iNDUSTRIAL SAFETY HANDBOOK

INDUSTRIAL SAFETY HAND BOOK RAMAN BOARDS LIMITED MYSORE OOTY ROAD, THANDAVAPURA - 571 302 MYSORE DISTRICT, KARNATAKA, INDIA INDUSTRIAL SAFETY HAND BOOK Released on 4th March 2005 RAMAN BOARDS LIMITED MYSORE OOTY ROAD, THANDAVAPURA - 571 302 MYSORE DISTRICT, KARNATAKA, INDIA Aroon Raman Cdr M S Chandrashekar Managing Director Raman Boards Limited Vice-President (Operations) Raman Boards Limited - IMD MESSAGE MESSAGE It is now widely recognised that the well-being of the people serving any organisation is a fundamental prerequisite for all companies that have set global ambitions for themselves Safety of the working environment lies at the core of this well-being However much we focus on training, development and otherwise empowering our people, these positive effects can be easily negated by poor safety in the working environment In order to ensure that the culture of safety takes firm roots in the organisation, Raman Boards Limited has placed great emphasis on improving its work culture through education and training, and executing a large number of safety related projects in the plants on an on-going basis As you are all aware, we have also conducted audits by internal and external agencies at periodic intervals, assessed the results and then taken various corrective actions There is no doubt that we have made large strides in creating a safe working environment, but is equally clear that this is a never-ending journey One important milestone in this journey is our Safety Manual, which lays down our Safety Policy in clear and comprehensive terms to all our company employees and stakeholders It is my earnest request that all of you use this booklet as a guide to ensure that our company remains at all times a safe place to work for you and your colleagues Your valuable suggestions will also go a long way to help improving this publication Aroon Raman Managing Director I am pleased to note that the "Safety Committee" of Raman Boards Ltd., has decided to bring out a Safety Handbook during the occasion of National Safety Day - 4th March 2005 The Handbook will serve as a ready reference and increase the awareness of Health and Safety among the industrial workforce I would like to emphasise here that, by following safe work methods, an employee can ensure his own safety and thereby his family's future I would like to congratulate the safety committee for their endeavour to bring out the safety Handbook on this occasion of safety day I would like to also wish all the employees of Raman Boards an accident free worklife Cdr M S Chandrashekar Vice-President (Operations) Chairman - Safety Committee Raman Boards Limited - IMD T.M Vikram Talaulikar GM (Operations) Raman Boards Limited - FD MESSAGE I am pleased to note that Raman Boards Ltd., has decided to release a safety hand book on the occasion of National Safety Day on 4th March 2005 A handbook such as this will go a long way in increasing peoples awareness of safety Industrial safety today is imperative and goes hand in hand with industrial progress My best wishes to the committee members for this safety handbook PREFACE The work ambience in industries is amply allied with unsafe working conditions and risks It is the knowledge that industrial accidents are culminating in loss of life, limbs and damage to environment To prevent and eliminate these accidents there are various enactment in force The enactment alone not bring any changes unless the process, safe procedure of work are understood and inclulcated in its letter and spirit by all the concerned alike The recent incident world over has revealed that most of the accidents are due to either human failure or deviations in the set procedures These themes has drawn the attention of many agencies in view of great hardship caused by them Therefore there is a need to address this issue on priority One of the tools is to educate the employer and their employees by enlightening them on the issues concerned In this context, Raman Boards Ltd., Safety Committee has brought out a safety instruction book on the occasion of celebration of 34th National Safety Day celebrated on 4th March 2005 at Thandavapura, Nanjangud The instruction book contains few tips with regard to Do's and Don'ts to be observed in day to day working in the factory and to prevent any incidents or accidents It is opined that this instruction book will be of immense help and useful for all the concerned Wishing you a happy, safe, risk-free work environment T.M Vikram Talaulikar GM (Operations) D C JAGADEESH Deputy Director of Factories Mysore Region, Mysore CONTENTS 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 Introduction House-keeping Electrical Safety Tips on Instrumentation Safety Hand-tools Gas cutting & Welding Material Handling Lifting machines Material storage and handling Pressure Vessels Machine guarding Safety in grinding Surface grinder First-Aid Fire Danger tags Boiler Safety L.P.G safety at home GAS hazards Working at Height Contractor role in the plant General Points Red slips Safety committee & its activities Functions of safety committee Obligation of Occupier Obligation of workmen SAFETY NEEDS INVOLVEMENT OF EVERYBODY 10 11 16 17 23 24 25 27 30 31 31 34 34 36 40 41 44 48 51 56 56 58 61 61 62 64 RIGHT KEYS INTRODUCTION What is Safety? * * * * Safety is freedom from accident, freedom from the fear of meeting with accident! Safety is that which gives protection from known dangers & risk; Safety helps to take calculated risk (and even helps man to land on moon and come back to mother earth, happily!) Safety is a pro-active Means to achieve the positive Ends! In all planning remember the need of safe working SAFETY IS A CATALYST TO GET THE DESIRED RESULTS! What is Accident ? Accident is an unplanned, unexpected event, which causes interference to work, may or may not result in injury, damage to property and /or to environment "Accidents not happen, they are caused" *Main Causes of accidents are: *Unsafe Actions - 80% *Unsafe Conditions - 18% *Natural Calamities - 2% *Recent revelations indicate that some of the natural calamities are due to man's actions! YOUR DOWNFALL IS DUE TO YOUR OWN CARELESSNESS HOUSE-KEEPING "A Place for everything & Everything in its place" GOOD HOUSE KEEPING Health is important to an individual Similarly tidiness is important to the working environment, There is no doubt that lack of tidiness and orderliness slows down work But this lack can also cause serious accidents Therefore before you start S Plan for tools, implements, materials etc S Ensure clearance and cleanliness at work place S Minimize hazards from sharp/pointed objects S Beware of oily and slippery surfaces S No haste's and short cuts S Maintain control over activities and task's S Concentrate on the task on hand S To follow 5S Practice strictly to ensure proper, safe and clean environment 10 ELECTRICAL SAFETY F The main cause for electrical accidents are exposed live wires, bare live conductors, open switches, temporary/loose/hanging wires; fuses, inadequate knowledge and unsafe working methods F F F DO'S F F F F F F F F Only qualified & experienced persons should be allowed to undertake electrical works Treat all circuits as live unless ensured dead by testing Ensure extension cords are free from cuts, damaged insulations, kinks or joints Ensure that pins of the socket/plug are not loose Ensure easy access to put off the power supply, While using any portable electrical equipment, ensure that it is properly earthed, no leakage of current though the body of the equipment Report all electrical hazards to the competent person In case of short-circuit or fire, put off main switches immediately 11 F F F F F F F F F CO2 / DCP are the extinguishing mediums in case of fire Place rubber mats in front of the distribution boards Use protection such as rubber gloves, shoes and insulated tools while working with electricity Remove the fuse cut-outs and keep them in self-custody while undertaking repairs Label the feeders Use switches which clearly indicate "ON"/ "OFF" and are of appropriate amperage Use work permit in areas of flammable atmosphere Know First-Aid procedures Remember, AC is more dangerous than DC Do not meddle with the Interlocks with regular Inspection of cords and related tools Avoid temporary connections Use Standard Materials for complete protection Ensure safety by personal observation and not by other persons report Cable ducts and trenches to be covered with proper covers and regularly cleaned All switches on phase wire and not on neutral wire 12 If you don't monitor, you can't manage it! N Don't work wet, on electrical equipment N Don't just operate any switch unless you know the repercussions Leave electrical repairs to authorized People N Don't overload an electrical point N Don't use water for extinguishing electrical fire; Use dry sand, CO2, or DCP extinguishers N Don't take short-cuts in tapping electric current N Don't store any material near the electrical mains/switch-boards N Don't work on live circuits, even when the job is very small Don't tamper with the switch when you are on the job Electricity cannot be seen, cannot be tasted; Use electricity carefully to avoid accidents Do not leave Electrical equipment Within the reach of Children DON'Ts N Don't tamper with settings of Earth Leakage Circuit Breakers N Don't have any unsafe temporary connections, naked joints/wirings 13 14 ELECTRICAL INJURIES TIPS ON INSTRUMENTATION SAFETY K Electric Shock Flow of electric current through human body is the cause of electric shock Voltage, resistance of the body to electricity, duration of current flow are important Alternating current(AC) is more dangerous than DC; the former causes involuntary grip which prolongs time of contact and therefore more dangerous On receiving an electric shock; K The current flows through nerves, and muscles causing disturbance in their normal functions If the path is through the heart, the accident can be fatal K A person may fall from height as he may loose his balance on getting a shock K A person may be thrown away at the same level causing him bodily injury K K K K K K K K Ensure isolation valves are closed before removing pressure & flow transmitters from lines Ensure that no leak of process fluid exists after installing pressure, flow and temperature sensors Ensure power supply is put off to instruments before removing from panel Ensure proper fuses are put for each instrument and solenoid valves Don't use copper lead in place of fuse Ensure process line is isolated before removing Rotameter Ensure tank is empty before removing and bottom, mounted, diaphragm-type level transmitter Never by-pass any interlocks without obtaining written permission from plant incharge Never allow a loose connection, as it may spark off and create fire hazards ACCIDENTS DO NOT HAPPEN: THEY ARE CAUSED! BURNS: K 15 Burns are caused by electrical flashes if a body part comes within flashing distance of a 16 control it by using extinguishing media F Raise alarm when you notice a fire F Immediately report to the concerned for further action F Use right type of extinguishing media for specific type of fire F ind, I nform, R esort, E xtinguish, By dismantling any one segment, the triangle is incomplete and so the fire will not occur By removal of any one of the above elements Best method is removal of Air or Heat What are the extinguishing elements? Water, Dry powder, Carbon dioxide Gas and Sand What is the effect of Extinguishing Elements? Removal of air: Blanketing Effect, Removal of Heat: Cooling Effect, How fire can be prevented? By keeping all combustible and flammable materials away from heat sources ALL BECAUSE ONE GUY WASN'T CAREFUL Fire Safety instructions How is fire formed? By the combination of elements: Air (Oxygen) Fuels (Combustible & flammable) Heat (Heat Producing sources) What are the causes of fires? Heat producing sources like: Welding, gas cutting, Electric Sparks, Hot Metal, Hot Flames, Smoking etc., What is the Principle of extinguishing fire? 37 38 Cigarettes are fire hazards Carelessly discarded cigarette or "beedi" butts are major fire starters They combine with the rubbish strewn about and cause disasters Suitable ash-trays containing water should be provided These ash-trays must be cleaned before the time of closing, Never throw cigarette ends or match sticks out of the window Prevent smoking within the premises Strictly prohibit smoking where chemicals and combustible materials are stored FIRE FIGHTING FIRE PREVENTION Fire usually starts in a small way The main principle is keep any source of Always be alert If you happen to ignition well protected, controlled and away Discover a fire: from any inflammable substance F Do not panic F Inform your fellow workers/Superiors/security department, F Find out what is on fire and what is the ignition source F Use the extinguisher cylinder/water as may be appropriate ACCIDENT PREVENTION TAGS (1s:8095-1976) F Used as a temporary means of warning of an existing hazards till positive means can be adopted to eliminate the hazard F Not to be considered as complete warning 39 method F Tags are to be printed in English and regional language of State where tags are likely to be used SAFETY & PRODUCTION GO HAND-IN HAND! "DO NOT START" TAGS These should be placed in conspicuous position or in such a manner that they effectively block the starting mechanisms which could cause hazardous conditions should the equipment be energized "DANGER" TAGS These shall be used only where an immediate hazard exists All employees should be instructed that it indicates danger and that special precautions should be taken for safety 40 OBEY THE RULES, RESPECT THE PROCEDURES TO ENSURE SAFETY BOILER SAFETY ü ü ü ü ü ü ü ü ü DO's ü ü ü ü ü Check the water level in the gauge glass and in the storage tank, before starting the boiler Check the feed-water pump discharge valve is in open position Check the valve position of fuel system Gauge glass tube should be drained in every shift to avoid false reading and possible failure Mobery unit should be drained periodically and also check the low water level alarm is functioning 41 ü ü ü ü ü ü Clean feed-water level alarm is functioning Clean feed-water storage tank periodically Use treated water as per the specifications recommended Check the quality of feed-water& blow-down water regularly Blow down the boiler water at low loads Blow-down valve to be always kept in closed position while in operation Drain the main steam line before opening the main steam stop-valve Check steam traps are working property and clean them if found malfunctioning Check for the insulation of fuel and steam lines for any damage Check for any steam leakages and attend to them as early as possible Check boiler pressure gauges for proper functioning and get it calibrated regularly Test safety-valves regularly to ensure that they are popping up at the set pressure Check and replace fusible plug once in a year, minimum Ensure proper temperature & pressure of fuel Ensure proper air-to-fuel ratio is maintained such that the smoke from the top of the 42 ü ü ü ü ü ü chimney will have a hazy-brown colour Check for boiler fire box doors leak-tight Check for cleanliness and proper functioning of photo-cell Check for cleanliness of peep-hole glass Clean the smoke-side of the boiler-tubes at least once in weeks, to prevent from clinker accumulation and tube overheating Clean the burner nozzles regularly Display firing procedure DON'Ts û û û û û û û THE MEANS JUSTIFY THE END WHEN WE SAY SAFETY FIRST, PRODUCTION MUST! û û Never leave the boiler unattended or allow unauthorized persons to meddle Never start firing without reaching correct oil temperature & correct oil pressure Never cut-in the boiler unless the pressure is nearly same as the header pressure Never ignore any abnormal conditions like hissing sound, excessive white smoke from chimney; investigate the baffle crumbling, puncture etc., 43 û û Never use oversized burners and so cause loss in efficiency Never allow formation of heavy clinker and failure due to overheating etc Limit excess air supply in such a way that to keeps oxygen below 5% in the flue gas Never work the boiler below its rated working pressure in preference to pressure reducing station where steam at low pressure is sought Never rely on automates always, be alert than complacent Never use the boiler without changing the fusible plug after annual inspection Never hit the safety valves or the mounting on the boiler with hammer while it is in operation LPG SAFETY AT HOME IN CASE YOU SUSPECT LPG LEAKAGE: F Close the burner knobs and the cylinder valves and refix the safety protection cap F Extinguish any open flame F Don't light a match or bring in other ignited material 44 F Do not touch electrical switches F Open windows for free ventilation F Do not tamper with installation N N N F F 45 PREVENTION OF DOMESTIC FIRES Do not wear synthetic inflammable clothes, when cooking Do not lean over a burning fire Do not keep combustible material near a stove After use, extinguish fires effectively If you smell raw gas, open doors and windows and inform your supplier Immediately contact your distributor and the fire brigade; keep their phone numbers handy Using LPG Safety Liquefied Petroleum Gas (LPG), stored as liquid under pressure in cylinders, is widely used in homes as cooking gas The main hazards associated with LPG are fire or explosion in case of even minor leakage In case of major, leakage in confined spaces; asphyxiation due to deficiency of oxygen may also result LPG being colourless and odourless, a distinctive foul odour is added to enable easy detection of a leak As LPG vapour is lower levels and fire or explosion may result -Keep stoves on a raised platform rather than on the kitchen floor 46 ... National Safety Day on 4th March 2005 A handbook such as this will go a long way in increasing peoples awareness of safety Industrial safety today is imperative and goes hand in hand with industrial. .. pleased to note that the "Safety Committee" of Raman Boards Ltd., has decided to bring out a Safety Handbook during the occasion of National Safety Day - 4th March 2005 The Handbook will serve as... his family's future I would like to congratulate the safety committee for their endeavour to bring out the safety Handbook on this occasion of safety day I would like to also wish all the employees