixture was reacted with 1-naphthol chemical at Bhopal plant
to produce Sevin pesticide. This pesticide is very harmful if inhaled in
gaseous form because it blocks the presence of Oxygen in the body. This gas
is colorless, has low boiling point, high vapor pressure and hence it is highly
110
unstable. Case Study and
Excercise
In the memory of lives which were lost in the incident a memorial was built
by a Dutch artist as shown in Figure 4.3.

Figure 4.3: Memorial of Bhopal gas disaster (1984) built by Dutch artist.

4.2.2 The Gas Disaster

The MIC was stored in the tanks in UCIL plant. The investigation of gas
disaster which occurred due to leakage of this gas was performed by many
authorities to find out concrete reason behind this unfortunate accident.
However some deviation from safety norms during each investigation was
noticed. Most of the people validated this theory that since the MIC has to be
stored in refrigeration condition and is highly volatile; it was stored around
air cooling system. During the accident it was noticed that tank number 610
(of 60 ton capacity) in the plant was not functioning properly. Due to this
corrosion and malfunctioning of tank, it was assumed that water entered the
tank and mixed with MIC which was stored the tank.
This resulted in violent, exothermic reaction catalyzed by corrosion in tank
which started in late hours of 02nd December 1984. By midnight of 03rd
December 1984, the tank got damaged and nearly 27 tons of MIC in the form
vapors discharged in the atmosphere. The toxic amounted to 21 ppm in the
air. By this time Bhopal was covered in this deadly gas atmosphere and later
harmful consequences in the form of death of living beings were seen. Partial
and permanent damage to human lives was also noticed in the accident.
Around 3 lack people were exposed to this gas. As per government data
around death of 5000 peoples were attributed to the inhalation of this gas.
Many people are still living with harmful effects of that incident in the form
of genetic diseases and permanent gene mutations. Physical and mental
retardation of children was uridespread in the children living in the area and
exposed to the deadly gas.

4.2.3 The International Medical Commission (IMC)

Many government and non-government organization came forward to address the
problems of victims of Bhopal gas disaster. Later in 1992, IMC tribunal organized a
meeting in Bhopal to examine the situations of victims in terms of their living due
to harmful implications of gas disaster. With the suggestions of all the members
(from 60 European, Asian and American universities) a commission was constituted
in Bhopal with the name International Medical Commission on Bhopal.
111
 Safety in Machinery 4.2.4 Immediate Effects of the Disaster
The incident took place at such a time (midnight) that people covered in the
radius of gas leakage could not understand much before they were affected
by the harmful effects of MIC. Around 3 lack people were affected by the
MIC. As an immediate effect of gas stinging of the eyes and throat were
reported by the survivors. Moreover, due to low boiling point of MIC, the gas
re-vaporized inside the lungs after it was inhaled, this further exaggerated its
ill effects. Lungs were badly affected, damage to the bronchial, necrosis with
pulmonary edema, acute pulmonary toxicity and hemorrhage was observed
after detailed investigation of survivors and post-mortem of the dead. Exact
number of deaths is still a matter of enquiry since a huge number of people
evacuated the city immediately after the incident and most bodies were
cremated before they could be counter and the cause of death could be
officially documented. As a result, only the number of deaths founded in the
city accounted the total toll of results of incident. According to a Government
of Madhya Pradesh report nearly 1700 people died within 24 hours of gas
leakage. The final toll reported to increase year after year as reported.

4.2.5 Toxicity of MIC

Many studies confirmed that leakage of MIC in vapor form formed many
additional compounds which were severely harmful. The exothermic heat of
reaction including hydroxyurea and nitrogen oxide exposed to methylamine
and dimethylurea caused losses of lives. After Bhopal incident several
experimental studies have been carried out in order to predict the extent of
harmful effects of MIC. A study indicated that MIC which was used as
pesticide, if used in permissible quantity (within levels of 0.4 ppm) has lesser
effects on living beings but if its dose increased up to 21 ppm, its effect
becomes unbearable. Its irritant properties were confirmed when a mice
exposed for two hours to the concentration of MIC (11) reported harmful
outcomes.

4.2.6 Epidemiological Study

The severe effect of MIC has been understood and confirmed. Within weeks
many authorities started carrying out analysis on human effects due to gas
leak. Some of these authorities are Indian Council of Medical
Research (ICMR), the Tata Institute for Social Sciences (Bombay), the World
Health Organization (WHO), Bhopal University, other academic institutions
in India and Union Carbide itself. Study performed with the clinical
experience and patients hospitalized indicated the occurrence of
epidemiological problems. Though, many of the research findings were not
published, some that were published in ICMR Council's Annual Reports were
with limited details. Other small published reports compiled from the
survivors are also available which declared the incident to be epidemiological
which occurred mainly due to the respiratory problems as shown in Table 1.
A long term follow up of victims was not done. Due to lack of common
conclusions from the study it remained questionable that up to what extent
the findings could be generalized. There were many reasons why the studies
could not be generalized. Unfortunately, only group average values were
presented, making it impossible to establish whether there were individual
variations in response.
112
 Table 4.1: Studies of respiratory problems in survivors of the Bhopal Case Study and
Excercise
disaster, 1984

Duration of follow-
Nos. Related health problem (s)
up
500 72 hours pulmonary oedema

978 2 days respiratory tract irritation, pulmonary oedema

respiratory tract irritation, pulmonary oedema,
33 1 week
pneumonia
224 3 months lung disease
569 3 months Spirometrycloser to the factory
1109 3 months Radiographic changes
82 6 months Interstitial deposits

4.2.7 Attribution of Harmful Disease due to Gas Exposure

A prominent weakness of findings was due to performance of studies beyond
a week or two after the disaster, has been the question of finalization of the
results. This resulted in abnormalities in the findings. On ground most of the
respiratory outcomes are distinguishable, since a frequent and elaborate
investigation of disease states prior to incident is unavailable. This type of
difficulties is not only limited to Bhopal disaster but common in the case of
assessment of industrial disasters, where specific outcomes are rare.
However, the difficulties in this case are compounded by the continuing
uncertainty over exactly which gases were discharged and the lack of
previous, human toxicological data on MIC (the probable major constituent).
A common method of analysis of such incidents is comparison of disease
frequencies across two or more groups with differing levels of estimated
exposure-response relationship. This type of approach is followed in the case
of disaster caused due to losses as a result of harmful respiratory symptoms.
Besides this study of population with the distance of their residing is also
important factor to consider. But both of these criteria unfortunately failed to
correlate this with morbidity.

4.2.8 Safety Failures

The deadly gas leak in Bhopal could have been prevented if Union Carbide
India had met the plant safety recommendations and Indian officials had
examined worker complaints. The international Confederation of Free Trade
unions and International Union of Chemical Energy and General Workers’
blamed the tragedy as part of ‘dangerous and irresponsible’ operating
procedure. As early as 1976, the workers demanded better safety provisions.
There were at least 5 small accidents involving toxic materials that happened
between 1981 to December 1984.
The report released simultaneously by international unions at Geneva and
New Delhi and AFL-CIO in Washington blamed the accident on inadequate
maintenance, faulty equipment, insufficient attention to safety in the process
design, poor training and lack of emergency response planning.
113
 Safety in Machinery The inspector’s opinion was that water flowed into the tanks during a routine
cleaning because of mistakes by management, faulty equipment design and
maintenance and cuts in staffing that led to this accident.
Factors Causing Accident:
a) Storing of MIC and filling beyond recommended levels
b) Poor Maintenance
c) Lack of effective safety systems in place
d) Undersized safety devices
e) Dependence on mutual operations
f) Location of plant next to densely operated area
g) Safety systems were switched off to save money, including MIC tank
refrigeration which could have prevented or reduced the impact of
disaster.

SAQ 1
a) What is UCIL and which material was causing the Health Hazard
in UCIL accident?

b) Why this accident is one of the most severe chemical disasters in

the world?
c) What were the health hazards in the immediate and long
term?
d) What are the main factors for the accident?

4.3 CASE 2: VIZAG GAS LEAK CASE

4.4.1 The Leak
The Vizag gas leak case was an industrial accident that occurred at the LG
Polymers chemical plant in a village of Vishakhapatnam on May 7th, 2020. A
vapour cloud was created as a result of the gas leak which spread over a
radious of three kilometers affecting the nearby villages and areas. Initially, it
was reported that a 1000 people were sick after being exposed to the gas.
Preliminary investigations suggested the likely reason to be insufficient
maintenance of the units, improper storage and operation errors. The South
Korean company, LG Polymers was into manufacturing polystyrene, co
polymer products and engineering plastic compounds.

4.3.2 Facilities and Leakage

The plant contained 2000 metric tons of styrene in tanks which were left
unattended. Higher temperature may lead to vapourisation of styrene, so it is
necessary to maintain a storage temperature of around 20oC. A malfunction
in the factory’s cooling system led the temperature yo exceed safe levels
causing vapourisation of styrene. This led the gas leak and affect the nearby
villages.
114
 Case Study and
4.3.3 Steps for Damage Control Excercise

Experts from National Disaster Management Authority inspected the storage

facilities of the plant and recommended the removal of materials from the
facility. The state government directed the company to remove 13,000 metric
tonnes of material and take it out of the country. The material was sent to the
company’s headquarters in seoul.

4.3.4 Safety Failures

Lack of environmental clearance was cited to be the major failure. The
company did not have clearance from the Ministry of Environment, Forest
and Climate Change. The clearance is issued after Environment Impact
Assessment (EIA) which is for substantiating the produced quantity and for
continuing operations. According to the EIA notification, petrochemical
industry falls under Category ‘A’ and requires clearance from MoEFCC
everytime they expended their plant or brought about a change to their
manufactured product.
One of the reasons for such failure is also the weak environment laws in
India. The storage facilities were not designed to keep the material for a long
duration.

SAQ 2
a) What were the major cause of failures in Vizag gas leak?
b) Explain the steps taken to control the priliminary damage.

4.4 SOME MORE CASE STUDIES

The purpose of sharing these case studies is to draw your attention to the
reasons why accidents happen and what kind of negligence can lead to
accidents and loss of life. A number of case studies are listed below:
CASE 1: A 30-year-old male electrical technician was helping a company
service representative test the voltage-regulating unit on a new rolling mill.
While the electrical technician went to get the equipment service manual, the
service representative opened the panel cover of the voltage regulator’s
control cabinet in preparation to trace the low-voltage (420 V) wiring in
question (the wiring was not color-coded). The service representative was not
using PPE
The service representative climbed onto a nearby cabinet in order to view the
wires. The technician returned and began working inside the control cabinet,
near exposed, energized electrical conductors. The technician tugged at the
low-voltage wires while the service representative tried to identify them from
above. Suddenly, the representative heard the victim making a gurgling
sound and looked down to see the victim shaking as though he were being
shocked. Cardiopulmonary resuscitation (CPR) was administered to the
victim about 10 minutes later. He was pronounced dead almost 2 hours later
as a result of his contact with an energized electrical conductor.
115
 Safety in Machinery Causes:
1. Unmarked wires
2. Not using PPE during high voltage work.
3. No specialised training to work on high voltage.
CASE 2: In a fireworks manufacturing factory, while one of the worker tried
to cut the fuses with an Iron knife, sparks were generated and fell on the
waste stored nearby and resulted in a fire accident resulting into the death of
a worker
CASE 3: In semi-mechanized safety matches manufacturing unit there was
a frame filling cum dipping machine in the factory. Dipped splints (Match
sticks) were received from this machine in a poly woven sack and weighed.
This sack was then transferred to the dipped splints room manually. While a
worker was dragging the bag and storing the above sack by the side of the
wall in the Dipped Splints Racks (DSR) room he noticed sparks of fire from
the sack. This fire spread to the other sacks containing the match sticks and it
developed into a major fire. This in turn within a short while spread to the
adjacent box filling hall through the door. Due to this fire accident, 13
workers died and 41 workers received bum injury.
Causes:
Synthetic bag contained dipped splints was dragged on the floor. Floor
friction ignited the match stick.
CASE 4: In a Match factory in the Box Filling Section. filling the match
sticks in the match box was carried out with the help of box filling machine.
Around 20 workers were engaged in box filling section.
Dipped splints which were kept In the Aluminum tray were filled in the
empty match boxes with the help of filling machine. While doing so, due to
friction of match stick heads with the friction composition of the empty
match boxes, fire broke out and spread over the match sticks kept in the
Aluminum tray and further the fire spread to the adjacent room where 300
trays of dried match sticks were stored. Due to this fire accident, 4 workers
died and 14 workers received burn injured
Causes:
Due to friction between the head composition and the friction composition of
the empty match boxes fire broke out.
CASE 5: In a Fertilizer manufacturing factory urea manufactured in prill
tower passes through a grizzly (a stainless steel selve) and falls on a
conveyor. To facilitate repairing works to be carried out to a grizzly bar, two
mental rods were placed above the grizzly bar and this was covered
by a tarpaulin sheet right below this arrangement welding of grizzly bar was
carried out.
When the welding process was being carried out heavy lumps of urea started
falling down from the prill tower and fell on the iron plates placed over the
grizzly bar. The iron plates along with heavy lumps of urea fell on the
workers working right below the covered tarpaulin sheet and they sustained
head injuries and died.
116
Causes: Case Study and
Excercise
The temporary arrangement made above the grizzly bar to facilitate welding
work was not of a strong and rigid construction to withstand falling of heavy
lumps of urea from prill tower.
CASE 6: In a cement factory. the Coal Mill which was a horizontal,
rotary unit of 4 m. dial consisting of two chambers divided by a diaphragm -
the first chamber Is called "Drying Chamber" and the second one was called
the "Grinding Chamber". The accident took place in the Drying Chamber of
the coal mill. Lumps of coal were carried to the Drying chamber by the hot
gas comprising of carbon dioxide, Nitrogen and Oxygen from the pre-heater.
Drying takes place as the coal mill rotates. As the maintenance crew wanted
to tighten the "felt packing" In the inlet seal ring of the drying chamber, they
tried to open the "seal ring" by unscrewing the bolts. While doing so, some
three bolts got jammed; hence a contract worker (welder) and a company
employee (Helper) were assigned the job of cutting the jammed bolts by
means of Oxy-Acetylene gas flame.
These two workers entered the inside of coal mill through the manhole
opening using a ladder and were then given the oxygen and Acetylene
Cylinder hoses. The Cylinders were kept outside the coal mill. At that time,
two other contract workers were already inside the coal mill and were
working on the Diaphragm side of the chamber.
Actually these two contract workers were chiseling out the worn-out
ball sticking to the holes in the diaphragm. The welder and the Helper
meanwhile started cutting the jammed bolt using Oxy Acetylene Flame and
finished cutting the first one. When they started cutting the second bolt, there
was a big bang followed by a flash-fire. Flame and smoke came out of the
manhole. All the four workers who were working inside the coal mill came
rushing out of the coal mill with burnt skin and fire injuries.
Inspite of hospitalization and medical treatment, all the four victims died later
due to burn injuries.
Causes:
1. In the drying chamber of the coal mill, there was a residual coal dust
formed at the bottom. Due to the shuffling and movement of the workers
inside the coal mill, the dormant coal dust got disturbed and
started getting dispersed inside. As soon as the Oxy Acetylene torch was
lit for cutting the second bolt, the coal dust exploded followed by a flash
of fire. The rapid release of heat from the explosion caused severe burn
injuries to the workers.
2. There was no "work permit system" followed in the factory.
CASE 7: In a foundry, a worker was operating the die casting machine along
with an apprentice. The apprentice in an attempt to remove the component
which has fallen down in between the dies earlier, bent down and inserted his
head between the dies and the operator did not notice this and operated the
die casting machine. The dies closed and the head of worker got crushed in
between the dies and the worked died.
Causes:
Doors covering the 2 dies (fixed and movable) with an interlock arrangement
which will prevent the machine from being operated when the doors are open
were not provided. 117
 Safety in Machinery CASE 8: In a chemical factory yellow phosphorous was converted into
red phosphorous in a rotary furnace. When the yellow phosphorous was
cooked in the rotary furnace for its conversion to red phosphorous
at 244oC, water which was surrounding the yellow phosphorous, became
steam. When steam was vented, it carried away certain amount of
phosphorous and this caused the vent line choke. This ultimately increased
the temperature and pressure of the vessel. Temperature shot up to 300oC and
pressure was not being monitored. Suddenly the furnace exploded and the
stored up hot gases caused flash fire injury on the worker and he died.
Causes:
1. The outlet for the generated steam and system pressure was chocked by
the phosphorous and there was a pressure and there was a pressure
temperature built up in the vessel.
2. Pressure was not monitored by the pressure gauge installed in the
furnace.
3. No safety valve with the proper scrubber arrangement was installed in
the furnace.
CASE 9: In a textile mill there was a dangerous occurrence caused due to
the collapse of partition wall separating the third & the fourth compartments
of the Cotton Mixing area. The said wall was 17' long 11' high and half inch
thick. It was just constructed above the floor without any foundation. Huge
quantity of cotton was stored in the fourth compartment whereas the third
compartment was empty. The partition wall separating the two
compartments suddenly collapsed due to the stress developed by huge
quantity "of cotton stored in the 4th compartment and fell on the workers in
the 3rd compartment. Due to this one worker died and three were injured.
Cause:
Partition wall was constructed without proper foundation
CASE 10: In a factory, Steel Ingots were manufactured from iron scrap
through induction furnace. Due to the cracks in the ramming mass, lining the
furnace, the hot metal in the furnace penetrated through the cracks and
punctured the S.S.coil and a hole of about 5 mm. diameter developed in the
S.S. ring due to this puncture. Hence, water from the above S.S. coil leaked
into the furnace which on contact with the hot molten metal at 1550°C, inside
the furnace resulted in formation of steam below the furnace top. Due to high
pressure developed in the furnace, the hot molten metal from the top opening
of the furnace splashed on the workers, working on the platform as well as
the side of the platform. Out of 15 injured workers four of them died.
Causes:
1. The ramming mass lining was not packed properly without any cracks.
2. The work of segregation of the iron was carried out the furnace platform.
3. Splash arrestors were not provided all around and above the top opening
of the induction furnace.
CASE 11: In a fireworks manufacturing factory, rockets which
was manufactured using aluminium powder, potassium nitrate, sulphur
& charcoal were not properly dried on the drying platform. In the
wet stage, the rockets were kept in the working shed. Due
118
to moisture content, aluminium powder had undergone exothermic reaction Case Study and
Excercise
and with the evolution of heat, the rockets exploded. As a result of this
explosion ten workers died and three working sheds completely collapsed.
Causes:
Lighting arrestors were not provided in the manufacturing shed.
1. Rockets, which were not properly dried had undergone exothermic
reaction due to moisture content and exploded with the evolution of heat.
2. Mixing and manufacturing sheds were not provided with rubber mats on
the floor.
CASE 12: In a fertilizer factory, as the granulator discharge chute got choked
the plant was stopped and the workers cleaned the choked discharge chute by
means of poking. After cleaning, the plant was, started without feeding the
raw materials namely phosphoric acid, sulphuric acid and ammonia; the
granulator was put on dry run. Meanwhile, the heavy lump which caused the
block in exhaust duct fell down and consequently the unreacted ammonia,
came out from the discharge end in the form of heavy puffing and injured
five contract workers. They were given medical treatment and were
discharged later
Causes:
1. Un-reacted ammonia in the granulator came out from the discharge end
in the form of heavy puffing and injured the workers.

4.5 LET US SUM UP

 This unit was focused on highlighting important cases that have happened
in the past and continue to happen due to negligence of owner and
supervisor, and workers and due to lack of training, lack of awareness
and lack of policy formulation by the government to enforce stricter
safety norms. Effective implementation of policies is also an area that
requires attention and amendment.

4.6 KEYWORDS
NGO: NGO is a Non-government, non-profit organization that operates
independently of any government, typically one whose purpose is to
address a social or political issue.
Toxicity: poisonous
Pesticides: a substance used for destroying insects or other organisms
harmful to cultivated plants or to animals.
Industrialization: It is the period of social and economic change that
transforms a human group from an agrarian society into an industrial society,
involving the extensive re-organisation of an economy for the purpose of
manufacturing.
Environmental pollution: It is the contamination of the physical and
biological components of the earth/atmosphere system to such an extent that
normal environmental processes are adversely affected.

119
 Safety in Machinery
4.7 ANSWERS TO SAQS
SAQ 1
a) Union Carbide India Limited (UCIL) which is a subsidiary of the US
based Dow Chemical Company, set up a plant in the capital of Madhya
Pradesh, Bhopal in 1934. It produced pesticide, batteries, carbon product
and industrial chemicals. The company was set up originally to import,
mix and package pesticides manufactured in the United States. In 1979,
methyl isocyanate (MIC) production unit was installed, for the
production of pesticide with the name 'Sevin'.
Leak of this deadly MIC gas from UCIL plant on midnight of 2-3
December 1984 resulted in Bhopal gas disaster (1984).
b) Because the 3 lacks population of Bhopal got covered in this deadly gas
atmosphere and later harmful consequences in the form of death of living
beings. Partial and permanent damage to human lives was also noticed in
the accident. As per government data around death of 5000 peoples were
attributed as an effect of inhalation of this gas.
c) Immediate Effects: As an immediate effect of gas stinging of the eyes
and throat were reported by the survivors. Lungs were first of all badly
affected, damage to the bronchial, necrosis with pulmonary edema, acute
pulmonary toxicity and hemorrhage was observed after detailed
investigation of survivors and post-mortem dead persons.
Long term effects: respiratory tract irritation, pulmonary oedema,
pneumonia, lung disease, Spirometrycloser to the factory, Radiographic
changes, interstitial deposits
d) Factors causing accident
• Storing of MIC and filling beyond recommended levels
• Poor Maintenance
• Lack of effective safety systems in place
• Undersized safety devices
• Dependence on mutual operations
• Location of plant next to densely operated area
• Safety systems were switched off to save money, including MIC
tank refrigeration which could have prevented or reduced the impact
the disaster.
SAQ 2
a) Refer Section 4.3
b) Refer Section 4.3

4.8 REFERENCES AND FURTHER READINGS

[1] Electrical Safety Foundation International, “Workplace Electrical Injury
and Fatality Statistics, 2003-2010,”Rosslyn, VA: ESFI, February 2012. [2]
Cone JE, Wugofski L, Balmes JR, Das R, Bowler R, Alexeef G, and
Shusterman D (1994) Persistent respiratory health effects after a metam
120 sodium pesticide spill. Chest 106, 500-508.
[3] ENVIRONMENTAL TOXICOLOGY AND HUMAN HEALTH - Vol. I Case Study and
Excercise
- Case Study of the Bhopal Incident - Paul Cullinan
[4] Indian Council for Medical Research (1991) Bhopal Gas Disaster
Research Centre. Annual Reports, Bhopal India.
[5] Jones RN, Hughes JM, Glindmeyer H, and Weill H (1986) Lung function
after acute chlorine exposure. Am Rev Resp Dis 134, 1190-1195.
[6] Naik SR, Acharya VA, Bhalerao RA, Kowli SS, Nazareth H, Mahashur
AA, Shah S, Potnis AV, and Mehta AC (1986) Medical Survey of methyl
isocyanate gas affected population of Bhopal. J Postgrad Medicine (India) 32,
185-191.
[7] Electrical Safety Foundation International, “Electrical Safety Then and
Now,” Rosslyn, VA: ESFI, February2012. [8] Vijayan VK, Pandey VP,
Sankaran K, Mehrotra Y, Darbari BS, and Misra NP (1989) Bronchoalveolar
lavage study in victims of toxic gas leak at Bhopal. Indian JMed Res 90, 407-
414.
[9] “Auditing is Key,” Jamil, S.; Aeiker, J.; Crow, D., In NFPA 70E ®,
“Standard for Electrical Safety in the Workplace”, 2012 edition, Chapters 1
and 2. Kowalski-Trakofler, Ph.D. Kathleen, Non-Contact Electric Arc-
Induced Injuries in the Mining Industry; a Multidisciplinary Approach, 2004
IEEE/IAS Electrical Safety Workshop
[10] https://www.osha.gov/shpguidelines/case-studies.html
[11] https://www.hse.gov.uk/electricity/experience.htm
[12] Charles F. Dalziel, "Dangerous electric current", A/EE Transactions,
vol. 65, pp. 579-585, 1946.
[13] Theodore Bernstein, "Electrocution and fires involving 120/240-V
appliances", IEEE Transactions on Industry Applications, vol. IA-19, no. 2,
pp. 155-159, 1983.
[14]
https://www.esasafe.com/assets/files/esasafe/pdf/Safety_Reports/2011/ESA_
OESR_2011_2-CaseStudy.pdf
[15] Fubara M.T. (1999) Guildlinesand standards for environmental pollution
control in Nigeria. Eguavoen Printers
[16] Henderson V. (2002) Issues and problems of the environment “The
World Bank Research observer (17) 1 (spring)
[17] Hutchpull G. (1996) ‘Pollution, Problems and Abatement in oil and gas
sector’ Journal of Nigeria (4) 1.pp29-37
[18] John E. (2002) The effect of Environmental Pollution on property
values. Unpublished B.Sc Thesis submitted to the department of Estate
Management O.A.U Ile-Ife. of the natural endowments such as Air, Land,
Water, and other natural resources should be encouraged.
[19]. Sofoluwe T. (1997) Principles and Pictures of Public Health in Africa.
The World Bank AF 41E and Carl Bro. International.

121
 Safety in Machinery

122
 Case Study and
Excercise

BLOCK 2
SAFETY IN ELECTRICAL WORKS

123
 Safety in Machinery

124
 Indira Gandhi
National Open University
MIS – 024
School of Engineering & Technology Mechanical and Electrical
Safety Management

Block

2
SAFETY IN ELECTRICAL WORKS

UNIT 5
Electrical Safety, Fire and its Prevention 127

UNIT 6
Safety of lectrical
E Equipments 150

UNIT 7
Indian lectricity
E ulesR 183

UNIT 8
First id A 202
SAFETY IN ELECTRICAL WORKS
Safety is very important aspect for any industry, as an accident free work
environment boosts the moral of the team members working in any hazardous
situations. Recognizing these facts industries involving various hazards and
risks prepare their own safety policy, safety manual,, proper training and have
a separate department/section for safety so as to create proper awareness and
provide the know-how-about the safety.
This block cover electrical safety, fire and its prevention, electrical equipment
safety, various Indian electricity rules or guidelines and first aids during
injuries at the workplace.
Unit-5 describes electrical safety during different work conditions and how
injuries and accidents can be minimized at the workplace specially working
on high voltage or on height. This unit also covers various protective devices,
importance of employee’s special training and application of various
protective equipments at the workplace. This unit also covers different type of
fires and its preventions.
Unit-6 provides principles and procedures for safety of electrical equipments.
This unit explains the various safety precautions during working on electrical
equipments like protective equipments, what to wear at the time of working
on electrical equipments, special training requirement, testing of electrical
equipments etc with golden safety rules and basic concepts and laws of
electricity.
Unit-7 discuss various Indian Electricity Rules included regulations, specific
training, certification requirement, work permit from authority, earthing
condition, working at height, safety provisions for electrical installations,
apparatus operating at high voltage, use of personal protective equipments
etc.
Unit-8 describes first aid and its importance in industries specially when
working on heavy machines, construction sites, working on high voltages,
working on height, handling heavy materials etc. This unit also discusses on
emergencies and ways of tackling these circumstances to minimized losses
like training of CPR and handling various injuries at work place.
In conclusion safety means continuing and healthful living without injury. All
undesired events in a workplace which can give rise to death, ill health,
injury, damage or other loss need to be thoroughly investigated, people are
trained to safeguard against them, and need to be eliminated.
UNIT 5 ELECTRICAL SAFETY, FIRE AND
ITs PREVENTION
Structure
5.1 Introduction
Objectives
5.2 Electrical Hazards
5.3 Use of PPE in Electrical Works
5.4 Tips to Reduce Electrical Accidents
5.5 Electrical Fire Controls and Preventions
5.6 Working at Height
5.7 Permit to Work: Ensuring Safe and Efficient Work Management
5.8 Earthling and Current Leakage
5.9 Working at High Voltage and Related Hazards
5.10 Electrical Safety Case Studies
5.11 Let Us Sum Up
5.12 Key Words
5.13 Answers to SAQs
5.14 References and Further Readings

5.1 INTRODUCTION
Basically, there are two kinds of electricity - static (stationary) and dynamic
(moving). This module is about dynamic electricity which is the most
common electricity we come across. Electricity (dynamic) is characterized by
the flow of electrons through a conductor.

Electrical hazards can be classified into three types:

1) Electrical shock
2) Electrical burns
3) Harmful effects of blasts which include breath considerations, flying
particles from vaporized conductors and pressure impact.

On the jobsite, working around electricity can be very safe when workers
properly recognize and manage hazards. But, scarce training, lack of
understanding and failure to identify potential hazards could result in electric
shock or death.

The construction industry poses maximum challenges like those from

electrical hazards, and most of these incidents and fatalities are caused by
direct worker contact with overhead power lines and contact with machines,
tools, and hand-carried metallic objects.

So in this unit we will be concentrating on some of the common electrical

hazards that are a challenge at the workplace and how one can be safe around
127
 Safety in Electrical them. It also features collection of electrical safety checklists which can be
Works
used to assess electrical dangers on the worksite.
Objectives
After studying this unit, you should be able to:
• identify electrical hazards and ways for their prevention
• discuss personal protective equipments and their usage
• explain the working environment and precautions
• describe the way to prevent the electrical hazards
• identify the causes of electrical fire and its preventions

5.2 ELECTRICAL HAZARDS

Engineers, electricians and overhead line workers are at the top of the list of
professionals who are most exposed to electrical hazards. Common tasks that
put these workers at risk include electrical installation and repairs, testing of
fixtures and equipment and inspection and maintenance activities. However,
people who are indirectly working with electricity like office workers are also
exposed to electrical hazards.

Electricity has long been recognized as a serious workplace hazard. OSHA's

(Occupational Safety and Health Administration) electrical standards are
designed to protect employees exposed to dangers such as electric shock,
electrocution, fires and explosions.

Electrocution is one of the most common hazards across construction

sites and by identifying electrical hazards, we can help in raising awareness
of the risks, their severity, and how it can harm workers. Here are some of the
most common electrical hazards that took place in the workplace and tips on
by which these risks can be mitigated:

5.2.1 Overhead Power Lines

Overhead powered and energized electrical lines have high voltages which
can cause major burns and electrocution to workers. Remember to maintain a
minimum distance of 10 feet from overhead power lines and nearby
equipment. Conduct site surveys to ensure that nothing is stored under
overhead power lines. Also, safety barriers and signs must be installed to
warn nearby non-electrical workers of the hazards present in the area.

5.2.2 Damaged Tools and Equipment

Exposure to damaged electrical tools and equipment can be very dangerous.

Do not fix anything unless you are qualified to do so. Thoroughly check for
cracks, cuts or abrasions on cables, wires and cords. In case of any defects,
have them repaired or replaced. Lock Out Tag Out (LOTO)
procedures should be performed at all times before commencing electrical
128
maintenance and repairs. LOTO procedures are there to protect all workers Electrical Safety, Fire
and its Prevention
on a worksite.

5.2.3 Inadequate Wiring and Overloaded Circuits

Using wires with inappropriate size for the current can cause overheating and
fires to occur. Use the correct wire suitable for the operation and the
electrical load to work on. Use the correct extension cord designed for heavy
duty use. Also, do not overload an outlet and use proper circuit breakers.
Perform regular fire risk assessments to identify areas at risk of bad wiring
and circuits.

5.2.4 Exposed Electrical Parts

Examples of exposed electrical parts include temporary lighting, open power

distribution units, and detached insulation parts on electrical cords. These
hazards can cause potential shocks and burns. Secure these items with proper
guarding mechanisms and always check for any exposed parts that need
immediate repair.

5.2.5 Improper Grounding

The most common OSHA electrical violation is improper grounding of

equipment. Proper grounding can eliminate unwanted voltage and reduce the
risk of electrocution. Never remove the metallic ground pin as it is
responsible for returning unwanted voltage to the ground.

5.2.6 Damaged Insulation

Defective or inadequate insulation is a hazard. Be aware of damaged

insulation and report it immediately. Turn off all power sources before
replacing damaged insulation and never attempt to cover them with electrical
tape.

5.2.7 Wet Conditions

Never operate electrical equipment in wet locations. Water increases

manifolds the risk of electrocution especially if the equipment has damaged
insulation. The inspection of the electrical equipment that has gotten wet
should be inspected, before energizing it.

5.3 USE OF PERSONAL PROTECTIVE

EQUIPMENT (PPE) IN ELECTRICAL
WORKS
The purpose of Personal Protective Equipment (PPE) is to protect the person
undertaking the task. The biggest risk to an electrician is coming into contact
with electricity but steps should be in place such as isolation to prevent this
129
 Safety in Electrical happening. Personal Protective Equipment would be a second line of defense
Works for the individual.

5.3.1 Basic PPE

Basic PPE consists of following:

• Cotton protective clothing with long sleeves
• Helmet or hard hat
• Goggles for eye protection
• Gloves (leather or rubber)
• Hearing protectors
• Safety footwear

Helmets normally need to be worn only when working on the outdoor

switchgear, where they serve to protect against falling objects and collisions
with solid objects at head height. Outdoor substations should always be
considered ‘safety helmet’ areas and helmet wear made compulsory.

Eye protection should be worn when working with hazardous fluids,

particularly mineral oil, to prevent splashes into the eye. They should always
be worn when washing down the internal parts of oil circuit breakers.

Rubber insulating gloves are among the most important articles of personal
protection for electrical workers. To be effective, electrical safety gloves
must incorporate dielectric properties and physical strength, along with
flexibility and durability. Leather protector gloves are used to help provide
the mechanical protection needed against cuts, abrasions and punctures.

Hearing protectors are only required when the worker is in a noisy situation,
that can occur during construction works.

Safety footwear should be routinely worn in all working areas and the shoes
or boots should incorporate steel toe-cap and non slip soles.

5.3.2 Requirement of Specific Protective Equipment for

Specific Work
Safety harness should be worn when working at any height greater than 1.5 m
above ground level and a full harness equipped with a connector is preferred.
Fall arrest equipment may be necessary when working at high level.
Harnesses should be chosen that are suitable for their intended application
and should be of a design that will support the user in the correct position. A
harness should be comfortable, allowing adequate movement of the user and
the unhindered operation of other devices within the system.
Depending on the conditions of the work a sit harness may be necessary; sit
harness has lateral and central attachment points and are designed primarily
to be used for work in suspension, although they may also be used for work
restraint purposes.
130
Respirators can also be necessary when a leakage of SF6 is suspected. Electrical Safety, Fire
and its Prevention
Although SF6 is not toxic, it degrades under the heat of arcing to gases.
When performing energized works or switching operations insulated gloves
and dielectric shoes are required. The gloves must be tested and suitable for
the working voltage.

5.3.3 PPE for Arc Flash

When a risk of arc flash exists, the selection of PPE and its characteristics can
be done as a consequence of the calculation of the incident arc energy or
consulting a “hazard category classification table”. One of those tables can
be found at NFPA (National Fire Protection Association) Standard 70E.
Protective equipment for arc flash consists of:
• Flame resistant protective clothing
• Arc Flash protection hood
• Hard hat
• Safety glasses
• Gloves

5.4 TIPS TO AVOID ELECTRICAL ACCIDENTS

Electrical wiring is everywhere, tucked behind the walls of your home and
within your HD television, DVD player, laptop computer, printer, smart
phone, security systems and other equipment. It only takes one electrical
accident to deliver a lethal jolt to a human body, or burn a home to the
ground. Copper Development Association (CDA) offers a few tips to keep
you and your property safe which are as follows:

5.4.1 Reduce Excessive Loft Temperatures

When you are up in a loft on a sunny summer day, you know the meaning of
hot. If the wires are buried in loft insulation, pass over light fixtures or, worst
of all, are arranged in tight bundles, they become even hotter than if they are
out in the open. The heat does not affect the copper conductors in the wiring;
it’s the plastic insulation and jacketing that surrounds the wires that are the
problem. These are usually rated to withstand up to 194 degrees of
temperature. The cumulative effect of ambient heat and current on attic
wiring can result in temperatures that come close to or exceed the limit.
To help reduce excessive temperatures that could possibly lead to fires, use
larger diameter wires than minimum requirements because they offer less
resistance to electrical current, and they permit more current flow while
staying cooler.

5.4.2 Replace old Wiring

Along with spring cleaning, it is a great time to update electrical wiring. If
home is more than 25 years old, then upgrade electrical service, as it might 131
 Safety in Electrical have an inadequate and possible hazardous wiring system. Homes more than
Works
40 years old are especially susceptible to bare or frayed wires, crumbling
insulation or faulty switches. Passing too much current through a wire, or
overloading, can melt or burn the wire’s insulation and start a fire. If your
home is wired with aluminum branch circuit wiring – largely used 50 or more
years ago – consider replacing the wiring with modern copper branch
circuits.

5.4.3 Avoid Overloaded or Damaged Extension Cords

Electrical tools and appliances have different power ratings, these rugged,
weather-resistant portable cords are designed to accommodate a variety of
temporary power requirements, but not all extension cords are created equal,
varying in gauge (wire diameter) and thus capacity.

An unacceptably sized extension cord can cause a tool or appliance motor to

burn out if allowed to run for too long. It can also cause a dangerous situation
if it overheats. So, it is important to know how much electrical current
(typically rated in amperes, or amps) each electric tool requires.

High-powered tools and appliances like saws, mowers, heaters, and

conditioners use considerably more amperage, so extension cords rated to
handle greater electrical loads should be used with them. Amperage ratings
are also marked on the equipment itself.

5.4.4 Stay Away from Wet Locations

It is not safe to go near the water with electrical equipment. Wet locations
such as kitchens, baths and utility rooms – as well as grounded areas like
your basement or garage – require outlets protected by Ground Fault Circuit
Interrupters (GFCIs). If GFCIs have already been installed near sinks and
dishwashers, test their reset buttons to be sure they are working properly.

5.4.5 Install a Lightning Protection System

Severe thunder and lightning may occur only during the spring and summer
months, but when a storm does pass through, the number of strikes it
produces can be alarming. Lightning protection systems do not attract
lightning to structures, nor do they repel it. Rather, these systems intercept
the lightning and channel the energy onto a low-resistance path, thus safely
discharging, or ‘grounding,’ the electrical current to the earth. Copper and its
alloys are the most common materials used in lightning protection because of
superior corrosion resistance and tight connections, although manufacturers
offer the same products made of either copper or aluminum.

Additionally proper grounding, use of suitable circuit protection devices and

Special Training to Employees is also useful for prevention hazards.

132
5.4.6 Grounding Electrical Safety, Fire
and its Prevention

“Grounding” a tool or electrical system means intentionally creating a low-

resistance path that connects to the earth. This prevents the buildup of
voltages that could cause an electrical accident. Grounding is normally a
secondary protective measure to protect against electric shock. It does not
guarantee that you would not get a shock or be injured or killed by an
electrical current. It will, however, substantially reduce the risk, especially
when used in combination with other safety measures discussed here.

5.4.7 Circuit Protection Devices

Circuit protection devices limit or stop the flow of current automatically in

the event of a ground fault, overload, or short circuit in the wiring system.
Well-known examples of these devices are fuses, circuit breakers, ground-
fault circuit interrupters, and arc-fault circuit interrupters. Fuses and circuit
breakers open or break the circuit automatically when too much current flows
through them and when that happens, fuses melt and circuit breakers trip the
circuit open.

Fuses and circuit breakers are designed to protect conductors and equipment.
They prevent wires and other components from overheating and open the
circuit when there is a risk of a ground fault. Ground-fault circuit interrupters,
or GFCIs, are used in wet locations, construction sites, and other high-risk
areas. These devices interrupt the flow of electricity within as little as 1/40 of
a second to prevent electrocution.

5.4.8 Special Training to Employees

All employees should be trained to be thoroughly familiar with the safety

procedures for their particular jobs. Moreover, good judgment and common
sense are integral to preventing electrical accidents. When working on
electrical equipment, for example, some basic procedures to follow are to:
• de-energize the equipment,
• use lockout and tag procedures to ensure that the equipment remains de-
energized,
• use insulating protective equipment, and
• maintain a safe distance from energized parts.

SAQ 1
a) Electrical injuries are commonly caused by:
i) Unsafe equipment or installations
ii) An unsafe environment
iii) Unsafe work practices.
iv) All of the above

133
 Safety in Electrical
Works b) One of the main functions of personal protective grounds is to
provide a _______ impedance path for a short circuit.

i) High
ii) Low
iii) Smooth
iv) Adequate
c) TRUE or FALSE: Only authorized employees are permitted to
work on electrical systems and equipment
d) What is the use of Circuit Protection Devices?

5.5 ELECTRICAL FIRE CONTROLS AND

PREVENTIONS
Electrical malfunctions are the 3rd most common cause of residential building
fires, representing about 6% of all home fires. Fortunately, home electrical
fires can be preventable. This is considerable that before each project begins,
the project manager or designee will contact the local fire department and
determine whether any variations from the company’s standard fire-
prevention procedures are required or not.

Just being aware of the dangers and potential causes of electrical fires will
help you learn how to avoid them.

5.5.1 Loose Outlets

i) Electrical fire risk: If you plug a cord into an outlet with no resistance
at all or the cord easily falls out, this outlet is a fire hazard. Loose
connections cause the outlet to generate more heat than it is designed to,
which could start a fire.

ii) Fire prevention techniques: Repair or replace loose outlets as soon as

you notice them. You may be able to tighten the wire nuts to improve the
connection, or you may need to replace the outlet.

5.5.2 Old Light Fixtures

i) Electrical fire risk: Every year, the light fixtures in your home or
industry degrade a little more. A fixture may last 25 or even 50 years, but
eventually the wire insulation becomes charred, connections corrode, and
bulbs do not fit well in the socket. Continuing to operate light fixtures
with these problems could present a fire hazard.

ii) Fire prevention techniques: If your lights flicker or would not stay lit
and you have ruled out light switch problems, replace these fixtures as
soon as possible. Also, be careful not to overload light fixtures. For
instance, never use a 100-watt incandescent bulb in a fixture rated for 40
watts. However, a 100-watt equivalent CFL is acceptable because it
134
 produces the same light level, but not nearly as much heat, as a 100-watt Electrical Safety, Fire
and its Prevention
incandescent bulb.

5.5.3 Extension Cords

(i) Electrical fire risk: Misusing extension cords is a common cause of

residential fires. Kinked or smashed cords produce more heat, eventually
melting the insulation from the inside out. Plugging a heat-producing
appliance like heater, motors, conditioners etc into an extension cord can
also cause overheating.
(ii) Fire prevention techniques: Choose heavy-duty extension cords for
every application. Lay the cord out of the way where no one will step on
it. Do not run cords under floor rugs, which could generate excessive
heat. Never permanently rely on extension cords. If you do not have
enough outlets, have an appropriate electrician install, as required.

5.5.4 Limited Electric Power and Circuits

(i) Electrical fire risk: In some homes, there simply is not enough power
available or individual circuits to handle electrical demand. Every time a
breaker trips, the circuit has overloaded. Older homes are especially
prone to this problem because they were not designed with today’s high
electrical demand in mind. Tripped circuit breakers gradually become so
damaged that they no longer work properly. Excessive heat can melt
wiring insulation and expose wires, creating a recipe for disaster.
(ii) Fire prevention techniques: If the kitchen or bathroom circuit breaker
trips constantly, do not simply reset the breaker and do it all over again –
instead, hire an electrician to install additional circuits and protect your
home from electrical fires.

5.5.5 Defective Appliances or Damaged Cords

(i) Electrical fire risk: Individual electrical devices can malfunction and
draw more current than they should without tripping a breaker. This
creates excessive heat and can melt wiring insulation. If wiring is
exposed for any reason, it can pose a fire hazard.
(ii) Fire prevention techniques: Pay attention to your appliances. Check
cords for excessive heat or exposed wires. If a device makes strange
noises or operates improperly, do not wait until the cord catches on fire –
repair or replace it immediately.

5.5.6 Improper Wiring

(i) Electrical fire risk: Outdated wiring or improperly installed fixtures and
electrical upgrades could increase your fire risk.
(ii) Fire prevention techniques: Qualified, reputable electricians always
follow the National Electrical Code, so if you are not confident you can
complete a rewiring job safely, hire someone who can.
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 Safety in Electrical 5.5.7 Use of Correct Equipments to Prevent Fire
Works

One great way of preventing fires in the workplace is by placing the correct
equipment in the building or industry. You may want to ask the local fire
department to visit your business during the remodeling process to make sure
the building is properly enhanced with fire prevention equipments. The
following items should be placed inside or near the building:
• Fire Alarm System
• Fire doors and/or shutters
• Fire hydrants that are operational
• Automatic Sprinkler System (sprinkler heads should be protected against
potential damage)
• Fire extinguishers (mounted and easily accessible to all employees)

5.6 WORKING AT HEIGHT

Working at heights means that an individual is working in a place that
requires necessary precautions to prevent them from falling at a distance,
resulting in serious injury. Injuries from working at heights is one of the most
prominent causes of major work related injuries and fatalities. Falls from
ladders, scaffolding, and lifts onto debris can cause serious injury even when
the height is perceived to not be dangerous. Employers need to ensure that
they take all measures necessary to lower the risk of their workers falling
from a height using preemptive hazard recognition to constant site
assessment.

5.6.1 The DO’S of Working at Heights

• DO as much work as you can while you are on the ground.
• DO make sure that the employees can safely move to and from the area
where they are working at height.
• DO ensure that the equipment that you are using for the job is strong,
stable and suitable enough to get the job done. Inspect and maintain them
regularly.
• DO be careful when you are working near to a fragile surface.
• DO ensure that you are protected from falling objects.
• DO make preparations for emergency evacuations and rescues.

5.6.2 The DON’TS of Working at Heights

• DON’T overload the ladders that they are working on, with equipment or
materials.
• DON’T try to reach too far when you are on a ladder or stepladder.
• DON’T use ladders or stepladders to do work that entail heavy or
strenuous tasks. Only use them to do work that are quick and light.
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• DON’T allow incompetent workers do any work at height. Electrical Safety, Fire
and its Prevention
• DON’T lean or place the ladder on or fragile upper surfaces.
• DON’T stay quiet when you feel someone is compromising their own
safety or the safety of others

5.7 PERMIT TO WORK: ENSURING SAFE AND

EFFICIENT WORK MANAGEMENT
Permit To Work (PTW) refers to management systems used to ensure that
work is done safely and efficiently. These are used in hazardous industries
and involve procedures to request, review, authorize, document and most
importantly, de-conflict tasks to be carried out by front line workers. Permit
to work is an essential part of control of work (COW), the integrated
management of business critical maintenance processes. Control of work is
made up of permit to work, hazard identification and risk assessment (RA),
and isolation management (IM).

Permit to work is a core element of integrated safe system of work (ISSOW)

systems, which along with risk assessment and isolation planning; enable as
low as reasonably practicable (ALARP) reduction of unsafe activities in non-
trivial work environments. Permit to work adherence is essential in process
safety management.

Instructions or procedures are often adequate for most work activities, but
some require extra care. A permit to work system is a formal system stating
exactly what work is to be done, where, and when. A responsible person
should assess the work and check safety at each stage. The people doing the
job sign the permit to show that they understand the risks and precautions
necessary.

Permits are effectively a means of communication between site management,

plant supervisors and operators, and those who carry out the work. Examples
of high-risk jobs where a written permit to work procedure may need to be
used include hot work such as welding, vessel entry, cutting into pipes
carrying hazardous substances, diving in the vicinity of intake openings, and
work that requires electrical or mechanical isolation. It is also a means of
coordinating different work activities to avoid conflicts.

A permit to work is not a replacement for robust risk assessment, but can help
provide context for the risk of work to be done. Common failures in control
of work systems are a failure to follow the permit to work or isolation
management procedures, risk assessments that are not suitable and sufficient
to identify the risks, and/or the control measures and a combination of the
two.

A work permit system is a technical measured document to prevent hazards

and accidents. A work permit system spells out:
1. Nature of job 137
 Safety in Electrical 2. Equipment involved
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3. Time limitations
4. Location
5. Personnel involved

Permit to work is a written record document raised by shift in-charge/ area in-
charge and authorized by safety personnel, permitting the work in a specified
time in a defined area. It ensures the responsibility of individuals for
performing the work. These work permits will identify the hazards full to
personnel, equipment and property.

Following aspects should be considered with respect to the permit to work

systems:
• Human factors
• Management of Work Permit System (WPS)
• Skilled manpower
• Knowledge, wisdom and experience
• Competence
• Objectives of WPS
• Types of Work permit required
• Contents of work permit

SAQ 2
a) What are the correct equipments to prevent fire in the work
place?
b) What is the motive of work permit system?

5.8 EARTHING AND CURRENT LEAKAGE

Electricity is carried by conductors that are supported above the earth or
inside the earth but are electrically isolated by insulators which prevent the
electricity from neutralizing itself as it would if it shorted to earth. However,
there is some very small leakage across these insulators, especially aerial
insulators during wet or humid conditions. This is called earth leakage. We
may sometimes hear the discharge from high voltage wires in foggy
conditions.

An earth leakage circuit breaker (ELCB) is a device used in electrical

installations that measures the amount of leakage to earth by comparing the
electrical flow through the phase (live) wire and the neutral (return) wire. If
these differ by a significant amount, then it will assume there is a fault in the
wiring and will trip, cutting off electricity supply and possibly preventing
electrocution or fire.
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Leakage current is the current that flows through the protective ground Electrical Safety, Fire
and its Prevention
conductor to ground. In the absence of a grounding connection, it is the
current that could flow from any conductive part or the surface of non-
conductive parts to ground if a conductive path was available (such as a
human body). There are always extraneous currents flowing in the safety
ground conductor.

Electrical equipment commonly includes a grounding system to provide

protection against a shock hazard if there is an insulation failure. The
grounding system usually consists of a grounding conductor that bonds the
equipment to the service ground (earth). If there is a catastrophic failure of
the insulation between the hot (power) line and touchable conductive parts,
the voltage is shunted to ground. The resulting current flow will cause a fuse
to blow or open a circuit breaker; preventing a shock hazard. Obviously, a
possible shock hazard exists if the grounding connection is interrupted, either
intentionally or accidentally. The shock hazard may be greater than supposed
because of the leakage currents. Even if there is no insulation failure,
interruption of the leakage currents flowing through the ground conductor
could pose a shock hazard to someone touching the ungrounded equipment
and ground (or other grounded equipment) at the same time. The double
insulation provided in non-grounded equipment provides protection by using
two separate layers of insulation. The protection in this case is ensured
because both layers of insulation are unlikely to fail. However, the conditions
that produce leakage currents are still present, and must be considered.

There are two types of leakage current: (i) AC leakage and ( ii) DC leakage.
(i) AC leakage current
AC leakage current is caused by a parallel combination of capacitance
and resistance between a voltage source (AC line) and the grounded
conductive parts of the equipment.
(ii) DC leakage
DC leakage current usually applies only to end-product equipment, not to
power supplies. The leakage caused by the DC resistance usually is
insignificant compared to the impedance of various parallel capacitances.

The capacitance may be intentional (such as in EMI filter capacitors) or

unintentional. Some examples of unintentional capacitances are spacing’s on
printed wiring boards, insulations between semiconductors and grounded heat
sinks, and the primary-to-secondary capacitance of isolating transformers
within the power supply.

A meter specially designed for measuring leakage currents is used. The

current flowing in the ground conductor is measured by connecting the meter
in series with the grounding connection. For information processing
equipment, the ground connection is opened and the current flowing to the
neutral side of the power line is measured. For very low leakage currents, the
meter is replaced with a network consisting of either a resistor or a resistor 139
 Safety in Electrical and capacitor combination. The voltage drop across the network is then
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measured using a sensitive AC voltmeter. Ungrounded or double-insulated
equipment is checked by connecting the meter between any touchable
conductive part and ground. In the case of nonconductive housings, a copper
foil of a specific size is placed on the housing, and the current flowing from it
to ground is measured.

5.9 WORKING AT HIGH VOLTAGE AND

RELATED HAZARDS
Electricity is classified as high voltage (HV) if it exceeds 1,000 Volt AC or
1,500 Volt DC. Equipment and conductors that carry high voltage have
specific safety requirements and procedures. In alternating current (AC), the
flow of electric charge periodically reverses direction, whereas in direct
current (DC), the flow of electric charge is in one direction.

Usually high voltage means electrical energy that is high enough to harm
living beings.Equipment and conductors that carry high voltage require
special safety, precautions and procedures. In some industries, high
voltage means voltage above a definite threshold levels (see below table 5.1).
Table 5.1: Threshold Voltage Levels

IEC Voltage AC RMS Voltage DC Voltage

Defining Risk
Range (V) (V)
Electrical
High Voltage > 1000V > 1500V
Arcing
Electrical
Low Voltage 50 to 1000 V 120 to 1500 V
Shock
Extra-Low
< 50 V < 120 V Low Risk
Voltage

The numerical definition of "high voltage" depends on particular cases. Two

factors considered in classifying a voltage as "high voltage". First is the
possibility of causing a spark in air and second the danger of electric shock
by contact or proximity. The definitions may refer to the voltage between any
conductor and ground or between two conductors of a system.

In electric power transmission engineering high voltage means,

approximately 35,000 volts. This is a classification based on the design of
apparatus and insulation.

The IEC (International Electrotechnical Commission) and its national

counterparts (IET, IEEE, VDE, etc.) define high voltage as above
1000 V for alternating current, and at least 1500 V for direct current—and
distinguish it from low voltage (50 to 1000 V AC or 120–1500 V DC)
and extra-low voltage (< 50 V AC or < 120 V DC) circuits. This is in the
context of building wiring and the safety of electrical apparatus.
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5.9.1 Causes of Injuries due to Electrical Currents Electrical Safety, Fire
and its Prevention

There are primarily four types of injuries that can occur due to electric
current. These include:
1. Electrocution

Electrocution occurs when the electric current passes through the body.
If the current flows through a vital organ of any living bodies, it is almost
always fatal. Contact with a low current can cause fibrillation within the
heart that can be reversed, however, contact with a high current can
cause significant burns and damage to cells.
2. Electric Shock

Electric shock can cause significant damage to the nervous system.

When any individual comes into direct contact with the current, it can
causethe injury and severe burns or long-term, chronic pain.
3. Electrical Burns

Eectrocal Burn are very difficult to treat and can cause permanent
scarring to an individual. The initial contact with an electric current can
cause burns to appear on the skin. These burns can range from minor to
severe. Electrical burns cause chronic pain, headaches, memory loss,
dizziness, or irregular heartbeat.
4. Falls

Direct contact with a high voltage electrical current can cause loss of
muscle control or loss of consciousness. This can cause an individual to
fall off from a tower, or a ladder. These falls can create serious injuries
that may be life threatening.

5.9.2 Staying Safe While Working Around Electricity

Staying safe when working on electrical equipment starts with staying

concentrated on your work and focused on your surroundings. Staying alert is
very important while working around electricity, which can save your life,
and the lives of the coworkers. This include carefully inspecting equipment
before working on it, and always following prescribed safety protocols while
you are on location. It is also very important to routinely check your safety
equipment like the soles of your rubber shoes and leather gloves when
working on electrical equipments and transmission lines.

Before starting work on electricity, remember to check yourself properly to

make sure you have removed all jewelry, watches, cell phones, etc. This can
significantly reduce your risk of injury. You should also ensure that the
power has been shut off before work on any electrical line or equipments.
Never work alone, is also very important while working on electricity. It is

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 Safety in Electrical always preferable to have someone nearby as it ensures help in case of a
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mishap.

Unfortunately, any individual come into contact with high voltage electricity
(above 50 volts) can receive a range of injuries including:
• those directly resulting from an electric shock (e.g. burns, breathing and
heart function disorders)
• those resulting indirectly from the electric shock (e.g. falling from
height, etc.)

We know that human body is a great conductor of electricity. It leaves a path

of destruction along the route it takes causing tissue damage and, potentially,
heart failure when electricity passes through the body. Voltages of magnitude
less than 40 volts can be lethal if a person has wet skin.

Direct contact with power lines or energy sources higher than 50 volts can
lead to death or severe injury. Even coming very close to high energy sources
can be harmful because the electric arc produced by these sources can jump
anywhere from a few inches to several feet depending on the voltage level
involved.

5.9.3 Effects of Electric Current in the Human Body

It is very important to know how electric current can affect the working
electrician/engineer while working on the electric line. The table below
shows the effects of various current strength on human body.

Below 1 milli ampere Generally not perceptible

1 milliampere Faint tingle
5 milliamperes Slight shock felt; not painful but
disturbing. Average individual can let
go. Strong involuntary reactions can
lead to other injuries.
6–25 milliamperes (women) Painful shock, loss of muscular control
9–30 milliamperes (men The freezing current or “let-go” range.
Individual cannot let go, but can be
thrown away from the circuit if
extensor muscles are stimulated.
50–150 milliamperes Extreme pain, respiratory arrest, severe
muscular contractions. Death is
possible.
1,000–4,300 milliamperes Rhythmic pumping action of the heart
ceases. Muscular contraction and
nerve damage occur; death likely
10,000 milliamperes Cardiac arrest, severe burns; death
probable
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5.9.4 Precautions Need to be Taken When Working Near Electrical Safety, Fire
and its Prevention
High Voltage Lines:
1. Keep safe distance from high voltage lines. Approximate 6 to 20 feet
away depending on the strength of the line voltage
2. Use non-conductive wood or fiberglass ladders.
3. Ensuring that the high voltage line has been de-energized before starting
work in the vicinity of a high voltage line.
4. Wear personal protective equipment, such as rubber insulating gloves
and insulating sleeves, and industrial protective helmets.
5. Educate workers on safety procedures and requirements. Some medical
devices e.g. pace makers, can be affected by Electro-magnetic fields
produced around high voltage, if you have one of these devices you
should inform to your project dealing officer.
6. Equipment (e.g. cranes): a ‘safe distance’ ranges from 10 feet to 42 feet
depending on the strength of the electrical source
7. Always discharge the high voltage from components or terminals by
using a safety probe.
8. Do NOT hold the test probe when circuits over 300 volts are tested.

It is very important that you only work with any sort of electricity if you have
completed an assessed training course run by an accredited training
organization. Additional training would be required to work with high
voltage electricity.

5.9.5 Responsibilities of Employer

Employers must do everything to ensure the safety of employees working

with electricity:
• Only trained and competent employees should be allowed to work on
electrical equipment specially on high voltage.
• All electrical equipment should be suitable for the environment in which
it is used.
• In case of damp or wet environments electrical equipment should be
suitably insulated to prevent electrocution.
• . Work on dangerous equipments or installation should be carried out
only after confirmation from appropriate authority This should be
confirmed through a suitable test procedure carried out by a competent
person before beginning the work.
• Any high voltage equipment should be earthed properly so that, in case
of equipment failure, the operator will be protected.
• Permit to work system will be required when work has to be carried out
on any high voltage electrical equipment/installation..

In addition to the guidelines associated with general electrical safety and

lockout/tag out procedures, there are more stringent safety requirements
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 Safety in Electrical when working on high voltage . The following list provides high-voltage
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safety tips.
• Only authorized employees work around high voltage equipment.
• High Voltage Sign should be labelled at the entrances.
• Terminal voltage ratings can withstand surges caused by electrical faults
or switching transients.
• Be careful around output circuits even when the input power is off
because parallel power sources and energy storage devices can still be
dangerous.
• Be careful when working with power supplies that serve more than one
area.
• Inspect the power supply and check all protective devices before
working on a high voltage. Never work alone at high voltage.
• Label equipment to identify power sources. Label input power sources to
identify connected power supply loads.
• Emergency shutdown instructions and phone numbers should be attached
to equipment that is remotely controlled or unattended while energized.

Before entering a power supply or associated equipment enclosure to work on

hazardous energy sources, ensure following procedures:
• First De-energize the equipment.
• Open and lockout the main input power circuit breaker.
• Check for auxiliary power circuits that could still be energized.
• Inspect automatic shorting devices for proper operation.
• Short the power supply with grounding hooks.

Turn off the power before connecting alligator clips to any circuit.

To test a "hot" line, never use your fingers. Use approved voltmeters or other
voltage-indicating devices.

SAQ 3
a) 1. What does ELCB stand for?
b) 2. What is Electrocution?
c) 3. What is the reason of AC leakage current?

5. 10 ELECTRICAL SAFETY : CASE STUDIES

5.10.1 Case Study One

A manufacturer kept a plant running 24 hours a day, 7 days a week, with two
12-hour shifts. One day after a shift change, a grinder dropped off-line and
would not function. The electrician assigned to repair the faulty grinder
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arrived shortly thereafter where he entered the motor control room and Electrical Safety, Fire
and its Prevention
opened a 2300-volt motor circuit breaker. During repair when he opened the
circuit breaker he caused an electrical fault by accidentally contacting
energized parts inside the circuit breaker cubicle.

The ensuing electric arc burnt the employee and ignited his clothing. Even
though he sustained third-degree burns over 50 percent of his body, he was
able to depart the motor control room and walk approximately 40 yards to the
first aid room. A nearby employee doused the remaining flames with water.
Co-workers attended to him and two emergency technicians arrived and
administered first aid. Emergency medical services arrived within a short
time to treat and transport him to a hospital where he was admitted. The
electrician died the next day due to the severity of his injuries and burn.

5.10.2 Case Study Two

A contracting firm was performing maintenance and repair work for a food
processing company. The contractors were working on the motor of 480 V
pneumatic roof-mounted conveyor system. When they were examining the
motor, which they found to be running roughly, the motor tripped the electric
starter. One of the contractors went to open 50-ampere standard-duty
disconnect switch, which was located in the electrical room on the second
floor. When he opened the switch, an explosion and electrical fault occurred
involving not only the switch but also a portion of the surrounding electric
equipment. The ensuing electric arc burnt the contractor. He was hospitalized
with first and second-degree burns to his hand, arm and face. Because of
inadequate equipment and housekeeping, combustible cork dust was present
throughout the electrical room. Since the combustible dust placed this
location in a Class II rating according to the National Electrical Code (NEC),
the open-type electric equipment that the contractor operated was unsuitable.

5.10.3 Case Study Three

A 40-year-old male electrician was testing the voltage-regulating unit on a

new rolling mill. While the electrician left the area to get the service manual,
the service representative opened the panel cover of the voltage regulator’s
control cabinet to prepare for tracing down the low-voltage wiring in
question. The wiring was not color-coded and the service representative was
not using personal protective equipment (PPE). The service representative
climbed onto a nearby cabinet in order to view the wires. The technician soon
returned and began working inside the control cabinet near exposed and
energized electrical conductors. The technician began tugging on the low-
voltage wires so that the service representative could attempt to identify them
from above. The company service representative heard the electrical
technician making gurgling sounds. As he looked down to see the victim, he
noticed the victim was shaking as though he were being shocked.
Cardiopulmonary resuscitation (CPR) was administered to the victim;
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 Safety in Electrical however, he was pronounced dead almost 4 hours later. It was determined
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that he had made contact with an energized electrical conductor.

The following hazards can lead to electrical accidents:

• When not using correct lockout tag out procedures
• When not using PPE or incorrect use of PPE
• When equipment not used in proper manner
• When incorrect equipment are used
• When using faulty equipment
• When path to ground is discontinuous or missing
• When there is lack of ground fault protection
• When there is improper use of extension cords
• When there is accidental live electrical contact (e.g. power lines)
Such incidents can be prevented when the workers are able to:
1. Receive and understand affiliated safety training to recognize and avoid
the hazards involved with the work they are expected to do.
2. Understand the importance of the work they are expected to do as the
outcome of the training.
3. Demonstrate they have the skills to do the work as per their job
description.

5.11 LET US SUM UP

On the job site, working around electricity can be very safe when workers
properly identify and control hazards. But, inadequate training, lack of
experience and failure to recognize potential hazards could result in electric
shock or death. The risk of electrical shock and death can be reduced by
applying the best electrical safety practices. It is safer to work within your
scope of expertise instead of taking the risk of working beyond your capacity.
If you are not confident to do the job, don’t hesitate to call for help from an
authorized person.

Instead of relying on your memory, use a checklist when applying electrical

safety practices in your workplace. A digital checklist is a powerful tool that
can serve as a guide for performing work near electrical equipment and
hazards.

Fire Prevention and Safety in the workplace is everyone's responsibility. It is

very important to train all employees on proper fire safety procedures and to
put into place a fire prevention plan in case a fire breaks out in the
workplace.

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5.12 KEY WORDS Electrical Safety, Fire
and its Prevention

Electrical hazards- can be classified into three types. The first and the
foremost being the electrical shock. The second is electrical burns while the
third one is due the effects of blasts which include first breath considerations,
flying particles from vaporized conductors and pressure impact.
Electricity (dynamic)- is characterized by the flow of electrons through a
conductor.
OSHA's (Occupational Safety and Health Administration)- electrical
standards are designed to protect employees exposed to dangers such as
electric shock, electrocution, fires, and explosions.
The purpose of Personal Protective Equipment (PPE)- is to protect the
person undertaking the task.
Grounding - a tool or electrical system means intentionally creating a low-
resistance path that connects to the earth.
Circuit Protection Devices - limit or stop the flow of current automatically
in the event of a ground fault, overload, or short circuit in the wiring system.
Earth Leakage Circuit Breaker- is a device used in electrical installations
that measures the amount of leakage to earth by comparing the electrical flow
through the phase (live) wire and the neutral (return) wire.
Leakage current- is the current that flows through the protective ground
conductor to ground.
Permit To Work - refers to management systems used to ensure that work is
done safely and efficiently.
Work Permits- are effectively a means of communication between site
management, plant supervisors and operators, and those who carry out the
work.
High Voltage - The International Electrotechnical Commission (IEC)- and its
national counterparts (IET, IEEE, VDE, etc.) define high voltage as above
1000 V for alternating current, and at least 1500 V for direct current—and
distinguish it from low voltage (50 to 1000 V AC or 120–1500 V DC)
and extra-low voltage (< 50 V AC or < 120 V DC) circuits.
Electrocution- This occurs when the electric current passes through the
body.
Electric Shock- An electric shock can cause significant damage to the
nervous system. When an individual comes into contact with the current,
whether directly or indirectly, they can become fused to the point of contact.
Burns- Electrical burns are difficult to treat and can cause permanent
scarring to an individual. The initial contact with an electric current can cause
burns to appear on the skin. These burns can range from minor to severe.
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 Safety in Electrical Falls- Contact with a high voltage electrical current can cause loss of
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consciousness or loss of muscle control. This can cause an individual to fall
off a tower, out of a bucket, or off of a ladder. These falls can create
significant secondary injuries that may be life threatening.

5.13 ANSWERS TO SAQS

SAQ 1
a) iv)
b) ii)
c) TRUE
d) Circuit protection devices limit or stop the flow of current automatically
in the event of a ground fault, overload, or short circuit in the wiring
system.
SAQ 2
a) Fire Alarm System, Fire doors and/or shutters, Fire hydrants that are
operational, Automatic Sprinkler System (sprinkler heads should be
protected against potential damage), Fire extinguishers (mounted and
easily accessible to all employees)
b) Permits are effectively a means of communication between site
management, plant supervisors and operators, and those who carry out
the work.
SAQ 3
a) Earth leakage Circuit breaker
b) This occurs when the electric current passes through the body. If the
current passes through a vital organ, it is almost always fatal.
c) AC leakage current is caused by a parallel combination of capacitance
and dc resistance between a voltage source (ac line) and the grounded
conductive parts of the equipment.

5.14 REFERENCES AND FURTHER READINGS

[1].https://www.osha.gov/SLTC/electrical/solutions.html
[2]R. B. Campbell, D. A. Dini, Occupational Injuries From Electrical Shock
and Arc Flash Events, Quincy, MA:Fire Protection Research Foundation,
2015.
[3]"NFPA 70E", Standard for Electrical Safety in the Workplace 2015
Edition, 2014
[4]W.B. Kouwenhoven, “Human Safety and Electric Shock,” Electrical
Safety Practices, Monograph, 112, Instrument Society of America, p. 93.
November 1968.
[5] The state of the National Initiative on Prevention through Design,
Cincinnati, OH:Nat. Inst. Occupational Safety Health, Centers Disease
Control Prevention, U.S. Dept. Health Human Services, 2013.
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[6]https://www.osha.gov/Publications/osha3075.pdf Electrical Safety, Fire
and its Prevention
[7] "CSA Z462", Workplace Electrical Safety Standard, 2015.
[8]https://www.lanl.gov/safety/electrical/docs/elec_hazard_awareness_study_
guide.pdf
[9]https://www.labtrain.noaa.gov/osha600/refer/menu12a.pdf
[10]ELECTRICAL SAFETY HAZARDS HANDBOOK:
https://www.lanl.gov/safety/electrical/docs/arc_flash_safety. pdf

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 UNIT 6 SAFETY OF ELECTRICAL
EQUIPMENTS

Structure
6.1 Introduction
Objectives
6.2 Basic of Electrical System
6.3 Principles and Procedures for Safety of Electrical Equipments
6.4 Safety Precautions for using Basic Measuring Equipments
6.5 Twenty One (21) Golden Safety Rules
6.6 Safety Precautions for Different Electrical Equipment
6.6.1 Transformer
6.6.2 Circuit Breakers
6.6.3 Capacitor Bank
6.6.4 Generator
6.6.5 Motor
6.6.6 Test Instrument
6.6.7 Relay
6.6.8 Extension Cords
6.7 Effect of Electrical Shock
6.8 Let Us Sum Up
6.9 Key Words
6.10 Answers to SAQs
6.11 References and Further Readings

6.1 INTRODUCTION
In this unit, we are going to discuss need for safety of electrical equipment
and what safety precautions should we take when we use different electrical
equipments. Equipment designed for high voltage capacity, such as
transformers, circuit breakers and instrument transformers can create hazards
to human health, which is why it’s important to prioritize safety measures
with its operation or maintenance. Avoiding safety precautions can lead to
equipment failure and injuries, which can shine a negative light on your
company. Keeping the design of your transformer in mind along with proper
installation will help maintain a safe environment for all components of the
equipment, regardless of the manufacturer or system type. Generally all
Electric machines and power electronics equipments involve electrical
currents, voltages, power, and energy quantities that should be handled with
highly diligence and care during experiments and operations. Electrocution
happens when an electrical path is established through the body with very
low currents that can damage vital organs, such as a person’s heart, and may
cause immediate death. All experiments must be performed in the presence of
expert trainer to handle electricity at these high voltages and current levels.
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Objectives Safety of Electrical
Equipments
After studying this unit, you should be able to:
• describe the basic safety steps to be followed while working with
electrical equipments
• define electricity and various concepts related to electricity
• differentiate about conductors, insulators, voltage, current and resistance
• explain the safety precaution during working on different types of
electrical equipments.
• discuss electrical shock and its effects.

6.2 BASIC OF ELECTRICAL SYETEM

Although we cannot see electricity, but we are aware of it in our everyday
life. There are countless ways in which we use it in our day-to-day activities.
We cannot taste or smell electricity, but we can feel it.

Electricity (dynamic) is characterized by the flow of electrons through a

conductor.

6.2.1 Conductors

Conductors are the materials or substances which allow electricity to flow

through them. They are able to conduct electricity because they allow
electrons to flow inside them very easily. Conductors have this property of
allowing the transition of heat or light from one source to another.

Metals, humans, earth, and animal bodies are all conductors. This is the
reason we get electric shocks! The main reason is that being a good
conductor, our human body allows a resistance-free path for the current to
flow from wire to our body.

Conductors have free electrons on its surface which allows current to pass
through. This is the reason why conductors are able to conduct electricity.
Examples of Conductors:
• Silver is the best conductor of electricity. However, it is costly and so,
we don’t use silver in industries and transmission of electricity.
• Copper, Brass, Steel, Gold, and Aluminum are good conductors of
electricity. We use them mostly in electric circuits and systems in the
form of wires.
• Mercury is an excellent liquid conductor that finds use in many
instruments.

Gases are not good conductors of electricity as the particles of matter are
quite far away and thus, they are unable to conduct electrons.

151
 Safety in Electrical 6.2.2 Insulators
Works

Insulators are the materials or substances which resist or don’t allow the
current to flow through them. They are mostly solid in nature and are finding
use in a variety of systems. The property which makes insulators different
from conductors is its resistivity.

Wood, cloth, glass, mica, and quartz are some good examples of insulators.
Insulators are also protectors as they give protection against heat, sound and
of course passage of electricity. Insulators don’t have any free electrons and it
is the main reason why they don’t conduct electricity.
Examples of Insulators:
• Glass is the best insulator as it has the highest resistivity.
• Plastic is a good insulator and it finds its use in making a number of
things.
• Rubber is a common component in making tyres, fire-resistant clothes
and slippers. This is because it is a very good insulator.

6.2.3 Current (AC and DC)

Alternating current is defined as the flow of charge that changes direction

periodically as shown in Figure 6.1(a). The result obtained will be, the
voltage level also reverses along with the current. Basically, AC is used to
deliver power to industries, houses, office buildings, etc.

Figure 6.1 (a): Aleternating Current

Direct current (DC) is the movement of electric charge carriers, i.e. electrons
in a unidirectional flow as shown in Figure 6.1(b). In DC the intensity of the
current will vary along with time, but the direction of movement stays the
same in all time. Here DC is referred to a voltage whose polarity never
reverses.

Figure 6.1 (b): Direct Current

152
6.2.4 Basic Elements Safety of Electrical
Equipments
(i) Resistance
Resistance is the property and resistor is a element which resists the flow
of electric current in a circuit.In metals such as silver or copper, which have
high electrical conductivity and therefore low resistivity, electrons are able to
skip freely from one atom to the next, with little resistance. Symbol of
resistance is shown in Figure 6.2(a). The unit of resistance is Ohm (Ω)

Figure 6.2 (a): Resistance

(ii) Inductor
Inductance is the property and inductor is a element that stores energy in the
magnetic field.It consists of a coil of wire with an electric current running
through it, creating a magnetic field. Symbol of inductor is shown in Figure
6.2(b). The unit for inductance is the Henry (H), named after Joseph Henry,
an American physicist who discovered inductance independently at about the
same time as English physicist Michael Faraday. One henry is the amount of
inductance that is required to induce 1 volt of electromotive force (the
electrical pressure from an energy source) when the current is changing at 1
ampere per second.

Figure 6.2 (b): Inductor

One important application of inductors in active circuits is that they tend to
block high-frequency signals while allowing lower-frequency signals.
(iii) Capacitor
Capacitance is the ability of a device by virtue of which it stores energy in the
electric field, and as such, the electronic component that stores electric charge
is called a capacitor. Symbol of capcitor is shown in Figure 6.2 (C). The
earliest example of a capacitor is the Leyden jar. This device was invented to
store a static electric charge on conducting foil that lined the inside and
outside of a glass jar.

Figure 6.2 (c): Capacitor

The simplest capacitor consists of two flat conducting plates separated by a
small gap. The potential difference, or voltage, between the plates is
proportional to the difference in the amount of the charge on the plates. This
is expressed as Q = CV, where Q is charge, V is voltage and C is capacitance.
The capacitance of a capacitor is the amount of charge it can store per unit of
voltage. The unit for measuring capacitance is the farad (F), named for
Faraday, and is defined as the capacity to store 1 coulomb of charge with an
153
 Safety in Electrical applied potential of 1 volt. One coulomb (C) is the amount of charge
Works transferred by a current of 1 ampere in 1 second.
(iv) Coil
An electromagnetic coil is an electrical conductor such as a wire in the shape
of a coil, spiral or helix as shown is Figure 6.2(d). Electromagnetic coils are
used in electrical engineering where electric currents interact with magnetic
fields.

Figure 6.2 (d): Coil

It is used in devices such as electricmotors, generators, inductors,
electromagnets, transformers, and sensor coils. Either an electric current is
passed through the wire of the coil to generate a magnetic field, or conversely
an external time-varying magnetic field through the interior of the coil
generates an EMF (voltage) in the conductor.
(v) Fuse
A fuse is an essential device used in various electrical circuits which gives the
protection from the overcurrent. It comprises a strip or a metal wire that
dissolves when the heavy flow of current supplies through it. Once this
device has functioned in an open circuit, it ought to rewire or changed based
on the type of fuse.

Figure 6.2 (e): Fuse Fuse wire

Fuse are used to prevent the home appliances from the high current or
overload damage. If we use a fuse in the homes, the electrical faults cannot
happen in the wiring and it doesn’t damage the appliances from the fire of
wire burning. When the fuse gets break or damage, then an abrupt sparkle
happens which may direct to damage your home appliances. That is the
reason we require different types of fuses to guard our home-appliances
against damage.

6.3 PRINCIPLES AND PROCEDURES FOR

SAFETY OF ELECTRICAL EQUIPMENTS
The "Safety Precautions" includes major guidelines and precautions to
perform safe lab and operating environment for persons performing
experiments on electrical equipments. These guidelines included all
necessary precautions, local electrical safety rules and regulations that should
be followed.
Experiments one electric machines and power electronics generally uses
common equipments to supply power and to measure electrical quantities.
154
However, circuits and apparatus being tested may vary for different Safety of Electrical
experiments. Equipments

Safety Precautions
In all electric power and experimental setup these following safety
precautions must be considered:
• Loose wires, cables, and connections must be avoided.
• No exposed metal is live with electricity
• All ON/OFF buttons on equipment, circuit breakers, and disconnect
switches of a bench must be familiarized.
• Circuit power is turned off before make any changes in the experimental
setup.
• Use suitable length of wires in the experimental setup. Long wires or
connections can cause clutter on a bench, and short wires or connections
can be too tight and may be easily disconnected.
• Isolate high power equipment and connections from low power
equipment, such as microcontrollers, to avoid interference and electrical
interconnections between sensitive electronic devices and high power
devices.
• Noted that all DC power supplies, AC sources, and other power sources
start from a zero voltage and zero current output or as instructed in the
experiment. Initial non-zero voltage is possible in some applications
where a voltage source should have a specific starting condition.
• Before leaving the lab all electrical equipments must be turned off.
• Avoid single user to perform an experiment. More than two users
perform an experiment when performing on more than 50 V DC and
three-phase AC.
Work Environment
• Familiarize oneself with all available equipments in the lab.
• Cluttered work environment must be avoided.
• Arrange pen, calculator, lab notebook, and experiment description before
performing experiments..
• Labeled cool and warm (due to heat dissipation) equipment.
Clothing and Personal Requirements
• Avoid jewelry, metal watches, or other metal accessories when
performing any experiment, as these can be dangerous in the vicinity of
rotation machinery and electrical connections.
• Avoid wearing loose apparel, shorts, or short skirts, as they expose direct
skin to electrical connections and rotation machinery.
• Avoid wearing hanging necklaces, glasses, ties, and other accessories, as
users tend to get close to rotating machinery and electrical connections.
• Long hair should be tied to the back of the head.
• Wear personal protective equipment (PPE) as required by local safety
rules and regulations. For example, common PPE includes fire-retardant
155
 Safety in Electrical coats, high-voltage insulating gloves (worn when handling live wires or
Works cables), and earplugs (used when operating loud machinery).

6.4 SAFETY PRECAUSION FOR USING BASIC

MEASURING EQUIPMENTS
Some of the most frequently used test instruments include non-contact
voltage testers, multimeters, insulation testers and ground-resistance testers.
A big issue with using non-contact or proximity devices, for example, is that
to prove a circuit is de-energised it is necessary for that circuit to be tested
phase-to-phase and phase-to-ground, which cannot be done using this type of
tester.

Due to the potential electrical hazards associated with the use of electrical
test instruments, only qualified persons are permitted to perform tasks such as
testing, troubleshooting, and voltage measuring when working within the
Limited Approach Boundary of exposed energized electrical conductors or
circuit parts operating at 50 volts or more, or where any other electrical
hazard may exist. Improper use of electrical test instruments can result in
shock or electrocution, as well as creating an arc flash incident.

The following requirements apply to test instruments, equipment, and all

associated test leads, cables, power cords, probes, and connectors:
• Must be rated for circuits and equipment where they are utilized.
• Must be designed for the environment to which they will be exposed and
for the manner in which they will be utilized.
• Must be visually inspected for external defects and damage before each
use.
• If there is a defect or evidence of damage that might expose an employee
to injury, the defective or damaged item shall be removed from service.

When test instruments are used for testing the absence of voltage, for de-
energized work, on conductors or circuit parts operating at 50 volts or more,
the operation of the test instrument must be verified on a known voltage
source before and after an absence of voltage test is performed. Now various
measuring equipments with safety precaution is discussed in detail.

This verification primarily applies to conductors or circuit parts operating at

50 volts or more. However, under certain conditions (such as wet contact or
immersion) even circuits operating under 50 volts can pose a shock hazard.

6.4.1 Megger

Megger is an electrical instrument that is used for testing insulation resistance

and machine windings to safeguard all electrical equipment from major
damage. The schematic diagram of megger is shown in Figure 6.3
156
6.4.1.1 Megger Test Procedure Safety of Electrical
Equipments
To measure electrical leakage in wire, we pass the current through devices
then; we verify the electrical insulation level in any device such as a motor,
cable, and transformer. The result of this can be measured in terms of Mega
ohm.
6.4.1.2 Working of Megger
• For electrical systems whose voltage is high, it requires 1000 V to 5000
V for testing.
• Connection of deflecting coil must be in series, so that the current that
flows, test the circuit.
• This circuit is connected with a PC coil across it.
• To protect the circuit, two resistors (Current Coil Resistor& Pressure
Coil Resistor) are connected in series and alsousing two coils like a
control coil &deflecting coil.
• In a manually operated megger, a test voltage is generated by the EMI
effect.
• When the voltage increases, then the deflection pointer shows to infinity.
Similarly, if current increases deflection the pointer shows zero.
Therefore
Torque is directly proportional to voltage, and
Torque is inversly proportional to current
You also note that in case of a short circuit, the pointer indicates zero
reading.

Figure 6.3: Schematic Diagram of Megger

6.4.1.3 Safety Measures while doing Megger Test

When megger is used for testing purpose, injury or damage equipment if
thefollowing minimum safety precautions are not observed.
• Use meggers on high-resistance measurements only (such as insulation
measurements or tocheck two separate conductors on a cable). 157
 Safety in Electrical • Never touch the test leads while the handle is being cranked.
Works
• De-energize and discharge the circuit completely before connecting a
megger.
• Disconnect the item being checked from other circuitry, if possible,
before using a megger.

6.4.2 Multimeter

A multimeter or a multitester, also known as a VOM (Volt-Ohm-

Milliammeter), is an electronic measuring instrument that combines several
measurement functions in one unit. A typical multimeter can
measure voltage, current, and resistance as shown in Figure 6.4. Multimeter
is also used for continuity check and for various electronics components
testing purpose.

Figure 6.4: Multimeter.

6.4.2.1 Continuity Check

• Before starting any measurement activity, you should check the
multimeter for continuity. For this, connect its leads and confirm that it
reads zero. When performing continuity check for a circuit, switch off
the power supply to the circuit.
• If there is a capacitor in the circuit, you will hear a beep sound until the
capacitor drains. Always confirm the presence of capacitor to avoid any
confusion.
• If you change the leads (between red and black), the readings should not
change.
6.4.2.2 Voltage Measurement
• While measuring voltage, never touch the bare probe tips together as it
will lead to a short circuit.
158
• Many digital multimeters have auto ranging facility so that you need not Safety of Electrical
worry about overloading but it makes them work slower and it increases Equipments
their cost also.
• If auto ranging is not available, appropriate range should be selected so
that multimeter reading is near midway on the scale.
• You should check for DC voltage and AC voltage modes in your digital
multimeter whether these are separate. Check the user manual to
confirm.
• If lower range is selected, the multimeter shows 1 which means that the
actual reading is out of selected range. If required voltage for a DC
circuit is not known, start from the highest value and go down until
correct range is identified.
• If you forget to put the red lead into appropriate socket for voltage
measurement and the red lead is connected to current socket in the
multimeter, a voltage measurement in this situation may lead to a short
circuit through the multimeter.

6.4.2.3 Current Measurement

• For current measurement, the multimeter should be connected in series

while it should be connected in parallel for voltage measurements.
• When the multimeter knob is set to current measuring mode and you
forget to change it to voltage measuring mode before taking voltage
measurements, it may be a cause of potential hazard.
Set the right current range before measuring higher current otherwise it
will blow the digital multimeter fuse.
• Don't try to measure the current in household AC mains as it is
dangerous.

6.4.2.4 Resistance Measurement

• Power should be tuned off before taking any measurement.
• A resister should be measured stand alone otherwise connected
components in the circuit may affect the reading.
• If you still need to measure a connected resister, ensure that any
capacitors in circuit are drained off.

6.4.2.5 Multimeter Safety Precautions

As with other meters, the incorrect use of a multimeter could cause injury or
damage. The following safety precautions are the minimum for using a
multimeter. When using digital multimeters, we should be careful and
observe few safety precautions in order to keep ourselves safe. We should
also follow general precautions during using of multimeter which are as
follows:
(i) When not in use, keep the digital multimeter knob in OFF position or
the highest voltage position.
(ii) If you want to check presence of hazardous voltage in a circuit with a
digital multimeter, it is important to check for both AC and DC voltage. 159
 Safety in Electrical 6.4.3 Power Supply
Works

A power supply is an electrical device that supplies electric power to

an electrical load. The primary function of a power supply is to
convert electric current from a source to the correct voltage, current,
and frequency to power the load. As a result, power supplies are sometimes
referred to as electric power converters. Some power supplies are separate
standalone pieces of equipment, while others are built into the load
appliances that they power. Examples of the latter include power supplies
found in desktop computers and consumer electronics devices. Other
functions that power supplies may perform include limiting the current drawn
by the load to safe levels, shutting off the current in the event of an electrical
fault, power conditioning to prevent electronic noise or voltage surges on the
input from reaching the load, power-factor correction, and storing energy so
it can continue to power the load in the event of a temporary interruption in
the source power (uninterruptible power supply).

All power supplies have a power input connection, which receives energy in
the form of electric current from a source, and one or more power
output connections that deliver current to the load, basic power supply is
shown in Figure 6.5 .

Figure 6.5: Power Supply

6.4.3.1 Precautions for Safe Use

Following precaustion should follow when we use power supply:
a) Input Voltage

Use a commercial power supply for the power supply voltage input to
models with AC inputs. Inverters with an output frequency of 50/60 Hz
are available, but the rise in the internal temperature of the Power Supply
may result in ignition or burning. Do not use an inverter output for the
power supply of the Product.
b) Grounding

Connect the ground completely. Electric shock may occur if the ground
160 is not connected completely.
c) Operating Environment Safety of Electrical
Equipments
i) Use each Product within the rated range for ambient operating
temperature, ambient operating humidity, and storage temperature
specified for that Product.
ii) Use the Power Supply within the ranges specified for vibration and
shock resistance.
iii) Do not use the Power Supply in locations subject to excessive
amount of dust or where liquids, foreign matter, or corrosive gases
may enter the interior of the Product.
iv) Install the Power Supply well away from devices that produce
strong, high-frequency noise and surge.
v) Do not use the Power Supply in locations subject to direct sunlight.
d) Mounting

The installation screws can be tightened into the Power Supply only to a
limited depth. Make sure that the lengths of the screws protruding into
the Power Supply are within the specified dimensions. Refer to the
dimensional diagrams for each model for specific dimensions.
e) Wiring
i) Use caution when connecting the input cable to the Power Supply.
The Power Supply Unit may be destroyed if the input cable is
connected to the wrong terminals. Use caution when using a model
with a DC input.
ii) The Power Supply Unit may be destroyed if the polarity is reversed.
iii) Do not apply more than 75-N force to the terminal block when
tightening the terminals.
f) Wiring Materials
i) Use a wire size that suits the rated output current of the Power
Supply to be used in order to prevent smoking or ignition caused
by abnormal loads.
ii) Caution is particularly required if the output current from one
Power Supply is distributed to multiple loads.
iii) If thin wiring is used to branch wiring, the Power Supply's
overload protection circuit may fail to operate depending on factors
such as the impedance of the load wiring even when the load is
short-circuited. Therefore, insertion of a fuse in the line or other
protective measures must be considered. Refer to Technical
Explanation for Power Supplies to select wiring materials.
g) Precautions against Ingress of Metal Fragments (Filings)
Drilling on the upper section of an installed Power Supply may cause
drilling fragments to fall onto the PCB, thereby short-circuiting and
destroying the internal circuits. Whether the Power Supply cover is
attached or not, cover the Power Supply with a sheet to prevent ingress
of fragments when performing work on the upper section of the Power
161
 Safety in Electrical Supply.Be sure to remove the sheet covering the Power Supply for
Works machining before power-ON so that it does not interfere with heat
dissipation.
h) Charging a Battery
When connection a battery at the load, connect an overcurrent limiting
circuit and overvoltage protection circuit.
i) Fan-equipped Power Supplies
• Power Supplies equipped with a fan have forced air cooling. Do not
block the ventilation holes on the fan installation surface and the
opposite surface. The cooling effect will decrease if the holes are
blocked.
• Always secure the finger guard when replacing the fan.
• Always turn OFF the input power before replacing the fan. The
input power terminals and internal circuits have a high voltage.
• Do not touch the internal parts when replacing the fan. Internal parts
have a high voltage and high temperature immediately after the
input power is turned OFF.
• Do not allow the removed screws or tools to enter the Power Supply
when replacing the fan.
• Use the specified installation direction and torque specified for each
product when replacing the fan.
j) Output and Ground Connections
The Power Supply output is a floating output (i.e., the primary side and
secondary side are separated), so the output line (i.e., +V or -V) can be
connected externally directly to a ground. Through the ground, however,
the insulation between the primary side and secondary side will be lost.
Confirm that no loops are created in which the Power Supply output is
short-circuited through the internal circuits of the load.
Example: When the +V side of the Power Supply is connected directly to
a ground and a load is used for which the internal 0-V line uses the same
ground.
k) Overload Protection
Power supplies often have protection from short circuit or overload that
could damage the supply or cause a fire. Fuses and circuit breakers are
two commonly used mechanisms for overload protection.
A fuse contains a short piece of wire which melts if too much current
flows. This effectively disconnects the power supply from its load, and
the equipment stops working until the problem that caused the overload
is identified and the fuse is replaced. Some power supplies use a very
thin wire link soldered in place as a fuse. Fuses in power supply units
may be replaceable by the end user, but fuses in consumer equipment
may require tools to access and change.
A circuit breaker contains an element that heats, bends and triggers a
spring which shuts the circuit down. Once the element cools, and the
problem is identified the breaker can be reset and the power restored.
162
 l) Current limiting Safety of Electrical
Equipments
Some supplies use current limiting instead of cutting off power if
overloaded. The two types of current limiting used are electronic
limiting and impedance limiting. The former is common on lab bench
PSUs, the latter is common on supplies of less than 3 watts output.
A foldback current limiter reduces the output current to much less
than the maximum non-fault current.

SAQ 1
a) Define conductor. Name some good conductor of electricity.
b) Differentiate AC and DC.
c) Write down the importance of fuse in electrical equipments?
d) What are the Safety Measures while measuring higher
resistances using Megger?

6.5 TWENTY ONE (21) GOLDEN SAFETY

RULES
A safe work environment is not always enough to control all potential
electrical hazards. You must be very cautious and work safely. Safety
rules help you control your and others risk of injury or death from
workplace hazards. If you are working on electrical circuits or with
electrical tools and equipment, you need to use following golden safety
rules:
Rule no. 1: Avoid contact with energized electrical circuits. Please do not
make fun of this rule if you already know this (and you probably already
know if you are reading these lines) and remember that if something bad
occurs – you probably would nothave second chance. That is not funny.
Rule no. 2: Treat all electrical devices as if they are live or energized.
You never know.
Rule no. 3: Disconnect the power source before servicing or repairing
electrical equipment. The only way to be sure.
Rule no. 4: Use only tools and equipment with non-conducting handles
when working on electrical devices. Easy to check.
Rule no. 5: Never use metallic pencils or rulers, or wear rings or metal
watchbands when working with electrical equipment. This rule is very
easy to forget, especially when you are showing some electrical part
pointing with metallic pencil. Always be aware.
Rule no. 6: When it is necessary to handle equipment that is plugged in,
be sure hands are dry and, when possible, wear nonconductive gloves,
protective clothes and shoes with insulated soles. Pictures of gloves,
clothes and shoes as shown in Figure 6.6.

163
 Safety in Electrical
Works

Figure 6.6: Safety Clothes, Gloves and Shoes.

Rule no. 7: If it is safe to do so, work with only one hand, keeping the
other hand at your side or in your pocket, away from all conductive
material. This precaution reduces the likelihood of accidents that result in
current passing through the chest cavity.
If you ever read about current passing through human body you will
know, so remember – work with one hand only. If you do not clue about
electric current path through human body, read more in technical articles.
Rule no. 8: Minimize the use of electrical equipment in cold rooms or
other areas where condensation is likely. If equipment must be used in
such areas, mount the equipment on a wall or vertical panel.
Rule no. 9: If water or a chemical is spilled onto equipment, shut off
power at the main switch or circuit breaker and unplug the equipment.
Very logical. never try to remove water or similar from equipment while
energized. After all, it is stupid to do so.
Rule no. 10: If an individual comes in contact with a live electrical
conductor, do not touch the equipment, cord or person. Disconnect the
power source from the circuit breaker or pull out the plug using a leather
belt. Tricky situation and you must be very calm in order not to make the
situation even worse. Like in previous rules – Always disconnect the
power first as shown in Figure 6.7.

Figure 6.7: Always Disconnect the Power FIRST.

Rule no. 11: Equipment producing a “tingle” should be disconnected and
reported promptly for repair.
Rule no. 12: Do not rely on grounding to mask a defective circuit nor
attempt to correct a fault by insertion of another fuse or breaker,
particularly one of larger capacity.
164
Rule no. 13: Drain capacitors before working near them and keep the Safety of Electrical
short circuit on the terminals during the work to prevent electrical shock. Equipments

Rule no. 14: Never touch another person’s equipment or electrical

control devices unless instructed to do so. Do not be too smart. Don’t try
your luck.
Rule no. 15: Enclose all electric contacts and conductors so that no one
can accidentally come into contact with them. If applicable do it always,
if not be very careful.
Rule no. 16: Never handle electrical equipment when hands, feet, or
body are wet or perspiring, or when standing on a wet floor. Remember:
Gloves and shoes
Rule no. 17: When it is necessary to touch electrical equipment (for
example, when checking for overheated motors), use the back of the
hand. Thus, if accidental shock were to cause muscular contraction, you
would not “freeze” to the conductor.
Rule no. 18: Do not store highly flammable liquids near electrical
equipment.
Rule no. 19: Be aware that interlocks on equipment disconnect the high
voltage source when a cabinet door is open but power for control circuits
may remain on. Read the single line diagram and wiring schemes – know
your switchboard.
Rule no. 20: De-energize open experimental circuits and equipment to be
left unattended.
Rule no. 21: Do not wear loose clothing or ties near electrical equipment.
Act like an electrical engineer, you are not on the beach.

6.6 SAFETY PRECAUTIONS FOR DIFFERENT

ELECTRICAL EQUIPMENT
The objective of these procedure is to specify minimum mandatory
requirements and advisory guidance for identifying and controlling hazards to
ensure ‘Zero Harm’ with regard to operation maintenance and testing of
electrical equipment. The established documentation for the elimination and
control of hazards is henceforth referred to as Electrical Safety Procedure.
There are different testing procedure for different instruments which are as
follows:

6.6.1 Transformer
A transformer is an electromagnetic device which is used to change the
voltage and current from one level to another, or transfer energy from one
circuit to another through a common magnetic path at a constant frequency. It
can be designed to "step up" or "step down" voltages and works on the
principle of electromagnetic induction. A transformer has no moving parts.It
consists, in its simplest form, of two or more coils of insulated wire wound
on a laminated steel core. When an alternating voltage is introduced to one
coil, called the primary, it magnetizes the iron core. An alternating voltage is
then induced in the other coil, called the secondary or output coil. The change

165
 Safety in Electrical of voltage (or voltage ratio) between the primary and secondary depends on
Works the turns ratio of the two coils.
Transformer can be classified into many categories:
i) Step up / Step Down
ii) Current Transformer or Potential Transformer
iii) Single phase Transformer / Three Phase Transformer
iv) Two winding transformer/ Auto Transformer/ Three winding
Transformer
v) Power / Distribution Transformer
The electrical transformer is a very powerful device and an essential source
of energy in any industry that runs operations using the aid of power but,
there are several risks associated with this device. So, it is very important to
take all important safety measures to prevent any equipment damage,
electrical fire or fatal injury and to ensure that operations remain up and
running at all times. Figure 6.8 shows diagram of a three phase transformer.

Figure 6.8: Transformer

These transformer safety tips can be followed for any model of electrical
transformer, regardless of the make or manufacturer:
i) Check the electrical transformer prior to installation for any burning
smell, faulty parts or abnormalities in continuity.
ii) Any maintenance work must only be undertaken after the equipment
is de-energized and tagged out and the circuit is shut down. This is
necessary to ensure that there is no leakage of current or continuity
between the horse current and the system.
iii) The maintenance crew must be provided appropriate personal protective
equipment that is specifically designed to ensure safety when working on
an electrical transformer with a high voltage output.
iv) No modifications should be made to the electrical transformers over
current protection. The over current protection mechanism of circuits and
conductors must be set to the manufacturer’s standards.
v) Transformer grounding should be in place at all times. It prevents the
accumulation of static charges and protects the windings from coming in
contact with the core or enclosures.
vi) The transformer must be inspected periodically to ensure that no foreign
nuts, bolts, or spare parts have fallen into it.
166
vii) The electrical transformer and all of its components must be kept free Safety of Electrical
from moisture at all times as any contact with water can prove to be Equipments
hazardous.
viii) A caution signage must be put up near the electrical transformer warning
people to stay away from it so that workplace hazards are averted.
ix) Anyone handling the electrical transformer must be familiar with the
maximum use voltage requirements.
x) If any irregularity or abnormality is observed in the functioning of the
electrical transformer, it must be shut off and all the cables and power
cords must be unplugged before analyzing which part of the transformer
is malfunctioning.
xi) Keep spare nuts, bolts and other objects away from your work, so that
they don’t touch or fall into the transformer.
xii) Be certain that your transformer is grounded, which will prevent static
electricity and protect the coils from contacting the enclosure or core.13.
Always keep your transformer and all of its components dry and free
from any kind of moisture or water. To protect unskilled onlookers, set
up caution signs that warn people to keep away from danger.

6.6.2 Circuit Breakers

When dealing with circuit breakers of any kind, safety is vital for every task
large or small since electricity is involved. Circuit breakers in themselves are
safety devices because they work to cut off the power to a building when
there is too much of an electrical current flowing through the wires.
However, there are safety precautions that can be taken to prevent any
electrical problems or harm to people. There is also a product that can help
prevent electrocution when working with industrial Circuit Breakers as
shown in Figure 6.9.

Figure 6.9: Circuit Breaker

All personnel working on industrial circuit breakers should be trained in

Electrical Circuit Breaker and Switch Operation Safety. Safety is the number
one concern during repairs and maintenance of industrial circuit breakers to
help prevent and issues or problems that may occur. All personnel should
always wear personal protective equipment (PPE) when working
with industrial circuit breakers. There are also industrial circuit
breakers locks which help to lock the circuit breaker while it is being serviced
so that it does not accidentally close in the middle of the process. Special care 167
 Safety in Electrical and precautions should always be taken because of the high level of risk
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involved in working with industrial circuit breakers.
6.6.2.1 Inspection and Testing for Industrial Circuit Breaker
The proper inspection and maintenance of industrial circuit
breakers should be taken into special consideration because of their high
level of importance. Circuit breakers are involved with routine switching and
help to protect other equipment. If there is dust or other materials on any
moving parts or contacts on the industrial circuit breakers then problems
can arise as a result. Depending on the type of circuit breakers, some require
little or no routine maintenance. However, the operating conditions that
surround the industrial circuit breaker can sometimes require that
maintenance be completed more often. A minimum of once per year for an
inspection of industrial circuit breakers should be required and every three to
five years routine trip testing should be performed to ensure that the
industrial circuit breakers are working properly. Tools, cords, and electrical
fittings should also be examined before use for any damage or wear that can
cause harm or increase danger when working with the industrial circuit
breakers. Everything in the box should also be clearly labeled to make repairs
and maintenance an easier process.

The proper training and equipment as well as inspection and testing of

industrial circuit breakers is vital for safety of everyone. Dealing with
electricity is dangerous to begin with, so it is necessary to take the proper
precautions.
6.6.2.2 Safety Tips for Working with Circuit Breakers
Anything that involves working with electricity is something that you need to
take precautions with. Circuit breakers are no exception. They are a safety
feature in and of themselves, as their purpose is to shut off power when too
much electricity is present. This prevents a power surge that could lead to
fires or the destruction of appliances.

Circuit breakers are a vital piece to the electrical system of a building, but not
following these major safety tips when working with them can lead to more
damage than they will prevent. Following are the safety tips for working
with circuit breakers:
• Switch off all electrical input power
Before you do any work on the circuit breaker panel, you need to turn
off the main breaker and ensure that the panel is isolated. This needs to
be done prior to even the simplest of procedures done to the breakers,
including inspections for worn-out breakers.
• Use personal protective equipment
If there is even a slight possibility of an arc flash hazard, you should
take precautionary measures and wear personal protective equipment
(PPE). To identify an arc flash hazard, take into account if there are
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 circuit parts exposed as well as the overall design of the equipment. Safety of Electrical
Also look into when the equipment was installed and if it was installed Equipments
properly.
• Selection of the suitable circuit breaker as per requirment
Ensure that the breaker you choose is compatible with the existing
panel. To do so, check that it has the appropriate amperage rating as
well as matching wiring. If you are uncertain about the type of breaker
circuit you are needing, contact the experts at Breaker Outlet.
• Checking of tools, wire and new parts
When replacing or adding a new circuit breaker, you should take a
moment and inspect that all the tools, wires, and new parts are free from
damage. These quick inspections will not only ensure that connections
will work properly, but they will also save you time in the long run.
• Be careful of if any part is still hot
Even when the main breaker is off, the main bus bar has the potential to
still be hot. The same can be true for the conductors leading into the
panel. Always take precautionary measures and use proper tools and
procedures to get the job done.
• Inspect before turning on the circuit breaker
Once the circuit breaker has been replaced or installed, a thorough
inspection of all new parts and connections should be performed by a
licensed technician. Failure to do so could cause damage to the entire
panel as well as all the electrical components of the building. Never just
flip the breaker to see if it works. That is not the proper way to inspect
that everything was connected appropriately, and could lead to severe
damage.
• Perform regular maintenance
Another major precautionary measure that should be taken for the
safety of a building’s circuit breaker panel is performing regular
inspections and maintenance to ensure that all the breakers are in good
condition. Breakers will get old and worn, and should be replaced
accordingly. Many issues can be found during these inspections, and
further damage can be prevented if found early.

6.6.3 Capacitor Bank

A Capacitor Bank is a group of several capacitors of the same rating that are
connected in series or parallel with each other to store electrical energy as
shown in Figure 6.10 . The resulting bank is then used to counteract or
correct a power factor lag or phase shift in an alternating current (AC) power
supply. They can also be used in a direct current (DC) power supply to
increase the ripple current capacity of the power supply or to increase the
overall amount of stored energy.

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 Safety in Electrical
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Figure 6.10: Capacitor Bank

6.6.3.1 Safety Precautions

Safety precaution that should take care while testing capacitor bank are as
follows:
a) While entering Capacitor bank cage ensure that it is fully discharged.
b) Do not reclose capacitor bank breaker immediately after tripping.
c) Ensure Discharge Timer in Protection circuit for the above.
d) One must be aware of the corrosive and dangers of the electrolyte in the
capacitor
e) Ensure proper Voltage and KVAr rating of the capacitor being
commissioned /replaced.

6.6.4 Generator

In electricity generation, a generator is a device that converts motive power

(mechanical energy) into electrical power for use in an external circuit.
Sources of mechanical energy include steam turbines, gas turbines, water
turbines, internal combustion engines, wind turbines and even hand cranks.
The first electromagnetic generator, the Faraday disk, was invented in 1831
by British scientist Michael Faraday. Generators provide nearly all of the
power for electric power grids, real diagram of electric generator is shown in
Figure 6.11.

Figure 6.11: Electrical Generator

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Following are precautions that should be done while testing generator: Safety of Electrical
Equipments
i) While entering generator HV (High Voltage) side bus duct, etc. ensure
that the generator is at standstill and not on turning gear. Ensure primary
drive is isolated.
ii) Ensure to disconnect space heater supply during work. If space heater is
to be kept in service this condition should be clearly highlighted. Space
heater terminals should be adequately covered to prevent personnel
coming in contact to live terminals. Precaution against contact with hot
surface of space heater should also be taken.
iii) Ensure that Generator is not taken on turning gear when testing in
Generator Bus duct is in progress.
iv) Ensure proper sound protection for ears while working in vicinity of
running generators
v) While doing generator shaft voltage measurements ensure proper safety.
vi) In case of Hydrogen filled generators follow the laid down procedures as
Hydrogen gas is highly explosive.Ensure decoupling of generator from
primary mover where ever possible. The isolation valves to the turbine
should be closed.
vii) DO NOT operate a generator indoors. Generators should be placed
outdoors in a location where the exhaust gases cannot enter a home or
building. Good ventilation is key to operating a generator safely.
viii) Be sure the main circuit break is OFF and locked out prior to starting any
generator. This will prevent inadvertent energization of power lines from
backfeed electrical energy from generators and help protect utility line
workers from electrocution.
ix) Turn off generators and let them cool prior to refueling.

6.6.5 Motor
The reverse conversion of electrical energy into mechanical energy is done
by an electric motor. Motors and generators have many similarities. Motor
have mainly two parts i.e. strator and rotor. Internal diagram of electrical
motor source different parts of motor as shown in Figure 6.11.

Figure 6.11: Internal Diagram of Electrical Motor

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 Safety in Electrical While testing motor, following safety precautions must be followed:
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i) Ensure that the motor is at standstill and not on turning gear. Even after
standstill ensure the windings are discharged before testing.
ii) It should be decoupled from load. The motor should not drive the load
and vice versa the load should not rotate the motor during testing.
iii) Ensure to disconnect space heater supply during work. If space heater is
to be kept in service this condition should be clearly highlighted.
iv) Space heater terminals should be adequately covered to prevent
personnel coming in contact to live terminals.
v) Precaution against contact with hot surface of space heater should also be
taken.
vi) Ensure that Motor is not taken on turning gear when testing.
vii) Ensure proper sound protection for ears while working in vicinity of
running motors
viii) While disconnecting motor make sure to note down cable connections to
prevent reverse rotation. One should ensure correct rotation of motor
before coupling to load after overhaul or testing. Wrong direction of
rotation may cause severe damage.

6.6.6 Test Instruments

Following safety precautions should be adopted while using test instrument:
i) Ensure proper grounding of test instruments especially while working in
High Voltage areas.
ii) Ensure proper grounding of equipment under test before test lead
connections.
iii) Ensure all grounds are removed after completion of all tests.
iv) Do final Maintenance IR measurement before charging the equipment.
v) Use of Dimmerstat should be done keeping in mind that both phase and
neutral may have high voltages with respect to ground.
vi) Dimmerstat body should be earthed properly before it is used.
vii) Before HV tan delta measurement at high voltage do one reading at low
voltage to ensure healthiness of circuit.
viii) Keep all test instruments in cool place/shaded area for protection against
heat.
ix) Ensure field calibration of instrument if required.

6.6.7 Relay
A relay is an electrically operated switch. It consists of a set of input
terminals for a single or multiple control signals, and a set of operating
contact terminals. The switch may have any number of contacts in
multiple contact forms, such as make contacts, break contacts, or
combinations thereof as shown in Figure 6.12.
Relays are used where it is necessary to control a circuit by an independent
low-power signal, or where several circuits must be controlled by one signal.
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 Safety of Electrical
Equipments

Figure 6.12: Electric Relay

6.7 ELECTRICAL SHOCKS AND THEIR

EFFECTS
6.7.1 Electrical Shock

Electric shock occurs when the human body becomes part of a path through
which electrons can flow. The resulting effect on the body can be either
direct or indirect.
• Direct. Injury or death can occur whenever electric current flows
through the human body. Currents of less than 30 mA can result in death.
A thorough coverage of the effects of electricity on the human body is
contained in the section of this module entitled Effects of Electricity on
the Human Body.
• Indirect. Although the electric current through the human body may be
well below the values required to cause noticeable injury. Human
reaction can result in falls from ladders or scaffolds, or movement into
operating machinery. Such reaction can result in serious injury or death.

6.7.2 Effect

Burns

Burns can result when a person touches electrical wiring or equipment that is
improperly used or maintained. Typically, such burn injuries occur on the
hands.
Arc-Blast

Arc-blasts occur from high-amperage currents arcing through air. This

abnormal current flow (arc-blast) is initiated by contact between two
energized points. This contact can be caused by persons who have an
accident while working on energized components, or by equipment failure
due to fatigue or abuse. Temperatures as high as 35,000°F have been
recorded in arc-blast research. The three primary hazards associated with an
arc-blast are:

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 Safety in Electrical i) Thermal Radiation.
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In most cases, the radiated thermal energy is only part of the total energy
available from the arc. Numerous factors, including skin color, area of
skin exposed type of clothing have an effect on the degree of injury.
Proper clothing, work distances and over current protection can improve
the chances of curable burns.
ii) Pressure Wave

A high-energy arcing fault can produce a considerable pressure wave.

Research has shown that a person 2 feet away from a 25 kA arc would
experience a force of approximately 480 pounds on the front of their
body. In addition, such a pressure wave can cause serious ear damage
and memory loss due to mild concussions.

In some instances, the pressure wave may propel the victim away from
the arc-blast, reducing the exposure to the thermal energy. However,
such rapid movement could also cause serious physical injury.
iii) Projectiles
The pressure wave can propel relatively large objects over a considerable
distance. In some cases, the pressure wave has sufficient force to snap
the heads of 3/8 inch steel bolts and knock over ordinary construction
walls.
The high-energy arc also causes many of the copper and aluminum
components in the electrical equipment to become molten. These
"droplets" of molten metal can be propelled great distances by the
pressure wave. Although these droplets cool rapidly, they can still be
above temperatures capable of causing serious burns or igniting ordinary
clothing at distances of 10 feet or more. In many cases, the burning effect
is much worse than the injury from shrapnel effects of the droplets.
• Explosions
• Explosions occur when electricity provides a source of ignition for an
explosive mixture in the atmosphere. Ignition can be due to overheated
conductors or equipment, or normal arcing (sparking) at switch contacts.
OSHA standards, the National Electrical Code and related safety
standards have precise requirements for electrical systems and equipment
when applied in such areas.
• Fires

Electricity is one of the most common causes of fire both in the home and
workplace. Defective or misused electrical equipment is a major cause,
with high resistance connections being one of the primary sources of
ignition. High resistance connections occur where wires are improperly
spliced or connected to other components such as receptacle outlets and
switches. This was the primary cause of fires associated with the use of
aluminum wire in buildings during the 1960s and 1970s.
Heat is developed in an electrical conductor by the flow of current and is
equal to I2R. The heat thus released elevates the temperature of the
174 conductor material. A typical use of this formula illustrates a common
 electrical hazard. If there is a bad connection at a receptacle, resulting in a Safety of Electrical
resistance of 2Ω, and a current of 10A flows through that resistance, the Equipments
rate of heat produced (W) would be:
W = I 2 R = 102 × 2 = 200W
If we have ever touched an energized 200W light bulb, we will realize
that this is a lot of heat to be concentrated in the confined space of a
receptacle. Situations similar to this can contribute to electrical fires.

6.7.3 Effects of Electricity on the Human Body

The effects of electric shock on the human body depend on several factors.
The major factors are:
• Current and Voltage
• Resistance
• Path through body
• Duration of shock

The muscular structure of the body is also a factor in that people having less
musculature and more fat typically show similar effects at lesser current
values.
1. Current and Voltage
Although high voltage often produces massive destruction of tissue at contact
locations, it is generally believed that the detrimental effects of electric shock
are due to the current actually flowing through the body. Even though Ohm's
law (I=E/R) applies, it is often difficult to correlate voltage with damage to
the body because of the large variations in contact resistance usually present
in accidents.. Although currents greater than 10 mA are capable of producing
painful to severe shock, currents between 100 and 200 mA can be lethal.

With increasing alternating current, the sensations of tingling give way to

contractions of the muscles. The muscular contractions and accompanying
sensations of heat increase as the current is increased. Sensations of pain
develop, and voluntary control of the muscles that lie in the current pathway
becomes increasingly difficult. As current approaches 15 mA, the victim
cannot let go of the conductive surface being grasped. At this point, the
individual is said to "freeze" to the circuit. This is frequently referred to as
the "let-go" threshold.

As current approaches 100 mA, ventricular fibrillation of the heart occurs.

Ventricular fibrillation is defined as "very rapid uncoordinated contractions
of the ventricles of the heart resulting in loss of synchronization between
heartbeat and pulse beat." Once ventricular fibrillation occurs, it will continue
and death will ensue within a few minutes. Use of a special device called a
de-fibrillator is required to save the victim.

Heavy current flow can result in severe burns and heart paralysis. If shock is
of short duration, the heart stops during current passage and usually re-starts
normally on current interruption, improving the victim's chances for survival.
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 Safety in Electrical 2. Resistance
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The resistance of human skin varies from person to person and fluctuates
between different times of day. The NIOSH states "Under dry conditions, the
resistance offered by the human body may be as high as 100,000 ohms. Wet
or broken skin may drop the body's resistance to 1,000 ohms," adding that
"high-voltage electrical energy quickly breaks down human skin, reducing
the human body's resistance to 500 ohms". Studies have shown that the
electrical resistance of the human body varies with the amount of moisture on
the skin, the pressure applied to the contact point, and the contact area.

The outer layer of skin, the epidermis, has very high resistance when dry.
Wet conditions, a cut or other break in the skin will drastically reduce
resistance.Shock severity increases with an increase in pressure of contact.
Also, the larger the contact area, the lower the resistance.

Whatever protection is offered by skin resistance decreases rapidly with

increase in voltage. Higher voltages have the capability of "breaking down"
the outer layers of the skin, thereby reducing the resistance.
3. Path Through Body

The path the current takes through the body affects the degree of injury. A
small current that passes from one extremity through the heart to the other
extremity is capable of causing severe injury or electrocution. There have
been many cases where an arm or leg was almost burned off when the
extremity came in contact with electrical current and the current only flowed
through a portion of the limb before it went out into the other conductor
without going through the trunk of the body.

A large number of serious electrical accidents in industry involve current

flow from hands to feet. Since such a path involves both the heart and the
lungs, results can be fatal.
4. Duration of Shock

The duration of the shock has a great bearing on the final outcome. If the
shock is of short duration, it may only be a painful experience for the person.

If the level of current flow reaches the approximate ventricular fibrillation

threshold of 100mA, shock duration of a few seconds could be fatal. This is
not much current when you consider that a small light duty portable electric
drill draws about 30 times as much.

At relatively high currents, death is inevitable if the shock is of appreciable

duration; however, if the shock is of short duration, and if the heart has not
been damaged, interruption of the current may be followed by a spontaneous
resumption of its normal rhythmic contractions.

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6.7.4 Summary of Effects Safety of Electrical
Equipments
We can sum up the lethal effects of electric current which are as follows:
i) Current flow greater than the "let-go" threshold of an individual may
cause a person to collapse, become unconscious and can result in death.
The current flow would most often have to continue for longer than five
seconds. Although it may not be possible to determine the exact cause of
death with certainty, asphyxiation or heart failure is the prime suspects.
ii) Current flow through the chest, neck, head or major nerve centers
controlling respiration may result in a failure of the respiratory system.
This is usually caused by a disruption of the nerve impulses between the
respiratory control center and the respiratory muscles. Such a condition
is dangerous since it is possible for the respiratory failure to continue
even after the current flow has stopped.
iii) The most dangerous condition can occur when fairly small amounts of
current flow through the heart area. Such current flow can cause
ventricular fibrillation. This asynchronous movement of the heart causes
the hearts' usual rhythmic pumping action to cease. Death results within
minutes.
iv) When relatively large currents flow through the heart area, heart action
may be stopped entirely. If the shock duration is short and no physical
damage to the heart has occurred, the heart may begin rhythmic pumping
automatically when the current ceases.
v) Extensive tissue damage, including internal organ damage due to high
temperatures, occurs when very large currents flow through major
portions of the body.
vi) There are recorded cases of delayed death after a person has been
revived following an electrical shock. This may occur within minutes,
hours or even days after the event has occurred. Several assumptions for
such delayed effects are:
• internal or unseen hemorrhaging
• emotional or psychological effects of the shock
• aggravation of a pre-existing condition
In many accidents, there is a combination of the above effects, or additional
effects may develop after the initial accident, thus making an accurate
diagnosis is quite difficult.

SAQ 2
a) What is the application of electrical transformer?
b) Write down the Safety tips for working with circuit breakers.
c) What are the safety precautions when working on electrical motor?
d) What is the reason of electric shock?

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 Safety in Electrical
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6.8 LET US SUM UP
Electrically powered equipment can pose a significant hazard to workers,
particularly when mishandled or not maintained. Many electrical devices
have high voltage or high power requirements, carrying even more risk.
Electricity can kill or severely injure people and cause damage to property.
However, by take simple precautions when working with or near electricity
and electrical equipment to significantly reduce the risk of injury and damage
of working electrical equipments.
For the purposes of electrical safety related work practices, there are two
types of employees in the work place that may come in contact with electrical
equipment on a jobsite: qualified and unqualified. A Qualified employee is
defined as a worker who
• Has been trained to avoid electrical hazards when working on or near
exposed energized parts.
• Is familiar with the safety related work practices as required by OSHA
standards.
• Is able to distinguish exposed live parts of electrical equipment.
• Is knowledgeable of the skills and techniques used to determine the
nominal voltages of exposed parts and components.
An Unqualified employee is defined as a worker who has little or no training
regarding electrical hazards. Even though unqualified persons should not be
exposed to energized parts, they should be provided with information and
training necessary to perform their job in a safe manner and understand the
following:
• Be familiar with any electrical hazards in the workplace.
• Understand procedures to follow and to protect themselves when they
work around electricity.
• Understand which tasks that can only be performed by qualified workers
(e.g. maintenance and repairs).
• Know when and how to report electrical problems.
• Know what to do in the event of emergency involving electricity.
• Know how to inspect electrical tools and equipment before use to make
sure insulation and wiring are in good condition.
Live parts to which an employee may be exposed must be deenergized before
the employee works on or near them unless deenergizing the parts introduces
additional or increased hazards or is unfeasible due to equipment design or
operational limitations. Examples of increased or additional hazards include
interruption of life support equipment, deactivation of emergency alarm
systems, shutdown of hazardous location ventilation equipment, or removal
of illumination for an area. Live parts that operate at less than 50 volts to
ground need not be deenergized if there are no increased exposures to
electrical burns or to explosions due to electric arcs.

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6.9 KEY WORDS Safety of Electrical
Equipments

Alternating Current (AC) – the movement of electric charge periodically

reverses direction. In direct current (DC), the flow of electric charge is only
in one direction. AC is the form in which electric power is delivered to
businesses and residences.

Circuit breaker – a device designed to open and close a circuit by non-

automatic means and to open the circuit automatically on a predetermined
over current without damage to itself when properly applied within its
ratings.

Conductor – a wire, cable, or other form of metal installed for the purpose of
conveying electric current from one piece of electrical equipment to another
or to ground.

Current – a flow of electric charge (a phenomenon) or the rate of flow of

electric charge (a quantity). This flowing electric charge is typically carried
by moving electrons, in a conductor such as wire; in an electrolyte, it is
instead carried by ions, and, in plasma, by both.

Direct Current (DC) – is the unidirectional flow of electric charge. Direct

current may flow in a conductor such as a wire, but can also flow through
semiconductors, insulators, or even through a vacuum as in electron or ion
beams. The electric charge flows in a constant direction, distinguishing it
from alternating current (AC).

Electrical equipment – any apparatus, appliance, device, instrument, fitting,

fixture, machinery, material, or thing used in or for, or capable of being used
in or for, the generation, transformation, transmission, distribution, supply, or
utilization of electric power or energy, including, e.g., any assemblage or
combination of materials or things that is used, or is capable of being used or
adapted, to serve or perform any particular purpose or function when
connected to an electrical installation, even if part or all of such materials or
things are mechanical, metallic, or non-electric in origin.

Electrical hazard – a dangerous condition such that contact or equipment

failure can result in electric shock, arc flash burn, thermal burn, or blast.

Electric potential – is the energy required to move a unit electric charge to a

particular place in a static electric field.

Electrically safe work condition – a state in which an electrical conductor

or circuit part has been disconnected from energized parts, locked out in
accordance with established standards, tested to ensure the absence of
voltage, and grounded (if grounding is determined to be necessary).

Electricity – is a general term encompassing a variety of phenomena

resulting from the presence and flow of electric charge. These include many
179
 Safety in Electrical easily recognizable phenomena, such as lightning, static electricity, and the
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flow of electrical current in an electrical wire.

Fuse – an over current protective device with a circuit-opening fusible part

that is heated and severed by the passage of over current through it.

Ground – a connection to earth obtained by a grounding electrode.

Ground fault – an unintentional electrically conducting connection between

an ungrounded conductor of an electrical circuit and normally non-current-
carrying conductors, metallic enclosures, metallic raceways, metallic
equipment, or earth.

High Voltage – means any voltage over 750 volts. The Facility Management
Division (FMD) defines high voltage as any voltage above 600 volts.

Personal Protective Equipment (PPE) – means any clothing, device or

other article that is intended to be worn or used by a worker to prevent injury
or to facilitate rescue.

Power Supply – is a supply of electrical power. A device or system that

supplies electrical or other types of energy to an output load or group of loads
is called a power supply unit. The term is most commonly applied to
electrical energy supplies, less often to mechanical ones, and rarely to others.

Resistance – is a measure of its opposition to the passage of a steady electric

current. An object of uniform cross section will have a resistance
proportional to its length and inversely proportional to its cross-sectional
area, and proportional to the resistivity of the material.

Shock hazard – a dangerous condition associated with the possible release of

energy caused by contact with or approach to energized electrical conductors
or circuit parts.

Switch – a device for making, breaking, or changing connection in a circuit.

Transformer – a device that transfers electrical energy from one circuit to

another through inductively coupled conductors; the transformer's coils. A
varying current in the first or primary winding creates a varying magnetic
flux in the transformer's core, and thus a varying magnetic field through the
secondary winding. This varying magnetic field induces a varying
electromotive force (EMF) or "voltage" in the secondary winding. This effect
is called mutual induction.

Circuit Ground - A method of grounding whereby the metal chassis that

houses the assembly or a large conductive area on a printed circuit board is
used as the common or reference point: also called chassis ground.

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6.10 ANSWERS TO SAQS Safety of Electrical
Equipments

SAQ 1
a) Conductors are the materials or substances which allow electricity to
flow through them. They are able to conduct electricity because they
allow electrons to flow inside them very easily. Silver,Copper, Brass,
Steel, Gold, and Aluminium are good conductors of electricity.
b) Alternating current is defined as the flow of charge that changes
direction periodically while Direct current (DC) is the movement of
electric charge carriers, i.e. electrons in a unidirectional flow.
c) Fuse are used to prevent the home appliances from the high current or
overload damage. If we use a fuse in the homes, the electrical
faults cannot happen in the wiring and it doesn’t damage the
appliances from the fire of wire burning.

d) Use meggers on high-resistance measurements only (such as

insulation measurements or to check two separate conductors on a
cable).
i) Never touch the test leads while the handle is being cranked.
ii) Deenergize and discharge the circuit completely before
connecting a megger.
iii) Disconnect the item being checked from other circuitry, if
possible, before using a megger
SAQ 2
a) A transformer is an electrical apparatus designed to change alternating
current & voltage from one level to another.
b)
i) Switch off all electrical input power
ii) Use personal protective equipment
iii) Selection of the suitable circuit breaker as per requirement
iv) Checking of tools, wire and new parts
v) Be careful of if any part is still hot
vi) Inspect before turning on the circuit breaker
c) Ensure that the motor is at standstill and not on turning gear. Even
after standstill ensure the windings are discharged before testing.It
should be decoupled from load. The motor should not drive the load
and vice versa the load should not rotate the motor during testing.
Ensure to disconnect space heater supply during work.
d) Electric shock occurs when the human body becomes part of a path
through which electrons can flow.

6.11 REFERENCES AND FURTHER READINGS

[1]. Electrical Safety Handbook, 4th Edition, 2012, by John
Cadick (Author), Mary Capelli-Schellpfeffer (Author), Dennis
Neitzel (Author), Al Winfield (Author) 181
 Safety in Electrical [2]. Handbook of International Electrical Safety Practices, Princeton Energy
Works Resources International, 2010, Scrivener Publishing, Wiley
[3] Handbook on Electrical safety by Herbert William Swann
[4].https://www.lanl.gov/safety/electrical/docs/definitions.pdf
[5]. https://userwikis.fu-berlin.de/pages/viewpage.action?pageId=81690714
[6]. https://www.labtrain.noaa.gov/osha600/refer/menu12a.pdf
[7]. https://www.inteproate.com/support/definitions
[8] https://www.osha.gov/sites/default/files/2018-12/fy07_sh-16615-07_train-the-
trainer_manual2.pdf
[9].ELECTRICAL SAFETY HAZARDS
HANDBOOK:https://www.lanl.gov/safety/electrical/docs/arc_flash_safety. pdf
[10]. The state of the National Initiative on Prevention through Design,
Cincinnati, OH:Nat. Inst. Occupational Safety Health, Centers Disease Control
Prevention, U.S. Dept. Health Human Services, 2013.
[11].https://www.osha.gov/Publications/osha3075.pdf

182
UNIT 7 INDIAN ELECTRICITY RULES
Structure
7.1 Introduction
Objectives
7.2 Indian Electricity Rules
7.2.1 Indian Electricity Rules, 1956 Get Replaced
7.2.2 Central Electricity Authority Regulations At A Glance
7.2.3 Schedules: Shedding Light on Regulations
7.3 Personal Protective Equipment (PPE)/Personal Protective
Clothing (PPC) for Shielding against Electrical Hazards
7.4 Working Above the Ground Level
7.5 Work Permit System
7.5.1 Applicable Regulations
7.5.2 Types of Work Permit
7.6 Earthing/Grounding System and Earth Leakage Current
7.6.1 Earthing for Systems with Voltage Above 150 V and Below 650 V
7.6.2 Earthing for Apparatus Exceeding 650 V
7.6.3 Earthing of Star and Delta Connected Systems Exceeding 650 V:
7.6.4 Earth Leakage Protective Device
7.7 Sequence of Operations for Working at High Voltage
7.8 Use of Electrical Tools
7.9 Case Study
7.10 Let Us Sum Up
7.11 Key Words
7.12 Answers to SAQs
7.13 References and Further Readings

7.1 INTRODUCTION
Safety is the first and foremost priority in electric supply, generation,
transmission and electricity use. There must be rules and regulations for
safety measures. Post-independence the safety measures were spelled out, for
the first time, in 1956 as Indian Electricity Rules, 1956. Central Electricity
Authority (Measures relating to Safety and Electric Supply) Regulations
(CEAR), 2010 notified on 24th September, 2010 which then replaced Indian
Electricity Rules, 1956. There are a total of 116 regulations spread over 10
chapters under CEAR, 2010. There are 13 schedules to further elaborate
those regulations that need explanation. All regulations explicitly deal with
safety aspects of electricity right from generation to end use.
Some regulations delve into general safety requirements pertaining to
construction, installation, protection, operation and maintenance of electric
supply lines and apparatus under ‘Safety provisions for Electrical Installation
and Apparatus Earthing’. Other highlights of the regulations are safety
requirement for electric traction, mines and oil-fields. These regulations
cover the whole gambit of personnel safety, equipment safety, and systems
safety for all electricity work.
183
 Safety in Electrical Objectives
Works
After going through this unit, you will be able to:
• appreciate regulations for measures relating to safety and electric supply
• explain various earthing requirements for systems and apparatus
• describe various safety requirements

7.2 INDIAN ELECTRICITY RULES

Indian Electricity sector was guided by The Indian Electricity Act, 1910 and
The Electricity (Supply) Act, 1948 and the Electricity Regulatory
Commission Act, 1998. The generation, distribution and transmission were
carried out mainly by the State Electricity Boards in various States. Due to
politico-economic situation, the cross-subsidies reached at an unsustainable
level. For distancing state governments from tariff determination, the
Electricity Regulatory Commissions Act was enacted in 1998. So as to
reform electricity sector further by participation of private sector and to bring
in competition, Electricity Act was enacted in 2003. There is a long journey
of Indian Electricity Rules before it finally get its present shape as per CEAR
2010. In the subsequent sections, you will come to know the details about the
important milestones about the Indian Electricity Rules.

These acts related to consolidate the laws relating to generation, transmission,

distribution, trading and use of electricity. It also included the measures
ensuring development of electricity industry, enhancing competition therein,
protecting interest of consumers and supply of electricity to all areas,
rationalization of electricity tariff, ensuring transparent policies regarding
subsidies, promotion of efficient and environmentally benign policies etc.

7.2.1 Indian Electricity Rules, 1956 Get Replaced

Central Electricity Authority (Measures relating to Safety and Electric
Supply) Regulations (CEAR), 2010 was notified on 24th September
2010.CEAR, 2010 has replaced Indian Electricity Rules, 1956.
Let us try to understand how Indian Electricity Rules, 1956 stand repealed.
The answer to this lies in Section 185 (2) (c), Section 53 and Section 177 of
Electricity Act, 2003 which says that “ the Indian Electricity Rules, 1956
made under section 37 of the Indian Electricity Act, 1910, as it stood before
such repeal, shall continue to be in force till the regulations under section 53
of this Act are made.”
Under Section 53 of Electricity Act, 2003, there are provisions relating to
safety and electric supply. Under Section 177 of Electricity Act, 2003,
Central Electricity Authority (CEA) has power to make regulations pertaining
to suitable measures relating to safety and electric supply under Section 53.
CEA exercised its power conferred by Section 177 to make regulations for
measures relating to safety and electric supply. Thus, Indian Electricity
Rules, 1956 was replaced by Central Electricity Authority (Measures relating
to Safety and Electric Supply) Regulations, 2010.
184
7.2.2 Central Electricity Authority Regulations at A Glance Indian Electricity
Rules

In Central Electricity Authority (Measures relating to Safety and Electric

Supply) Regulations, 2010, there are 10 Chapters, 13 Schedules and 116
Regulations. You will have a brief introduction to some of relevant
regulations. Chapter-I has Title and Definition. Chapter-II contains
Regulations 3 to 11. Regulation 3 mentions that designated persons to operate
and carry out the work on electrical lines and apparatus must possess a
certificate of competency and his name must be entered in register.
Regulation 5 says that all suppliers of electricity including generating
companies, transmission companies and distribution companies shall
designate an Electrical Safety Officer for ensuring observance of safety
measures in their organization. Regulations 6 and 7 mention about
Educational Qualification and Training of Engineers and Supervisors
engaged in operation & maintenance of electric plants, transmission lines and
distribution systems respectively.

Chapter-III is about General Safety Requirements, which is our main focus.

This chapter consists of Regulations 12 to 32. Some of the relevant points
under this chapter are being provided here for your in-depth understanding
and to appreciate these regulations:
• Regulation 12 is about General Safety Requirements pertaining to
construction, installation, protection, operation and maintenance of
electric supply lines and apparatus. Relevant code of practice defined by
Bureau of Indian Standards (BIS) or National Electrical Code (NEC), if
any, has to be followed to carry out the purpose of this regulation.
Further, the material and apparatus used shall conform to the relevant
specifications as defined by BIS or International Electro-Technical
Commission where such specifications have already been laid down.
• As per Regulation 18, Danger Notices will have to be affixed
permanently on motor, generator, transformer and other electrical plant
equipments in a conspicuous position in Hindi or English and local
language of the District on any installation of voltage exceeding 250 V.
• Regulation 19 handling the Electric Supply Lines & Apparatus exhorts
for adequate precaution while handling any conductor or apparatus. It
further mentions that a person working on an electric supply line or
apparatus or both shall be provided tools and devices like gloves, rubber
shoes, safety belts, etc for protecting him from mechanical and electrical
injury.
• As per the provisions under Regulation 27 applicable to protective
equipment, fire buckets filled with dry sands, in addition to fire
extinguishers should be kept at all generating stations.
• According to Regulation 28, Instructions in Hindi or English and the
local language of the District for the resuscitation of persons suffering
from electric shock shall be affixed at prominent places in every
generating station and enclosed sub-station.

185
 Safety in Electrical Chapter-IV is about general conditions relating to supply and use of
Works
electricity. This chapter consists of Regulations 33 to 39. Regulations under
this chapter address issues like precautions against leakage before
connections, leakage on consumer’s premises, provisions of supply and use
of electricity in multistoried building more than 15 m in height, etc.

Chapter-V discusses safety provisions for electrical installations and

apparatus with operating voltage not exceeding 650 V. This chapter consists
of Regulations 40 to 42. Under Regulation 41 (you will find more details in
section 7.7), there is specific provision of earthing neutral wire of a 3-phase,
4-wire system and providing the additional third wire of a 2- phase, 3-wire
system. Earthing is to be done with two separate connections. Grounding
system should have minimum two or more earth pits (electrode) such that
proper grounding takes place. Regulation 42 mentions where earth leakage
protective device should be employed. This Regulation states that installation
with load above 5 kW exceeding 250 V shall have suitable earth leakage
protective device to isolate the load in case of earth fault or leakage.

Chapter-VI discusses safety provisions for electrical installations and

apparatus operating at voltage exceeding 650 V. This chapter consists of
Regulations 43 to 54. In Regulation 48, there are provisions for earthing of
apparatus exceeding 650 V. As per Regulation 48 all non-current carrying
metal parts associated with an installation of voltage exceeding 650 V shall
be effectively earthed to grounding system or grounding mat. Regulation 54
outlines conditions for using electricity for the purpose of operating an X-ray
generators and similar high frequency generators.
Chapter-VII discusses safety requirements for overhead lines, underground
cables and generating stations. This chapter consists of Regulations 55 to 77.
As per Regulations 58 (1) and 58 (2), Minimum clearances above ground of
the lowest conductor of overhead lines across and along a street has been
tabulated in Table 7.1
Table 7.1: Minimum clearance above ground of the lowest conductor of
overhead lines across and along a street

Minimum clearance Minimum clearance

above ground of the above ground of the
Voltage
lowest conductor lowest conductor
across a street along a street

Overhead lines
operating at voltage not 5.8 m 5.5 m
exceeding 650 V

Overhead lines
operating at voltage
6.1 m 5.8 m
exceeding 650 V but
not exceeding 33 kV

186
Minimum clearance above ground of the lowest conductor of overhead lines Indian Electricity
Rules
elsewhere than along or across any street is given in Table 7.2 [Regulation
58(3)].
Table 7.2: Clearance above ground of the lowest conductor of overhead
lines elsewhere than along or across any street

Clearance above ground of the

lowest conductor of overhead lines
Voltage
elsewhere than along or across any
street

Overhead lines operating at voltage

4.6 m
up to and including 11 kV, if bare

Overhead lines operating at voltage

up to and including 11 kV, if 4.0 m
insulated

Overhead lines operating at voltage

exceeding 11 kV but not exceeding 5.2 m
33 kV

As per Regulation 61 (2), Vertical and Horizontal clearances from buildings

for overhead lines operating at voltage exceeding 650 V and 33 kV are given
in Table 7.3 and Table 7.4:
Table 7.3: Vertical Clearances from buildings for overhead lines
operating at voltage exceeding 650 Volt

Voltage Vertical Clearance

For lines of voltages exceeding

650 Volts up to and including 33 3.7 m
kV

For lines of voltages exceeding 3.7 m + 0.30 m for every additional 33

33 kV kV or parts thereof

Table 7.4: Horizontal Clearances from buildings for Overhead lines

operating at voltage exceeding 650 Volt.

Voltage Horizontal Clearance

For overhead lines operating at

voltages exceeding 650 V up to 1.2 m
and including 11 kV

For overhead lines operating at

voltages exceeding 11 kV and up 2.0 m
to and including 33 kV

For overhead lines operating at 2.0 m + 0.3 m for every additional 33

voltages exceeding 33 kV kV or part thereof
187
 Safety in Electrical Regulation 69 (iv) gives the minimum clearances between lines when
Works crossing each other, and is given in Table 7.5
Table 7.5: Minimum clearances in metres between lines crossing each
other

System Voltage 11-66

110-132 kV 220 kV 400 kV 800 kV
kV

Low and
2.44 3.05 4.58 5.49 7.94
Medium

11-66 kV 2.44 3.05 4.58 5.49 7.94

110-132 kV 3.05 3.05 4.58 5.49 7.94

220 kV 4.58 4.58 4.58 5.49 7.94

400 kV 5.49 5.49 5.49 5.49 7.94

800 kV 7.94 7.94 7.94 7.94 7.94

Chapter-VIII discusses Safety Requirements for Electric Traction. This

chapter consists of Regulations 78 to 92.
Chapter-IX discusses Safety requirements for mines and oil fields. This
chapter consists of Regulations 93 to 115.
For your convenience, Regulation No. and Chapter have been summarized in
Table 7.6.
Table 7.6: Summary of Chapters and Regulation Numbers contained in it

Chapter Regulation No.

Chapter-I 1-2
Chapter-II 3-11
Chapter-III: General Safety Requirements 12-32
Chapter-IV: General conditions relating to supply and
33-39
use of electricity
Chapter-V: Safety provisions for electrical installations
40-42
and apparatus of voltage not exceeding 650 volts
Chapter-VI: Safety provisions for electrical installations
43-54
and apparatus of voltage exceeding 650 volts
Chapter-VII: Safety requirements for overhead lines,
55-77
underground cables and generating stations
Chapter-VIII: Safety Requirements for Electric Traction 78-92
Chapter-IX: Safety requirements for mines and oil
93-115
fields
Chapter-X: Miscellaneous 116

188
7.2.3 Schedules: Shedding Light on Regulations Indian Electricity
Rules

To spell out regulations in more detail, schedules are provided. Regulations

6(3) and 7(3) mentioned qualification and training for operation &
maintenance of electrical plants, transmission lines and distribution systems,
respectively. Detailed syllabus and duration of training for this purpose have
been delineated in Schedule-I and Schedule-II. Likewise Regulation 19 (3)
delineates handling of electric supply lines and apparatus. What precautions
need to be taken and what tools will be required for hot line maintenance
operation have been expressed in Schedule-III. Further, Minimum Safety
Clearance to be maintained for use of electricity at voltage exceeding 650 V
under Regulation 44 (2) (iii) has been elaborated in Scheduled–VII. For the
sake of completeness and your ready reference, all schedules with description
have been tabulated in Table 7.7.
Table 7.7: Summary of Schedules and their Description

Schedule Description

Safety measures for operation and maintenance of electrical

Schedule-I
plant

Safety measures for operation and maintenance of

Schedule-II
transmission and distribution system

Schedule-III Handling of electric supply and apparatus

Schedule-IV Form forinspection report

Forms for obtaining results during inspection by supplier at

Schedule-V
each supply point to consumer

Schedule-VI Form for notice in respect of failure of supply

Minimum safety Working Clearances where electricity at

Schedule-VII Voltage exceeding 650 V is supplied, converted, transferred
or used

Minimum Safety Clearances to be maintained for bare

Schedule-VIII conductors or live parts of an apparatus in outdoor sub-
station, excluding overhead lines of HVDC installation

Form for reporting failure of transformers or reactors of

Schedule-IX
rating 20 MVA/MVAR and above

Schedule-X Ground, Vertical and Horizontal Clearances

Schedule-XI Form for annual return for Mines

Schedule-XII Form forannual return for Oil-Fields

Schedule-XIII Log Sheet for Mines and Oil-Fields

189
 Safety in Electrical
Works
SAQ 1

a) What sections of Electricity Act, 2003 explain repealing of Indian

Electricity Act, 1956?
b) State the number of Chapters, Regulations, and Schedules
contained in Central Electricity Authority Regulations, 2010.
c) Which Regulations specify earthing guidelines?
d) Which Schedule deals with Handling of Electric Supply and
Apparatus?

7.3 PERSONAL PROTECTIVE EQUIPMENT

(PPE)/PERSONAL PROTECTIVE
CLOTHING (PPC)FOR SHIELDING
AGAINST ELECTRICAL HAZARDS
We all know that hazard exists in every work place in different forms. As
many hazards cannot be removed at source, use of Personal Protective
Equipment (PPE)/Personal Protective Clothing (PPC) plays an important role
in shielding against hazards. PPE protects the valuable life of working
personnel/workers on the site. Every industrial/construction worker,
supervisor and field engineer shall wear appropriate PPE and PPC which
shall be adequately provided by the management. All PPE except shoes,
disposable ear plug and disposable dust mask shall be for common use. High
visible safety vest shall be provided to the site personnel in all construction
areas.
PPE shall conform other relevant specifications of Bureau of Indian
Standards (BIS) or International Electro-technical Commission (IEC) where
such specifications have already been laid out. Indian Standard (IS) and
European (EN) Standard are two commercially acceptable standards in the
current market.
IS/EN Standards for some PPE:
 Industrial Safety Helmet: EN 397/IS 2925
 Electrical Resistance Hand Gloves: IS 4770
 Face Shields (for welders and grinders): IS 2553
 Retractable Type Fall Arrester: EN 360/2002
 Twin lanyard full body safety harness with shock absorber: EN
361/IS 3521

SAQ 2
a) Highlight the use of Personal Protective Equipment.
b) Mention list of some of Personal Protective Equipment.

190
7.4 WORKING ABOVE THE GROUND LEVEL Indian Electricity
Rules

It is almost unavoidable to work above the ground level while working of

power plants, transmission lines or distribution systems. Therefore, it is
necessary for you to learn about the safety standards when working at height.
‘Working at Height’ means working above 2 meters of ground level. The
main safety equipment while working above ground is called “Twin Lanyard
Full Body Safety Harness with Shock Absorber and Leg Strap arrangement”
.These safety equipments are essential for all workers working at height.
Before beginning any work on any pole/tower on overheadlines adjacent and
parallel to any other high voltage overhead line with live conductors, the
following special precautions should be taken in every case:
• Work permit is essential
• A Red Flag/Caution Tape which is available with maintenance crew
should be displayed on the side of the pole or structure on which the
conductors are “live”.
• Work should not be performed on any higher position of tower/line
when a line below is energized.

SAQ 3
a) What precautions should be taken for Working at Height?

7.5 WORK PERMIT SYSTEM

Work Permit is a written consent of the owner/issuing authority that
guarantees proper and safe conditions where personnel can work safely by
complying with the instructions on the permit. It also indicates that the people
executing the job have reviewed the permit and accept responsibility of
adhering to the instructions and limitations stipulated. Thus a permit
essentially becomes a document of consent by both parties i.e. the
owner/issuing authority and job executor. Work permit also assured that the
work is going on with permission and under authorized bodies which is
capable of handling all safety and securities issues.

7.5.1 Applicable Regulations

Regulation 19 (3) deals with handling of electric supply lines & apparatus.
According to which it is mandatory to get authorization before working on
any line or apparatus.
As per Regulation 19 (3):
“No person shall work on any live electric supply line or apparatus and no
person shall assist such person on such work, unless he is designated in that
behalf, and takes the safety precautions given in Schedule-III.”
Schedule-III explicitly mentions what precautions need to be taken. One of
the precautions to be observed pertaining to work permit system under
Schedule-III are: Work Permit will be taken from the terminal substations at
each end of the lines.
191
 Safety in Electrical Further, Regulation 3 also provide the information about designating
Works person(s) to operate and carry out the work on electrical lines and apparatus,
which says designated person is required to have certificate of competency or
work permit issued by appropriate Government body, and his name entered
in proper register.

7.5.2 Types of Work Permit

The types of Work Permit include:
i) General Work Permit: This is a permit issued for works of routine
nature such as housekeeping activities, replacement of used lamps etc.
ii) Hot Permit: Issued for work related to the use of heat or generation of
heat that is sufficient to ignite gases, vapours, dust, etc. Some examples
are welding, flame cutting,metal drilling, soldering, sandblasting,
grinding etc
iii) Electrical Work Permit System: Work on electrical installations,
equipment and apparatus is considered to be very hazardous. Therefore,
it is of utmost importance that sufficient safety precautions are taken
before carrying out any work on electrical circuits, line sand equipments
etc. Hence, to exercise greater control over such work and to ensure that
adequate precautionary measures are taken before commencement of
work on electrical equipment, an Electrical Work Permit system shall be
developed. This permit is issued to carry out work on electrical
equipment, installation after completely de-energizing the equipment
from electrical energy and providing effective grounding. The electrical
permit shall clearly indicate–the equipment/installation under work, the
person who is handling the work, duration of work, type of work that is
to be carried out, points/ means of isolation indicating each point of
isolation, grounds provided to the equipment, and additional precautions
required , if any. The permit shall be signed by the issuing authority and
also by the executing authority. All work shall be carried out under the
supervision of a competent supervisor. If more than one departments are
working on the same apparatus, a permit to work shall be issued to the
person in-charge of each department. No construction, repair or
maintenance work is permitted in the proximity of high or EHV
system/equipment (electrical or mechanical) where technical knowledge
or experience is required to avoid danger. The construction, repair or
maintenance work shall not be carried out unless a permit of work on the
prescribed form has been issued by the shift in-charge to an authorized
person. The person issuing a permit to work shall ensure that the
system/equipment is made perfectly safe for working. In case of
electrical system/equipment, the isolation shall be complete, the metal
parts adequately earthed and danger notices attached at suitable places.
iv) Working at Height Permit: In the event of any working person
required to stand, pass over or bear any roof or ceiling covered with
fragile material or required to work at an elevation of more than 3
meters height, adequate safety measures shall be provided to prevent
falls. For this purpose, it is suggested to use ladders, crawling board and
safety belt etc. Each time a person is required to work on the fragile roofs
or at higher elevations, the job shall be carried out under the authority of
a work permit issued by concerned department having responsibility of
192 that area.
 Indian Electricity
v) Excavation Permit: The originator of the permit having proprietary Rules
responsibility of the area where excavation work is intended to be
carried out will prepare the excavation permit in duplicate, indicating the
exact location where the excavation work will be carried out and send
both copies of the permit to the plant maintenance department. The plant
maintenance engineer studies the relevant drawing of the area to be
excavated and determines whether any pipelines or
electrical/communication cables are located in the area. If any such
obstacles are seen, he/she prescribes the special precautions to be taken
while excavating, and puts his signature on the permit.

SAQ 4
a) State applicable regulations in Work Permit System.
b) State different types of Work Permit.

7.6 EARTHING/GROUNDING SYSTEM AND

EARTH LEAKAGE CURRENT
In any electrical installation, an earthing system (or grounding system)
connects particular parts of that installation with the Earth's conductive
surface mainly for safety and different functional purposes. The point of
reference is the Earth's conductive surface. Leakage Current is the residual
flow of current through insulation after a high voltage has been applied for a
period of time. Earth Leakage Current is the leakage current from all earthed
parts of the product.This leakage current pass from the mains supply through
or across insulation into the Protective Earth Conductor.
The leakage current flowing in the ground conductor can be measured by
connecting the ampere clamp meter in series with the grounding connection
of the device concerned. Leakage current clamp meter is the most common
device used to measure leakage current.

7.6.1 Earthing for Systems with Voltage above 150 V and

Below 650 V
Under Regulation 41, there is a specific provision for earthing neutral wire
of a 3-phase, 4-wire system and the middle conductor of a 2-phase, 3-wire
system. Earthing has to be done with two separate and distinct connections.
The grounding system should also be having minimum of two different earth
electrodes for proper grounding.Regulation 41 (i) in this regard says:
“Neutral conductor of a 3-phase, 4-wire· system and the middle conductor of
a 2-phase, 3-wire system shall be earthed by not less than two separate and
distinct connections with a minimum of two different earth electrodes or such
large number as may be necessary to bring the earth resistance to a
satisfactory low value both at the generating station and at the sub-station.”
It further elaborates in 41 (ii) that the earth electrode so provided should be
interconnected to reduce earth resistance.
For direct current three wire system Regulation 41 (vi) specifies that the
middle conductor shall be earthed at the generating station only and the 193
 Safety in Electrical current from the middle conductor to earth shall be continuously recorded by
Works means of a recording ammeter, and if at any time the current exceeds one-
thousandth part of the maximum supply current, immediate steps should be
taken to improve the insulation of the system.
Regulation 41 (xv) spells out the characteristics of all earthing systems. All
earthing systems should consist of appropriate equipotential bonding
conductors as per relevant Indian Standards so as to maintain all non-current
carrying metal works at earth potential. This regulation further emphasizes on
the physical characteristics of earthing systems like mechanical strength so as
to work properly during its useful life and serve the purpose it is intended for.
Let us have a look on this Regulation to fully appreciate its usefulness:
Earthing System
Earthing system is very important part of electrical safety. All electrical
equipments/appratus/devices must be properly earthed. All earthing systems
shall:
a) consist of equipotential bonding conductors capable of carrying the
prospective earth fault current and a group of pipes, rods and plate
electrodes for dissipating the current to the general mass of earth without
exceeding the allowable temperature limits, as per relevant Indian
Standards in order to maintain all non-current carrying metal works
reasonably at earth potential and to avoid dangerous contact potentials
being developed on such metal works;
b) limit the earth resistance to sufficiently low value to permit adequate
fault current for the operation of protective devices in time and to reduce
neutral shifting;
c) be mechanically strong, with stand corrosion and retain electrical
continuity during the life of the installation and all earthing systems shall
be tested to ensure efficient earthing, before the electric supplylines or
apparatus are energized.

7.6.2 Earthing for Apparatus exceeding 650 V

In Regulation 48, there are provisions for earthing of apparatus exceeding
650 V. As per Regulation 48 all non-current carrying metal parts associated
with an installation of voltage exceeding 650 V shall be effectively earthed to
grounding system or mat so as to:
i) limit the touch and step potential to tolerable values
ii) limit the ground potential rise to tolerable values, and
iii) maintain the resistance of the earth connection to such a value as to
make operation of the protective device effective

7.6.3 Earthing of Star and Delta Connected Systems

Exceeding 650 V:
Regulation 48 (2) (ii) says, “For star connected systems with earthed neutral
or delta connected systems with earthed artificial neutral point, the neutral
point of every generator and transformer shall be earthed by connecting it to
the earthing system not by less than two separate and distinct connections
provided that the neutral point of a generator may be connected to the
194 earthing system through an impedance to limit the fault current to the earth.”
As per 48 (2) (ii), the generator or transformer neutral shall be earthed Indian Electricity
Rules
through suitable impedance where an appreciable harmonic current flowing
in the neutral connection causes interference with communication circuits.
In the case of generating stations, sub-stations, and industrial installations of
voltage exceeding 33 kV, the system neutral earthing and protective frame
earthing may be integrated into common earthing grid provided the resistance
to earth of combined mat does not cause the step and touch potential to
exceed its permissible values.

7.6.4 Earth Leakage Protective Device

Regulation 42 mentions where earth leakage protective device should be
employed. This regulation states that installation with load above 5 kW
exceeding 250 V shall have suitable earth leakage protective device to isolate
the load in case of earth fault or leakage.
An Earth-leakage circuit breaker (ELCB) is a safety device mainly used in
electrical installations with high Earth impedance for safety against shock.
ELCB evaluate small stray voltages on the metal enclosures of
electrical equipments, and interrupt the circuit in case of high voltage.

7.7 SEQUENCE OF OPERATIONS FOR

WORKING AT HIGH VOLTAGE
The following operations should be carried out in sequence for carrying any
work at high voltage.
1. The apparatus or cable or transmission line should be switched
out/offand isolated from all points of supply under the direction of
theauthorized person.
2. The switches, isolators and control links should be in ‘locked-in’ position
by the keys provided for that purpose.
3. Safety tags should be placed at all points where apparatus can be made
alive.
4. All apparatus should be discharged to earth and efficiently connected to
earth near all points from which supply could be connected to it or
between such points and the place of the work.
5. Earthing should also be carried out at the point of work by means of
temporary earths on each phase and in no case should the temporary
earths be removed from two phases simultaneously while the work is
being carried out.

SAQ 5
a) Under Regulation 41, what will be inspected in relation to earthing
of system exceeding 250 V and up to 650 V?
b) State the sequence of operations to be carried out for working at
High Voltage.

195
 Safety in Electrical
Works
7.8 USE OF ELECTRICAL TOOLS
Regulation 19 specifies the Electrical Tools to be used. You should read
Regulation 19 with Schedule –III for objectivity and greater clarity.
Regulation 19 (2) says “Every person who is working on an electric supply
line or apparatus or both shall be provided with tools and devices such as
gloves, rubber shoes, safety belts, ladders, earthing devices, helmets, line
testers, hand lines and the similar tools for protecting him/her from
mechanical and electrical injury.Such tools and devices shall always be
maintained in sound and efficient working Condition.”
Schedule III further elaborates that tools conforming to relevant Indian
Standards or equivalent specifications shall be used in online working. The
following tools with their uses and representational image are given in Table
7.8:
Table 7.8: Electrical Tools, uses and Representative Image

S. Electrical
Uses Representative Image
No. Tools

Used in pairs with

supporting
accessories to
support and move
the energized
1 Wire Tongs
conductors away
from the work area
for replacement of
insulators and cross
arm

Used to support a
Wire Tong
2 450 kg weight
Saddle
without extension

196
 Indian Electricity
Rules

Used to support
Strain link conductors for
sticks isolating rope
3
blocks and hoists
from energized
conductors

Used to spread and

hold conductors
Roller link apart for mid span
4 sticks clearances by
attaching tag lines
to the butt swivel
ring

5 Strain carrier Used to take the

load or strain from
suspension
insulators while the
insulators are
changed

Used for the

following functions
• opening and
closing
6 Hot Sticks
disconnect
switches.
• Replacing fuses
on transformers

SAQ 6
a) Uses of Electrical Tools have been specified in which Regulation
and Schedule?
b) List a few of Electrical Tools mentioned in Schedule –III.

197
 Safety in Electrical
Works
7.9 CASE STUDY
Case studies are very helpful in understanding the concepts. With the help of
used cases we can find out solution of the troubleshootings in easy and proper
way. Following is one such case.

7.9.1 Case-1
A Telephone Exchange witnessed a peculiar problem. The problem was
related to humming and noise of all telephone connections. Telecom officials
were clueless even after thorough internal checking and testing. There was
one conspicuous element in this problem. For a few hours this problem
automatically used to get resolved.
After thorough check up, internal problem was ruled out. Now the approach
to find solution moved outside Telephone Exchange. Underground
telecommunication cable was checked. Now the problem hovered around
interference from underground power cable. It was found that both
underground power cable and telecommunication cable were following the
same path. This underground power cable was used as standby, and had been
energized recently.
The problem in Telephone Exchange was resolved as Electric Supply
Company agreed to de-energize this power cable. As it was standby power
cable, problem stands resolved. What if they need to energize this power
cable again?
 Discussion Questions
i) Have both organizations (Telecommunication Company and Power
Company) followed guidelines for laying of underground cables?
ii) What are relevant Regulations for laying cables?
iii) If cables are laid as per guidelines, what may have caused this
problem?
 Analysis
1. It is difficult to say. Both organizations may or may not have
observed relevant guidelines. If both organizations may have
followed relevant guidelines, problem may be somewhat different.
De-energizing power cable was the easiest option. Other option
could have been analysis of real problem
Regulation 76 of Central Electricity Authority Regulations, 2010
specifies guidelines for laying of cables. Any underground power
cable of voltage exceeding 33 kV should be laid at least at the depth
of 1.2 m and the separation distance of underground power cable
and telecommunication cable should not be less than 0.6 m.
2. There may be damage in sheath of either of cable. There may be
issue related to appropriate earthing. You may give your own
thought, and may come of a variety of situations.

198
7.9.2 Case -2 Indian Electricity
Rules

During operation, suddenly 100 MW unit trips on Generator Earth Fault

protection. On investigation it is found that both E/F protection i.e. Stator
Main Earth fault protection & Stator Stand by earth fault protection got
operated.Disconnected the associated equipments & exhaustive testing done
of Generator, & all related equipment. No abnormality found.Re-started the
unit & syncronised with grid on full load.
After 15 days, the same unit again tripped on the same protection.As it was
rainy season, we suspect that some insulation puncture in generator bust
duct.We opened the generator bus duct & found that large amount of water
was there in the duct, so the gap between live bus & earth point (i.e. water
level) was reduced. Also due to water inside bus duct the insulating property
of the air inside the bus duct may have very poor.
So we presume that, any vibration or any disturbances may have caused
insulation breakdown between live bust & earth point in the bus duct,
resulting fault current tracking and operation of E/F protection relay.We
removed the water & re-started the machine with full load. No tripping
observed after words.

7.10 LET US SUM UP

In this unit you have learnt about measures relating to Safety and Electric
Supply in the light of Central Electricity Authority (Measures relating to
Safety and Electric Supply) Regulations, 2010. Wherever required these
Regulations have been made clear by Schedules. In total there are 10
chapters, 13 Schedules and 116 Regulations under CEAR 2010.The
regulations and requirements pertaining to earthing requirement for systems
and apparatus have been discussed for you in details. You have also learnt
about Work Permit System which is vital for safety. We have discussed
various issues in the light of relevant Regulations and Standards laid down or
recommended therein to equip you with the relevant information.

7.11 KEY WORDS

Bonding conductor: A conductor that connects the non-current-carrying
parts of electrical equipment to the system grounding conductor.
Touch Potential: Touch potential is the touch voltage between the energized
object and feet of a person in contact with the object.
Step potential: Step potential is the step voltage between the feet of a person
standing near an energized grounded object.
Electrical breakdown: When current flows through an electrical insulator and the
voltage applied across it is greater than the breakdown voltage. This results in
the insulator becomes electrically conductive.

7.12 ANSWERS TO SAQS

SAQ 1
a) Section 185 (2) (c), Section 53 and Section 177 of Electricity Act, 2003.
199
 Safety in Electrical b) 10 Chapters, 116 Regulations and 13 Schedules are there in Central
Works Electricity Authority Regulations, 2010.
c) Regulations 41 and 48.
d) Schedule-III deals with Handling of Electric Supply and Apparatus.
SAQ 2
a) As manyhazardscannotberemovedatsource,useofPersonal Protective
Equipment (PPE) playsanimportant role in shieldingagainsthazards. PPE
protects thevaluablelifeofworkersonthesite.
b) Industrial Safety helmets, Safety shoes, Twin lanyard full body safety
harness, Fall arrestor
SAQ 3
a) Following precautions should be taken for Working at Height:
a. Work permit must be obtained
b. Red flag / Caution Tape should be displayed
c. Not to perform work on higher position of tower when lower position
conductor is energized
SAQ 4
a) Regulation 19 (3) handling of Electric Supply lines & apparatus requires
authorization to be obtained before working on any line or apparatus. As
per Regulation 19 (3):
“No person shall work on any live electric supply line or apparatus and
no person shall assist such person on such work, unless he/she is
designated in that behalf, and takes the safety precautions given in
Schedule-III.”
Schedule-III explicitly mentions what precautions need to be taken. One
of the precautions to be observed pertaining to Work permit system
under Schedule-III is: Work Permit will be taken from the terminal
substations at each end of the lines.
Further, Regulation 3 also provide the information about designating
person(s) to operate and carry out the work on electrical lines and
apparatus, which says designated person is required to have certificate of
competency or work permit issued by appropriate Government body, and
his name entered in proper register.
b) General Work Permit, Hot Permit, Electrical Work Permit System,
andWorking at Height permit
SAQ 5
a) Checking as per Regulation 41:
i) Have the frames of every generator, stationary motor and the
metallic parts of all other apparatus used for controlling electricity
been earthed by two separate and distinct connections with earth?
ii) Is the earth wire free from damage?
iii) In the case of conduit or lead-cover, have they been efficiently
earthed?
b)
200 i) Switch out/off and isolate apparatus/cable from all points of supply
 ii) Switches, isolators are in‘locked-in’ position Indian Electricity
Rules
iii) Safety tags at all points where apparatus can be made alive
iv) Apparatus discharged to earth
v) Temporary earthing on each phase
SAQ 6
a) Regulation 19 specifies the Electrical Tools to be used. Regulation 19
should be read with Schedule –III for objectivity and clarity
b) Wire Tongs, Wire Tong Saddle, Strain link sticks, Roller link sticks and
Hot sticks

7.13 REFERENCES AND FURTHER READING

[1]. Central Electricity Authority Regulations, Universal Law Publishing
[2]. Electricity Act, 2003 Along with Rules, 2005 and Allied Rules and
Order, Universal Law Publishing
[3].Safety Standards for Construction and O&M,
http://cea.nic.in/safety_regulations.html
[4].Electricity Act, 2003, https://powermin.nic.in/en/content/electricity-act-
2003

201
 UNIT 8 FIRST AIDS

Structure
8.1 Introduction to First Aid
Objectives
8.2 First Aid: A General Overview
8.2.1 First Aid and First Aid provider
8.2.2 Safety Practices for First Aid provider
8.3 First Aid in Electrical Industry
8.3.1 Electricity as a Hazard
8.3.2 Electric Shock
8.3.3 Electric Arc
8.3.4 First Aid Steps
8.3.5 ABC of First Aid
8.3.6 Cardio-Pulmonary Resuscitation (CPR)
8.3.7 First Aid for Electric Shock and Burns
8.4 First Aid in Chemical/Hazardous Industry
8.4.1 Classification and Labeling of Chemicals
8.4.2 Hazard Communication
8.4.3 Hazard Communication: GHS Labeling
8.4.4 Hazard Communication: Safety Data Sheet
8.4.5 First Aid for Chemical Accidents
8.5 First Aid Education and Training
8.5.1 Purpose of First Aid Education and Training
8.5.2 Educational Model
8.5.3 Training Method
8.5.4 Points to take into Consideration While Preparing First Aid Education
8.6 Certification of First Aid Trainees
8.6.1 Institutions Offering First Aid Courses
8.7 Case Study
8.7.1 Case
8.7.2 Discussion Questions
8.7.3 Analysis
8.7.4 Post Analysis
8.8 Let Us Sum Up
8.9 Key Words
8.10 Answers to SAQs
8.11 References and Further Readings

8.1 INTRODUCTION TO FIRST AID

Safety and precaution are paramount for any installation, workplace, and
industry even if we cannot rule out the possibilities of accidents and
emergencies completely. Preparedness to emergencies reduces fatality and
casualties during accident but upto a certain limit. Causality can be
202 minimized by proper and complete preparation for such incidences. In the
backdrop of this discussion, it is evident that First Aid is vital. Emergencies First Aid
and ways of tackling these circumstances are situation dependent. So we have
General First Aid procedure and Industry specific First Aid procedures too. It
is important to assess victim’s condition before applying the First Aid. A
First Aid Provider, person who administers First Aid, must be trained and
competent to handle emergency cases. Acting quickly is prerequisite for any
emergency situation, but safety of First Aid Provider is also very important.
For administering First Aid to Electrical shock victim, de-energization of
accident scene is required. Likewise, for administering chemical accident
victim, Material Safety Data Sheet (SDS) will be required. SDS has
information regarding First Aid specific to that chemical. Depending upon
victim’s condition, Cardiopulmonary Resuscitation (CPR) and Automated
External Defibrillator (AED)are to be administered. CPR and AED are two
different steps in the process of saving the life of someone suffering from
cardiac arrest. CPR is the act of repeatedly compressing a person’s chest in
order to keep their blood pumping throughout their body. CPR acts like a
manual heartbeat, keeping vital organs alive even after the heart has stopped
beating. While many people are already familiar with CPR, its counterpart
often goes unnoticed. An AED is used to help those experiencing sudden
cardiac arrest. It's a sophisticated, yet easy-to-use, medical device that can
analyze the heart's rhythm and, if necessary, deliver an electrical shock, or
defibrillation, to help the heart re-establish an effective rhythm.If a victim is
unconscious, First Aid Provider has to check his breath and pulse. The
condition of breath and pulse will dictate the type of First Aid.
Objectives
After going through this unit, you will be able to:
• appreciate the importance of First Aid .
• distinguish between General First Aid Procedure and First Aid Procedure
in Electrical and Chemical Industry.
• explain different First Aid Training Methods.
• describe institutes offering Certifications in First Aid.

8.2 FIRST AID: AN OVERVIEW

First aid is the first and immediate assistance given to any person suffering
from either a minor or serious illness or injury, with care provided to preserve
life, prevent the condition from worsening, or to promote recovery. In general
we can say that first aid is the first action against any injury during accident
or illness to control situation.

8.2.1 First Aid and First Aid Provider

Emergency may arise any moment. Its location and nature may be varied and
unpredictable. Emergency can be anything. It may include injury, fall, and a
person falling sick. The assistance provided during emergency is of
paramount importance. First Aid is the first help that makes difference
between life and death. First Aid is the first assistance provided with
available supplies and materials before medical help arrives. In First Aid,
suitable interventions to sustain life are initiated and further damage is
reduced until the person is taken to hospital. The objectives of First Aid are to
203
 Safety in Electrical save life, increase chances of recovery, prevent further damage, and help the
Works victim to reach regular medical care quickly.
Hence the First Aid Provider, is an important and key link in preventing
further injury and shifting the victim to a suitable medical institution.
Some of the important attributes of a First Aid Provider are:
• She/he must be very calm, observant, tactful and patient.
• She/he must be adept in handling the crowd and involving onlookers for
help.
• She/he should be trained in First Aid and capable of administering
immediate treatment to the victims at the time of emergency.
It is the responsibility of the First Aid provider to reach the
accident/emergency spot quickly and administer First Aid after assessing the
situation and victim’s condition.
First Aid Box is an important item for a First Aid Provider. The purpose of
First Aid Box is to provide basic supplies for First Aid. First Aid Box can be
effectively used in controlling bleeding, preventing and treating shock and
treating conditions of burns. The First Aid Box checklist includes location
and position of First Aid Box, clear identification of First aid Box, contents
and quality of contents. In the absence of availability of certain required
items in the First Aid Box, First Aid Provider should improvise available
resources.

8.2.2 Safety Practices for First Aid provider

During administration of First Aid, it is essential for the first aid provider as
well as the victim to follow safety practices from the environment or souce of
injury. If the accident has taken place on road, victim should be provided
First Aid on road side, not on middle of the road. If a victim receives electric
shock, First Aid Provider has to first de-energize the source of electricity.
This will ensure the safety of First Aid Provider and victim also.
Planning comes first for the First Aid Provider when Environment or Source
poses hazard. Another approach could be removal of contact with the hazard.
In all cases the safety of First Aid Provider is important. If First Aid Provider
is not taking proper safety precaution, she/he may be the next victim .

SAQ 1
a) What is First Aid?
b) What are the attributes of a First Aid Provider?
c) What is the purpose of First Aid Box?
d) During administration of First Aid, Safety Practices are for whom?

8.3 FIRST AID IN ELECTRICAL INDUSTRY

We come across the news of electrocution often. Electrocution is the word
generally used in the case of death or severe injury due to electric shock or
electric current passing through the body. The word Electrocution is derived
from "electro" and "execution", but it is also used for accidental death.
204
Likewise we are also aware of cases of electric shock . The awareness of First Aid
electrocution and electrical shock prompts us to think about electrical
hazards. On further exploration we come across other electrical hazards.
These hazards include burns due to electric arc and electrical blast. Severity
of these hazards and resulting injury needs special attention. Administration
of First Aid measures of victim needs special care. Further, safety of first aid
provider is vital. We will learn about these issues step-by-step.

8.3.1 Electricity as a Hazard

Figure 8.1: Danger and Warning Signs for Electrical Hazards

Look at the danger and warning signs above as shown in Figure 8.1. What
message these signs are conveying? These signs are indicative of Electrical
Hazards. We are using electricity for various applications day in, day out.
Electricity as a companion and co-worker is everywhere. Likewise we often
come across the news of electrocution and electrical shock. Thus it is
important and necessary to see electricity as a companion as well as deadly
hazard. Whenever the term electrical hazard appears, electric shock first
comes into our mind. But electric shock is one of electrical hazards. Other
electrical hazards include arc and blast. Let us explore Electric shock, Arc
and Blast so as to understand the injuries and burns caused by these hazards
and corresponding First Aids that would be required to be administered.

8.3.2 Electric Shock

An electric shock is a dangerous and painful physiological effect caused by
the passing of electric current through the body of a human. Physical contact
with energized electrical wire or devices is the main common cause of an
electric shock. In cases of exposure to high voltages, such as on a power
transmission tower, physical contact with energized wiring or objects may not
be necessary to cause electric shock, in such cases voltage may be
sufficiently high to "jump" the air gap between the electrical device and the
victim. Severity of electrical shock depends upon many factors such as the
path of the current flow, the duration of the current flow, the magnitude of
the current, resistance of the human body, the frequency of the current (DC or
AC) and the voltage magnitude causing the shock. Now let us have a look at
these factors:

205
 Safety in Electrical i) Duration of Current Flow: The amount of energy delivered to the body
Works is directly proportional to the duration of current flow as evident from
the relation of energy given by
E = I2Rt,
Where, E is the Energy in Joules
I is current flowing through the body in Amperes
R is Resistance of the body in Ohms
t = duration of current flow in seconds.

ii) Magnitude of Current Flow: Current less than 1 mA causes no

sensation. Current between 1 mA and 8 mA causes sensation of shock,
but is not painful. Around 10 mA current is capable of producing painful
to severe shock. Current around 30 mA can cause respiratory paralysis.
The heart can fibrillate (quivering of heart) by current of around 75 mA.
This current can be found using Ohm’s Law (I =V/R, where V is the
voltage and R is the body resistance that includes skin resistance, internal
body resistance, and resistance of shoes worn by person).
iii) Body Resistance: The NIOSH (National Institute for Occupational Safety and
Health) states "In dry conditions the human body resistance offered may
be as high as 100,000 ohms. Wet or broken skin may drop the body's
resistance to 1,000 ohms," adding that "high-voltage electrical energy
quickly breaks down human skin, reducing the human body's resistance
to 500 ohms"
iv) Frequency of Current: The “let go” (release) threshold in DCcurrent
(frequency is zero Hz) is higher than AC current (frequency is 50 Hz).
v) Voltage: At above 400 V, the electric voltage may be sufficient to
puncture the epidermis (outer layer of the skin). As the epidermis
provides the major part of the resistance of human body, the current
magnitude will increase sufficiently and lethally when this puncture
occurs.

8.3.3 Electric Arc

An electrical arc is defined as a discharge of electricity through a gas,
normally characterized by a voltage drop in the immediate vicinity of the
cathode approximately equal to the ionization potential of the gas. Electric
arcs are extremely hot. The heat energy of an electrical arc can kill and injure
personnel at surprisingly large distances.
Arc burns are thermal in nature and fall into four categories:
• First-degree burning causes painful trauma to the epidermis (outer layer
of the skin).
• Second-degree burns cause damage to epidermis and dermis layers and
are more painful.
• Third-degree burns destroy epidermis and dermis.
• Fourth-degree burns cause severe damage to all three skin layers.

8.3.4 First Aid Steps

Following steps are to be followed in life-threatening emergencies:
206
1. Quick Response needed. First Aid

2. Situation must be assessed to ascertain whether circuit is still energized

(live) or victim still in contact of circuit.
3. Action plan needs to be made as per assessed situation.
4. Victim’s condition must be assessed for administering First Aid. If a
victim is responsive, no action may be required. If victim is
unresponsive, the ABC of First Aid (which will be discussed in 8.3.5)
should be administered.
5. De-energized accident scene should be ensured.
6. Required first aid for Electric Shock and Electrical burns should be
administered (which will be discussed in 8.3.6).

8.3.6 Aims of First Aid

First aid is an emergency process, generally include simple, life-saving
procedure that most people can train to perform with minimum equipments
and no past medical exposure.
The main aims of first aid are:
i) To preserve life: Saving lives is the main goal of first aid.
ii) To prevent further harm: The person who has injured must be kept
stable, and their condition must not deteriorate before medical services
arrive. This may include moving the patient away from harm, applying
first aid techniques include CPR (Cardio-pulmonary resuscitation),
keeping them warm and dry, and applying pressure to wounds to stop
any bleeding.
iii) Promote recovery: Taking steps to promote recovery may include
applying a bandage to a wound.

8.3.5 ABC of First Aid

ABC is a memory device for First Aid Provider to remember the proper
procedure when examining an unresponsive victim. Mnemonic ABC stands
for Airway, Breathing and Circulation. Details of Mnemonic ABC are as
follows:
A – Airway: Check the victim’s Airway. The correct way to clear an injured
person’s airway is head-tilt and chin-lift maneuver.
B – Breathing: There are few obvious signs that indicate if the victim is
breathing. The most obvious sign is the rise and fall of the chest as the victim
takes oxygen into his lungs. Further breath can be checked by placing one’s
mouth near victim’s nose and mouth and feeling for any breath. Breathing
can be counted for 15 seconds and may be multiplied by four to get per
minute breath.
C – Circulation: Check the victim’s circulation. Circulation should be
checked by feeling for the victim’s pulse at carotid artery. A victim’s pulse
may be checked by placing first two fingers into indentation to the side of
windpipe (carotid pulse).
Now you are aware of ABC of First Aid, and hence ready to handle
unresponsive victims. In case victim has No breathing and no Pulse, perform 207
 Safety in Electrical CPR until pulse is restored. In case victim is breathing normal but has no
Works pulse, perform CPR. In case victim has No breathing but Normal pulse,
perform mouth-to-mouth resuscitation until breathing is restored.
Note: Before physically approaching the victim, the scene must be de-
energized.

8.3.6 Cardio-pulmonary resuscitation (CPR)

Cardiopulmonary resuscitation (CPR) is an emergency procedure that include
chest compressions with artificial ventilation in an effort to manually
preserve intact brain function until further actions are taken to restore
spontaneous blood circulation and breathing in a person who has a heart
attack due to any reason as shown Figure 8.2.

Figure 8.2: Cardiopulmonary resuscitation (CPR) with manually chest compressions

If the victim is not breathing, the first aid provider will need to do CPR. Its
main purpose is to establish the flow of oxygenated blood to the brain and
heart, preventing or at least delaying tissue death. CPR can extend the brief
window of time during which successful resuscitation can take place without
permanent brain damage.
In 2005, the International Liaison Committee on Resuscitation (ILCOR)
agreed on new guidelines. The new guidelines make it simpler for first aiders
and healthcare professionals to carry out early resuscitation.
These new guidelines stated that rescuers should progress straight to CPR if
there is no breathing, instead checking for a pulse. They also added that
rescue breathing must not be performed without chest compression.
There are two main steps in CPR:
(i) Applying chest compressions and then
(ii) providing breaths.
Apply 30 chest compressions:
The first aider should kneel next to the victim and follow these steps:
• For adults, place the heel of one hand in the middle of the chest. Place
your other hand on top of the first hand and interlace the fingers as
shown in the above Figure.
• Push the chest down about 1.5 to 2 inches. If the person is a child aged
between 1 and 8 years, compress to a maximum of 1.5 inches with one

208
 hand. Let go, and wait for the chest to come back up completely before First Aid
repeating. Your elbows must remain straight throughout.
• Push the breastbone up and down to a depth of about 5 cm about 30
times, at a pulse rate of 100 beats per minute.
Provide two breaths:
• Make sure the airway is open, and pinch the nose so it closes.
• Gently raise the chin upwards with two fingers of your other hand.
• Take a deep breath, seal your mouth over victim and exhale into the
airway.
• You should see the chest rise and fall.
• To get another breath, lift your head and breathe in deeply. Perform steps
1, 2, 3, and 4 again.
Repeat the 30 chest compressions followed by the two breaths about five
times, and then check for normal breathing. If they are not breathing
normally, continue performing CPR. If breathing restarts as normal, stay with
the injured person until help arrives.
Note:
• Chest compressions alone can be lifesavers – the crucial factor is time.
Make sure you respond quickly.
• It is important not to let your hands bounce when performing chest
compressions. Make sure the heel of your hand is touching the chest
throughout chest compressions.
• You might hear some pops and snaps during chest compressions. These
are normal, so do not stop.

8.3.7 First Aid for Electric Shock and Burns

Following First Aid Procedures should be adopted for Electric Shock as well
as Electric Burn victims:
First Aid Procedures for Conscious Electric Shock/Burns Victims:
• Keep the victim still and quiet. Heart and respiratory problems can be
delayed in electric shock victims.
• Monitor the victim’s condition for at least one hour.
First Aid Procedures for Unconscious Electric Shock/Burns Victims:
• Check the ABCs. If the victim is not breathing or has heart irregularities,
perform resuscitation.
• If wounds are visible, cover them with sterile dressings.
• If external burns are visible, they should be cooled using pure water.
• Immediately seek medical aid.

209
 Safety in Electrical
Works SAQ 2
a) State the nature of Electric hazards.
b) State and explain ABC of First Aid.
c) Write First Aid steps.
d) What are the procedures of first aid to be followed for unconscious
Electric shock victims?
e) What is CPR?

8.4 FIRST AID IN CHEMICAL/HAZARDOUS

INDUSTRY
Chemicals play an important role in our life. When used judiciously and
carefully, it is beneficial. If out of control, it can cause devastation and
destruction for people and environment. So it is important to know hazards
associated with chemicals. This will help in safety of persons and
environment. It is important to know when chemicals are hazardous.
Chemicals are hazardous if they are:
• Corrosive
• Explosive
• Ignitable
• Toxic
We must know whether a chemical is hazardous or not. It is the Label on the
product that will warn against hazard. That is why Classification and
Labelling of chemicals is needed. Further First Aid approach towards
hazardous chemicals depends upon type of chemicals. The information
pertaining to First Aid measures is provided in Safety Data Sheets (this will
be discussed in section 8.4.4 in detail).

8.4.1 Classification and Labelling of Chemicals

It is important to have uniform system of Classification and Labelling for
internationally comprehensible communication system and international trade
of chemicals. This is how United Nations comes up with Globally
Harmonized System (GHS) of Classification and Labelling of Chemicals.
Classification of Hazards has been done according to (i) Physical, ( ii)
Environmental and (iii)Health Hazards.
Physical Hazards group has further been divided into separate classes such as
Explosives, Flammable Gases, Oxidizing Gases, etc.
Likewise Health Hazards group has been divided into separate classes such as
Acute Toxicity, Skin Corrosion, Serious Eye Damage, etc.
Classification takes into account Hazard class and Hazard Category. Every
hazard class has certain appropriate hazard category. Hazard category
signifies severity of hazards eg. Hazard class “Acute Toxicity” from Health
Hazards Group has five hazard categories. Category 1 denotes the most
severe category whereas Category 5 is relatively low acute toxicity.
210
8.4.2 Hazard Communication First Aid

Once we are aware of Hazard class and severity of hazard (Hazard Category)
of a chemical product, it needs to be communicated. Harmonized hazard
communication system performs this task through GHS (Globally
Harmonized System) Labelling and Safety Data Sheets.

8.4.3 Hazard Communication: GHS Labelling

GHS Labelling contains three standardized elements. These are: Pictogram
(Symbol), Signal Words and Hazard Statement.
i) Pictogram (Symbol): Convey health, physical and environmental hazard
information, assigned to a GHS hazard class and category. Table below
shows pictogram with appropriate Hazard Class.

Pictogram Hazard Class

Oxiders

• Flammables
• Emits Flammable Gas
• Organic Peroxides

• Explosives

• Acute toxicity (severe)

Corrosives

Gases under pressure

211
 Safety in Electrical
Works • Carcinogen
• Respiratory Sensitizer

Environmental toxicity

• Irritant
• Acute toxicity (harmful)
• Respiratory Tract Irritation

ii) Signal Words: A word used to indicate the relative level of severity of
hazard. GHS uses “Danger” or “Warning” as signal word.
iii) Hazard Statement: A phrase assigned to a hazard class and category that
describe the nature of the hazards of a hazardous product.

Now, let us illustrate Classification and Labelling through an example. The

following table 8.1 illustrates the Labelling (Pictogram/Symbol, Signal Word
and Hazard Statement) for the “Skin corrosion/irritation”. [Note: Hazard
Class “Skin corrosion/irritation” and Hazard category (1 and 2) fall under
broader Health Hazards Classification (Group).]
Table 8.1: Labelling (Pictogram/Symbol, Signal Word and Hazard Statement)

Classification Labelling

Hazard Class Hazard Pictogram Signal Hazard

Category Word Statemen
t

Skin 1 Danger Causes

corrosion/irritation severe
skin burns
and eye
damage

2 Warning Causes
skin
irritation

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8.4.4 Hazard Communication: Safety Data Sheets (SDS) First Aid

The Safety Data Sheets (SDS) provides comprehensive information for use in
workplace chemical control. Employers and workers use the SDS as sources
of information about hazards and to obtain advice on safety precautions. The
information in the SDS should be presented using the following 16 headings
in the order given below:
1. Identification
2. Hazards Identification
3. Composition/information on ingredients
4. First Aid measures
5. Fire Fighting measures
6. Accidental release measures
7. Handling and storage
8. Exposure controls/personal protection
9. Physical and chemical properties and safety characteristics
10. Stability and reactivity
11. Toxicological information
12. Ecological information
13. Disposal considerations
14. Transport information
15. Regulatory information
16. Other information
Each section of SDS should have the specified minimum information. Here
the illustration of minimum information for section “First Aid measures
(listed at S.No. 4 above)” has been provided:

Heading Minimum information for an SDS

First aid measures  Description of necessary measures,

subdivided according to the different routes of
exposure, i.e., inhalation, skin and eye
contact, and ingestion.
 Most important symptoms/effects, acute and
delayed.
 Indication of immediate medical attention and
special treatment needed, if necessary.

8.4.5 First Aid for Chemical Accidents

Inhalation, Ingestion, Skin contact and Eye contact are the likely routes of
entry of chemicals into the body. A quick assessment of the likely route of
exposure can be done by examining eyes, nose, mouth, and skin of the victim
for signs of chemical itself or damage it has caused such as swelling, redness,
bleeding, or burns. There are certain indications that tell whether it is the case
of inhalation or ingestion or eye contact. If the face has been splashed with 213
 Safety in Electrical chemical, eye contact has likely hapened. If respirations are rapid, shallow, or
Works labored, it may be the case of inhalation. If there is difficulty in swallowing
or abdomen is rigid, it may be the indication of ingestion of corrosive
substance.
First aid Provider should take the following measures in case of Poisoning
due to Inhalation, Ingestion, Skin contact and Eye contact.
A. Poisoning by Inhalation
1. Remove the victim from exposure while protecting yourself from
exposure.
2. If breathing has stopped, administer artificial respiration.
3. Maintain an open airway.
4. Notify the Emergency Medical Service about the nature of the accident
and arrange for transport to a medical facility.
B. Poisoning by ingestion
1. Remove the victim from exposure while protecting yourself from
exposure.
2. Call emergency room or a physician for advice.
3. Notify the Emergency Medical Service regarding the nature of the
accident and arrange for transport to a medical facility.
4. If victim is conscious, follow the following steps:
a. Help her/him rinse out her/his mouth with water.
b. Give her/him a cup or two of water or milk to drink. If he becomes
nauseated or cannot swallow, stop.
c. Do not induce vomiting if he has abdominal pain, a distended
abdomen or a rigid, hard abdomen.
d. Do not induce vomiting if he has burns in or around his mouth or if
he cannot swallow.
e. Help the victim sit up or lean forward while vomiting.
f. Again give the victim one or two cups of water to drink after
vomiting has ceased.
g. Keep talking with her/him to prevent sleepiness.
5. If victim is unconscious, follow the following steps:
a. Maintain an open airway.
b. Arrange for transport to the nearest medical facility.
c. Stand by to administer artificial respiration and CPR, if needed.
d. Be sure to wipe or rinse all traces of the chemical from in and
around the victim’s mouth before giving artificial respiration.
C. Poisoning by skin contact
1. Remove the victim from contaminated area.
2. Remove the victim’s clothing, and shoes from affected areas.
3. Continue to flush with water until all traces of the chemical are
gone. Rinse for at least 15 minutes.

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D. Poisoning by eye contact First Aid

1. Remove the victim from contaminated area.

2. Flush the victim’s eyes with clean water for at least 15 minutes
3. Ask the victim to look up, down, and side to side as you rinse
4. Call the Emergency Medical service and arrange for transport to the
nearest medical facility for examination and treatment as soon as
possible.

SAQ 3
a) What are the elements of Labelling?
b) What minimum information should be contained in “First Aid
measure” section of SDS?

8.5 FIRST AID EDUCATION AND TRAINING

Training is defined as a formal process used to generate a desired positive
change in the behavior of an individual or group. Training modifies one’s
behavior and teaches one how to do a task satisfactorily. Education teaches
one how to think.

8.5.1 Purpose of First Aid Education and Training

The purpose of first aid education and training is to:
1. assess the need for first aid.
2. administer First Aid carefully.
3. recognize constraints and seek additional care whenever required.

8.5.2 Educational Model

It is important to know who the target audience is. If First Aid Provider
happens to be adult, Training Program will have to be oriented taking Adult
Learning Principles into consideration. Some of the characteristics of adult
learning are: Adult Learners are pragmatic, goal oriented, practical in
approach, and carry a vast life experience and knowledge. Adult learners
learn the most when the training is interactive.
Educational foundations for first aid competencies revolve around
knowledge, skills and behaviours. Knowledge signifies understanding of
victim’s symptoms, and type of First Aid that needs to be administered. Skills
exhibit practical approach in administering procedures like ABC of First Aid.
Behaviours indicate readiness to act.

8.5.3 Training Method

There are a host of Training Methods. One of the methods may be
“Simulating Real Life”. Role Playing and Behaviour Simulation Games are
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 Safety in Electrical the example of “Simulating Real Life”. The Other methods are “Training in
Works
the Field”, Laboratory Training, Cases, Seminars and Lectures.

From First Aid Training perspective, three types of training can be envisaged
– Classroom Training, On-the-job Training and Self-Training. A complete
adult trainee package must include these three methods.

Classroom Training includes classroom teaching, laboratory activities for

learning by doing sessions, student materials communicating objectives of
training concisely, and of course an able instructor.

Laboratory for On-the-Job Training is a hands-on method of teaching the

skills, knowledge, and competencies. The student learns while on the job.
The most important element of Self-Training is the learning materials. Self-
supporting learning modules serve as the core of self-training materials. It is
good for renewal of knowledge and a part of Life Long Learning (3L).

Recommended Training methods adopted for First Aid Provider is a mix of

Lectures, Video-based, Interactive Lectures and Hands on Practice.

8.5.4 Points to Taken into Consideration While Preparing

First Aid Education
1. Employ mix methods (Lecture, Real Life Simulation, Audio/Video-
based Learning) to nourish knowledge, skills and behavior of the first
responder.
2. Prepare customized content, concise and precise, for enhancing learning
experience.
3. Encourage participants to interact and share their experiences.
4. Spell out trainer’s role for intended training course.
5. Measure effectiveness of training.

SAQ 4
a) What is the purpose of First Aid in Education and Training?
b) Explain various Training Methods.

8.6 CERTIFICATION OF FIRST AID TRAINEES

A corpus of trained manpower is always required to handle emergency
medical situations. And for this, Certified First Aid Professionals are
required. One can take First Aid course without any medical or science
background. This basic First Aid course is also known as Emergency First
Responder Course. This First Aid course equips her/him with the essential
life skills required to respond to medical emergencies quickly.

Ministry of Health and Family Welfare in “Training Curriculum Handbook:

First Responder” has spelled out curriculum to be used for training and
certification of First Aid Provider (also called First Responder). Minimum
216
recommended course duration is of 8 hours (a day). The method First Aid
recommended for training is a mix of didactic, video-based, interactive
lectures and hands on practice. This 8 hours duration is divided equally
between theory and practical, each of 4 hours.

Practical session includes Cardiopulmonary Resuscitation (popularly known

as CPR), Automated External Defibrillator and artificial breathing. Apart
from these, other First Aid topics cover thermal injury, wounds, fracture and
joint injuries.

8.6.1 Institutions Offering First Aid Courses

First Aid Training and Curriculum has evolved continuously, and Standards
to be followed in Emergency situations are fairly uniform. Hence
Certification institutions are catering to these Standards and imparting
training to First Aid Providers. Now let us have a look at institutions
providing First Aid Training. As we go through the course content of these
institutions, we find a lot of commonality. Prominent institutions providing
First Aid Training are: St John Ambulance, Indian Red Cross Society and
VIVO Healthcare. Apart from these institutions, there are many other
institutions providing First Aid Certificate Course. First Aid Certification
courses have validity period, varying from institution to institution and the
training course imparted.
To have a feel of the Training Courses offered and their availability in your
locality/area, you are required to complete the following activity as per
guidelines indicated.
Activity 1
Visit the website of St John Ambulance (present URL: https://sja.co.in ).
Note down the First Aid topics covered, duration of the course, course fee,
and validity of certification.
Activity 2
Visit the website of VIVO Healthcare (present URL:
http://vivohealthcare.com/hospital-programs/vivo-healthcare-life-support-
training-program/basic-life-support-training-program-BLS.html). Note down
the First Aid (Basic Life Support) topics covered, duration of the course,
course fee, and validity of certification.
Activity 3

Visit the website of Indian red Cross Society Andhra Pradesh Branch (present
URL: http://www.indianredcross-ap.org/Sr_first_aid.aspx) to have a pulse on
First Aid courses offered by them. Note down the topics covered, duration of
the courses, course fee, and validity of the course.
Activity 4
Find Institutions imparting First Aid Training nearby your locality/area.
Prepare the list of these institutions, courses offered, their duration and
validity as per following format:
217
 Safety in Electrical
Works S. No. Name of Courses Duration Validity
Institution Offered

SAQ 5
a) Name three institutions offering Certification courses in First Aid.
b) What are the topics covered under First Aid Certification course?

8.7 CASE STUDY

Case studies are very helpful in understanding the concepts with the help of
used cases. Following is one such case.

8.7.1 Case

Fire breaks out in a switch room of Telephone Exchange. It all began in a

shelf that caters to subscribers of telephone. The fire spreads very rapidly.
Staffs are present in the switch room. Fire alarm has operated as smoke fills
the room. There are fire extinguishers at prominent places for such
eventuality. It is day time. Still dousing of fire takes considerable time, and a
few staffs suffer burn injury, a few are unconscious. First Aid administered to
affected staffs before shifting to nearby hospital.

8.7.2 Discussion Questions

i) What might have caused fire?
ii) Why staffs could notuse the fire despite fire extinguisher use?
iii) Which type of burn it might be, and which type of First Aid procedure
might have been administered?
iv) What would have been approach to administer First Aid to unconscious
staff?

8.7.3 Analysis
i) It might have been due to electric potential/voltage from some telephone
subscriber premises. Some equipment in the shelf might have
malfunctioned, and would have provided spark and resulted in fire.
There may be other causes. Think over it.

218
ii) Staff may or may not be well trained in handling Fire extinguisher (FE). First Aid
Instead of directing FE into the root of fire, might have directed on
flames. Think of other causes.
iii) Burn might have electrical origin also. Think in terms of degree of burn
from electrical hazard perspective, and discuss First Aid from that
perspective. Another perspective is also welcome.
iv) Approach to First Aid for unconscious staff taking breath and pulse
matrix of four alternatives. Discuss First Aid in this light

8.7.4 Post Analysis

This accident might have been avoided, if proper safety measures would have
been taken. At least it could have been minimized by isolating shelf by de-
energizing it first.
Think logically and coherently. There are many approaches to discuss and
analyze a case.

8.8 LET US SUM UP

In this unit we got an overview of First Aid in General condition. We also
understood how to handle First Aid in Electrical Industry and Chemical
Industry. We also pondered over First Aid Education and Training. We saw
the purpose of First Aid Education and Training as well as Teaching
Methodology, and best Teaching Method. We also appreciated importance of
Certification in First Aid, and institutes offering First Aid Certification.

8.9 KEY WORDS

AED – is a portable electronic device that administers a small electric pulse
that helps revive the rhythm of the heart and restores blood circulation.
CPR – Heart-lung resuscitation is also called cardiopulmonary resuscitation
(CPR).
Didactic: Method of teaching where students are passive listeners and
teacher imparts instructions to students.
Ingestion: Swallowing of food, drink, or any other substance.
SDS – It is Material Safety Data Sheets, provided with every chemical, and
contains various information including First Aid measures for the particular
chemical.

8.10 ANSWERS TO SAQs

SAQ 1
a) First Aid is an immediate care provided to a person in an emergency.
b) She/he must be very calm, observant, tactful and patient. She/he must be
adept in handling the crowd, and involving onlookers for help. She/he
should be trained in First Aid and capable of administering immediate
treatment to the victims at the time of emergency
c) The purpose of First Aid Box is to provide basic supplies for First Aid.
219
 Safety in Electrical d) Safety Practices are for First Aid provider, the victim from Environment
Works or Source.
SAQ 2
a) Electric shock, Electric Arc, Electric Blast
b) Mnemonic ABC stands for Airway, Breathing and Circulation.
• A – Airway: Check the victim’s Airway. The correct way to clear an
injured person’s airway is head-tilt and chin-lift maneuver
• B—Breathing: There are a few obvious signs that the victim is
breathing. The most obvious sign is the rise and fall of the chest as
the victim takes oxygen into his lungs. Further breath can be
checked by placing one’s mouth near victim’s nose and mouth and
feeling for any breath. Breathing can be counted for 15 seconds and
may be multiplied by four to get per minute breath.
• C – Circulation: Check the victim’s circulation. Circulation should
be checked by feeling for the victim’s pulse at carotid artery. A
victim’s pulse may be checked by placing first two fingers into
indentation to the side of windpipe (carotid pulse).
c) i) Act Quickly
ii) Survey the situation
iii) Develop a plan
iv) Assess the victim’s condition
v) Establish a de-energized accident scene
vi) Administer required first aid for Electric Shock and Electrical burns
d) i) Check the ABCs
ii) If the victim is not breathing or has /Burns heart irregularities,
perform resuscitation
iii) If wounds are evident, cover them with sterile dressings
iv) If external burns are evident, they should be cooled using clear, pure
water
v) Try to cool burns with sterile compresses
vi) Immediately seek medical aid.
e) CPR is an emergency procedure that include chest compressions with
artificial ventilation in an effort to manually preserve intact brain
function until further actions are taken to restore spontaneous blood
circulation and breathing in a person who is in cardiac arrest due to any
reason.
SAQ 3
a) Pictogram, Signal Word and Hazard Statement
• Description of necessary measures, subdivided according to the
different routes of exposure, i.e., inhalation, skin and eye contact,
and ingestion.
• Most important symptoms/effects, acute and delayed.
220
 • Indication of immediate medical attention and special treatment First Aid
needed, if necessary.
SAQ 4
a)
• Recognize, assess and prioritize the need for first aid.
• Provide care using appropriate competencies, i.e. first aid
knowledge, skills and behaviours.
• Recognize limitations and seek additional care when needed
b) Classroom Training, On-the-Job Training and Self-Training.
SAQ 5
a) St John ambulance, Indian Red Cross Society and VIVO Healthcare
b) Cardiopulmonary Resuscitation CPR), Automated External
Defibrillator (AED), artificial breathing, suffocation, head injury,
stroke, wounds, bleeding, fracture, muscular and joint injury, burns,
heart attack, snake and scorpion bites, allergic reactions, heat stroke
and diabetic emergencies.

8.11 REFERENCES AND FURTHER READINGS

1. Electrical Safety Handbook, 4th Edition, 2012, by John
Cadick (Author), Mary Capelli-Schellpfeffer (Author), Dennis
Neitzel (Author), Al Winfield (Author)
2. Handbook of International Electrical Safety Practices, Princeton Energy
Resources International, 2010, Scrivener Publishing, Wiley
3. First Aid Manual for Chemical Accidents by Marc J. Lefevre
4. Occupational Safety and Health Simplified for the Chemical Industry by
Frank R. Spellman and Revonna M. Bieber
5. https://www.unece.org/fileadmin/DAM/trans/danger/publi/ghs/ghs_rev07
/English/ST_SG_AC10_30_Rev7e.pdf
6. https://www.osha.gov/dsg/hazcom/ghsguideoct05.pdf
7. Encyclopedia of Occupational Health and Safety, Chapter 18: Education
and Training (From the International Labour Office)
http://www.ilocis.org/documents/chpt18e.htm
8. International first aid and resuscitation guide 2016, International
Federation of Red Cross and Red Crescent Societies,
https://www.ifrc.org/Global/Publications/Health/First-Aid-2016-
Guidelines_EN.pdf
9. http://www.indianredcross.org/education.htm
10. http://delhi.gov.in/wps/wcm/connect/doit_homeguard/Homeguard/Home/
Organization/Casualty+Service/Training
11. http://indianredcross-ap.org/Sr_first_aid.aspx
12. https://www.livemint.com/Leisure/2x7LznXheJXgqMQERnIFaK/Know-
basic-firstaid.html
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 MIS – 024
MECHANICAL AND ELECTRICAL SAFETY MANAGEMENT

BLOCK 1 : SAFETY IN MACHINERY

Unit 1 : Job Safety Analysis and Machine Gaurds
Unit 2 : Safety in Mechanical Handling
Unit 3 : Safety in Design and Safe Working Practices
Unit 4 : Case Study and Excercise

BLOCK 2 : SAFETY IN ELECTRICAL WORKS

Unit 5 : Electrical Safety, Fire and its Prevention
Unit 6 : Safety of Electrical Equipments
Unit 7 : Indian Electricity Rule
Unit 8 : First Aid

MPDD-IGNOU/P.O.5H/___________2020 (Print)

ISBN-