TUTORIAL

MAC 2623: MACHINERY & EQUIPMENT SAFETY

Name: MUHAMMAD FARIHIN DANIEL BIN ZULKEFLI

Matrix No: SH20220711519

CHAPTER 4

1. Explain the main factors that influence electricity and sketch a simple circuit to
show the current flow

Electricity Influencers:

There are two main ways to think about how electricity is influenced:

1. In a circuit: Here, the flow of electricity itself is affected by:

• Voltage (V): The pressure pushing the electrons, like water pressure in a
pipe.
• Higher voltage means more "push" and generally more current flow.
• Current (I): The rate of electron flow, similar to the amount of water
flowing through a pipe per second. Measured in amperes (amps).
• Resistance (R): The opposition to current flow, like a narrow pipe
restricting water flow. Higher resistance means less current for the same
voltage.

2. Electricity consumption and cost: This is more about how much electricity you
use and how much it costs, influenced by:
• Appliance usage: The type and number of appliances you use heavily
impact consumption.
• Weather:Extreme hot or cold can make heating/cooling systems work
harder, increasing usage.
• Location and energy source: Electricity generation costs vary by region
and fuel source.

Simple Circuit Sketch:

Here's a sketch of a basic circuit with current flow:

 - The battery creates a voltage difference, pushing electrons through the wire.
- Electrons flow from the negative terminal (shown as -) to the positive (+)
terminal. (Conventional current flow, opposite actual electron flow) - The light
bulb provides resistance, converting some electrical energy to light.

2. Explain the purpose of electrical installation below:

a) Fuse
A fuse is a safety device that contains a metal strip that will melt and break
the circuit if too much current flows through it. This helps to prevent
electrical fires.

b) Circuit breaker
A circuit breaker is a safety device that can be reset after it has tripped. It
works in a similar way to a fuse, but it can be reused.

c) Main switch
The main switch is used to isolate a circuit from the power supply. This is
important for safety when working on electrical wiring.

d) Socket and plug

A socket and plug is a type of connector that allows electrical devices to be
connected to the circuit.

3. Discuss the main hazards of electricity

i. Electric shock
Electric shock can occur when a person comes into contact with live
electrical wiring. This can cause serious injury or death.

ii. Electrical fires

Electrical fires can start if electrical wiring is overloaded or damaged.
 These fires can cause extensive damage to property and loss of life.
iii. Arc faults
An arc fault is a type of electrical fault that can occur when there is a loose
connection in the wiring. Arc faults can cause sparks that can ignite fires.

4. Explain the effect of electrical current based on the following values:

a) V= 240V, R= 1500 Ohm

Current (I) = 240V / 1500 Ohm

Current (I) = 0.16 Amps

b) V = 1200V, R = 200000 Ohm

b) V= 1200V, R= 200000 Ohm

Current (I) = 1200V / 200000 Ohm

Current (I) = 0.006 Amps Effect
on Current:

- In scenario (a), with a lower resistance (1500 Ohm) and the same voltage
(240V), the current is significantly higher (0.16 Amps) compared to
scenario (b).

- In scenario (b), with a much higher resistance (200000 Ohm) and a higher
voltage (1200V), the current is significantly lower (0.006 Amps) compared
to scenario (a). Explanation:

- Voltage: Think of voltage like water pressure in a pipe. Higher voltage

creates more "push" for the electrons to flow, resulting in a higher current
for the same resistance. In scenario (b), the increased voltage partially
counteracts the high resistance, but the current remains much lower due to
the significant resistance.

- Resistance: Imagine resistance as a narrower section in a pipe, restricting

water flow. Higher resistance makes it harder for electrons to flow,
reducing the current for the same voltage. In scenario (b), the very high
resistance significantly restricts current flow, even with a higher voltage.

5. Sketch the electrical current flowing through human body.

6. Explain the dependence factors for the effect of electrical current.
i. Amount of current
The amount of current that flows through the body is the most important
factor. A higher current can cause more severe injury or death.

ii. Path of current

The path that the current takes through the body can also affect the severity
of the injury. Current that flows through the heart is more likely to cause
serious injury or death than current that flows through a limb.

iii. Duration of exposure

The length of time that a person is exposed to the current can also affect
the severity of the injury. Longer exposure times can cause more serious
injuries.

iv. Skin condition

Wet skin conducts electricity better than dry skin. This means that a person
is more likely to get a severe shock if their skin is wet.

CHAPTER 5

1. Please compare between electric arc welding, resistance welding and gas welding
a) Heat sources

(i) Electric arc welding

  Heat in generated by an electric arc between the electrode and
the workplace.

(ii) Resistance welding

• Heat is generated by the resistance to electric current flow
through the workplaces.
• Uses high current and low voltage to create heat quickly at the
joint.

(iii)Gas welding
• The flame in directed onto the workplace to melt the metals and
create the weld.

(b) Process characteristics

(i) Electric arc welding

 Suitable for a wide range of metals and thicknesses.

(ii) Resistance welding

• Mostly used for joining metals that are electrically conductive.

(iii)Gor welding
• Can weld thick sections effectively.

2. Discuss the functions of the flashback arrestor and non-return valve for gas
welding equipment.

• Flashback arrestor

A flashback arrestor is a safety device that is used to prevent flames from

traveling back into the oxy-fuel gas lines. This can happen if the flame at the
torch tip is extinguished for some reason. A flashback can be dangerous
because it can damage the welding equipment and cause an explosion.

• Non-return valve:

A non-return valve is a one-way valve that allows gas to flow in one

direction only. It is used to prevent gas from flowing back into the pressure
regulator if the torch tip is accidentally blocked. This can help to prevent
pressure buildup in the regulator, which could damage the regulator or cause it
to leak.
3. Sketch the blowpipe section and explain its function.

- Funtion welding tip :

• Making a Weld: In general welding terminology, "welding up" simply refers to

the act of creating a weld joint by melting the base metals and (sometimes)
filler metal using a heat source.
• Closing or Filling a Hole/Gap: In some specific scenarios, "welding up" might
imply using welding to close or fill an opening, hole, or cavity in a metal
object.

• Function mixing chamber

- Combine multiple substances: This is the core function. It allows you to

mix two or more fluids, gases, or even solids together.

- Promote even mixing: The chamber design often incorporates features to

ensure thorough mixing. This might involve baffles, stirrers, or specific
inlet/outlet configurations to create turbulence and promote even
distribution of the combined materials.

• Function barrel

- Contains the Propellant: It holds the rapidly expanding gases created when
the propellant ignites.
 - Directs the Projectile: The bullet or projectile travels through the barrel.
Imparts Spin (Rifled Barrels): Rifling (spiral grooves) inside the barrel
spins the projectile, improving accuracy and stability.

• Oxygen valve

- Regulation: Oxygen valves allow for precise adjustment of the oxygen

flow rate. This ensures the recipient (machine or person) gets the exact
amount of oxygen needed.

- Shutoff: They can completely stop the flow of oxygen, which is vital for
shutting down systems or isolating leaks.

- Safety: Due to oxygen's high reactivity, valves are built with special
materials and features to minimize the risk of fire or explosions.

- Pressure Control: Some oxygen valves, like pressure relief valves, help
maintain safe pressure levels within a system by automatically releasing
excess pressure.

• Gas valve

- Regulating gas flow in appliances: Gas valves control the gas supply to
home appliances like furnaces, water heaters, and stoves. By adjusting the
valve, you can control the intensity of a flame or the heating power of the
appliance.

- Safety shutoff: An important function of gas valves is to shut off the gas
flow in emergencies. They can be automatic or manual, stopping the gas
supply in case of a leak, malfunction, or when you shut off the appliance.

- Industrial processes: Gas valves are essential components in industrial

settings for regulating and controlling gas flow in various processes and
manufacturing operations.

4. Explain the factors for the following welding hazard exposures:

a) Fire and explosion

Welding can cause fires and explosions if proper safety precautions are not
followed. Some of the causes of fire and explosion in welding include:

• Using flammable materials near the welding arc

 • Improper handling of welding gases  Using faulty
welding equipment

b) Flying objects

• When metal is welded, it can splatter or chip away from the base metal.
This can create flying objects that can strike the welder or other people in
the area.

c) Heat stress

• Welding is a hot process, and welders can be exposed to high levels of

heat. This can lead to heat stress, which can cause a variety of symptoms,
including sweating, fatigue, nausea, and dizziness.

5. Discuss the safety measures before and during the welding activities

• Wear appropriate personal protective equipment (PPE): This includes

welding helmet, gloves, goggles, respirator, and ear protection.

• Inspect the welding equipment: Make sure that the welding machine,
cables, and torch are in good condition and free of any damage.

• Ensure proper ventilation: Welding can produce fumes and gases that can
be harmful if inhaled. Make sure that there is adequate ventilation in the
welding area.

• Clear the work area: Remove any flammable materials from the welding
area.

• Secure the workpiece: The workpiece should be securely clamped in place

to prevent it from moving or falling.

• Do not weld on containers that have held flammable liquids or gases:

These containers may still contain vapors that can explode if ignited.

CHAPTER 6

1. Define “ building operations” under Factory and Machinery Act 1967

  The Factory and Machinery Act 1967 does not define "building operations".
However, the Act applies to any factory where machinery is used. Building
operations are generally considered to be construction activities, and are
not covered by the Factory and Machinery Act.

2. State the uses of the following machinery

a) Mobile crane

 Mobile cranes are used for lifting and transporting heavy objects. They are
often used in construction, mining, and shipping

b) Passenger hoist

 Passenger hoists are used to transport people vertically. They are often used
in construction and maintenance applications.

c) Excavator

 Excavators are used for digging, trenching, and loading materials. They are
often used in construction, mining, and landscaping.

3. Discuss about hazards exposure, accidents, safety measures and relevant

regulations to be followed in relation to the following activities:

a) Excavation

Hazards:

- Cave-ins: The most serious hazard, caused by unstable soil collapsing on

workers in the excavation.

- Falls: Workers can fall into the excavation itself or from equipment.

- Slips and trips: Uneven surfaces, loose materials, and poor footing can
cause slips and trips.

- Falling objects: Materials or equipment falling from stockpiles or the

excavation edge can injure workers below.

Accidents:
 These hazards can lead to various accidents, some of which can be fatal:
- Workers being buried alive by cave-ins.
- Serious injuries or death from falls.
- Injuries from falling objects like tools or debris.
- Electrocution, explosions, or burns from damaged utilities. - Suffocation
from oxygen deficiency or toxic gases.

Safety Measures:

- Planning and Site Assessment: Before excavation begins, identify

underground utilities and assess soil conditions. Plan the excavation depth,
shoring system (supports for the excavation walls), and safe access/exit
points.
- Shoring Systems: Implement appropriate shoring systems (sloping, shoring
walls, trench boxes) to prevent cave-ins based on soil type and depth of
excavation.
- Personal Protective Equipment (PPE): Workers should wear hard hats,
safety glasses, high-visibility vests, sturdy boots, and fall protection
equipment when necessary.
- Safe Work Practices: Maintain a safe distance from the excavation edge for
equipment and materials. Train workers on safe work practices and proper
use of tools and equipment.

Relevant Regulations:

- OSHA (Occupational Safety and Health Administration) Excavation

Standards (US):
https://www.osha.gov/sites/default/files/publications/osha2226.pdf

- HSE (Health and Safety Executive) Excavation Safety Topics (UK):

https://www.hse.gov.uk/construction/safetytopics/excavations.htm

b) Piling

Hazards:

- Falling from heights: Workers climbing piles, operating machinery at

elevated positions, or working on unstable platforms are at risk of falls.
- Struck by objects: Falling piles, swinging machinery arms, or dislodged
materials can cause serious injuries or fatalities.
- Equipment failure: Malfunctioning pile driving rigs, cranes, or lifting
equipment can lead to accidents.
 Accidents:

- Workers being crushed by falling piles or equipment.

- Injuries from falling due to slips, trips, or missteps while working at
heights.
- Electrocution from contact with overhead power lines or faulty electrical
wiring in equipment.
- Hearing damage due to prolonged exposure to loud noise without proper
protection.

Safety Measures:

- Personal Protective Equipment (PPE): Workers should wear hard hats,

safety glasses, high-visibility vests, gloves, and appropriate footwear
depending on the task.
- Fall protection: Guardrails, safety harnesses, and proper scaffolding should
be used for work at heights.
- Safe work procedures: Clear procedures for operating machinery, handling
piles, and conducting lifting operations should be established and followed.
Relevant Regulations:

- The Occupational Safety and Health Administration (OSHA) in the US sets

standards for construction safety, including piling operations
https://www.osha.gov/laws-regs/
- The Department of Safety and Health (DOSH) in Malaysia enforces
regulations for workplace safety, including piling activities
https://www.dosh.gov.my/index.php/legislation/guidelines/general/598-
05guidelines-on-occupational-safety-and-health-act-1994-act-514-2006/
file

c) Demolition

Hazards:

- Falling objects: Debris from collapsing structures, falling tools, and

materials pose a major risk of serious injuries or death.
- Electrocution: Exposure to live wires during demolition of buildings with
electrical systems can be fatal.
- Crush injuries: Uncontrolled equipment movement, collapsing structures,
and falling materials can cause crushing injuries.

Accidents:
 - Worker struck by falling object: This is the most common cause of serious
injury or death in demolition.
- Electrocution: Workers accidentally contacting live wires is a major
electrical safety concern.
- Equipment malfunction or rollover: Accidents involving heavy machinery
can be catastrophic.

Safety Measures:

- Pre-demolition survey: A thorough inspection by a qualified engineer to

identify potential hazards like asbestos, structural weaknesses, and buried
utilities.
- Demolition plan: A detailed plan outlining the demolition method,
sequence, safety measures, and emergency procedures.
- Personal Protective Equipment (PPE): Hard hats, safety glasses, respiratory
protection, earplugs, sturdy footwear, and high-visibility clothing are
essential.

Relevant Regulations:

- Specific regulations for demolition vary by region, but most follow

guidelines set by national occupational safety agencies.
- In the United States, the Occupational Safety and Health Administration
(OSHA) has regulations for demolition work outlined in Subpart T of 29
CFR 1926 [OSHA Demolition]. These regulations cover topics like
preparation, fall protection, equipment operation, and worker training.

- Similar regulations exist in other countries, such as the Workplace Safety

and Health (Construction) Regulations in Singapore and the Health and
Safety at Work Act in the United Kingdom.

d) Working at height (Scaffolding)

Hazards:

• Falls: This is the biggest risk associated with scaffolding. Falls can
happen due to:
• slips, trips, or missteps on the scaffold platform
• Loss of balance while reaching for tools or materials
• Falling objects from above (tools, materials)
 • Scaffold collapse due to improper construction, overloading, or
unstable base
• Electrocution: If working near power lines or electrical equipment.
• Struck-by objects:Falling tools, materials, or debris from higher levels.
• Muscle strain: From lifting heavy materials or awkward postures while
working on the platform.

Accidents:

• Falls from height are the leading cause of accidents on scaffolding,

resulting in broken bones, head injuries, spinal cord injuries, and even
death.
• Scaffold collapse can injure or kill multiple workers at once.
• Electrocution can cause serious burns, cardiac arrest, and even death.
• Struck-by objects can cause head injuries, broken bones, and other
injuries.

Safety Measures:

• Use properly constructed and inspected scaffolding: Ensure the

scaffolding is erected by a qualified person, meets load capacity
requirements, and is inspected regularly.
• Wear fall arrest harnesses: Always use a properly fitted harness with a
lanyard securely attached to a lifeline anchored to a suitable point on
the scaffold.
• Follow safe work practices:Don't overload the platform.
• Maintain three points of contact (two hands and a foot or two feet and
a hand) when climbing or descending the scaffold.

• Keep tools and materials organized to avoid tripping hazards.

• Ensure proper ventilation when using gas-powered tools.
• Use guardrails and toeboards: Guardrails prevent falls from the
platform edge, while toeboards prevent objects from falling off the
platform.