CHAPTER S

Safety
S.1 Safe Work………………………………………………………………... S.2
S.2 Safety during Installation Work ……………………………………….. S.2
S.2.1. Machine Specifications……….…………………………….. S.2
S.2.2. During Installation…………………………………………… S.3
S.2.3. Transport…………………………………………………….. S.4
S.2.4. Assembly and Adjustment…………………………………. S.5
S.2.5. Before Trial Running………………………………………... S.6
S.2.6 During trial running………………………………………....... S.7
S.3 Rules for Safe Operation……………………………………………....... S.8
S.3.1 General Rules……………………………………….............. S.8
S.3.2 Precautions for spinning…………………………………… S.9
S.4 Safety Rules for Maintenance…………………………………………… S.9
S.4.1 Before maintenance work……………………………………. S.10
S.4.2 Precautions for Maintenance personnel……………………. S.10
S.4.3 During Maintenance work……………………………………. S.11
S.4.4 Lubrication…………………………………………………….. S.11
S.5 Rules for Operating or Checking the Electrical Devices……………… S.12
 ‘e’ version

S.1 Safe work

! "

# $ % &
! % !

&
%
%
' !
& %
! !

S.2 Safety during Installation Work

S.2.1 Before Installation

1. Check the safety rules and the workmanship standards of the plant.

2. Make sure that all personnel involved know the nature of job and the
installation procedure.

3. For jobs requiring group effort, choose a supervisor whose instructions

will be followed by all.

4. For jobs requiring group effort, agree before hand, on words or gestures
for giving and confirming signals.
 5. Check the work places and the
surrounding areas. If any unsafe point is
found, take the necessary action to
make it safe. For example,

i. When foundation bolts, power cable

conduits and air inlet piping are laid
out before installation, mark them
clearly with brightly coloured cloth or
a flag so that workers can avoid
tripping or hitting the machine and
carriers against them during
installation.

ii. Put a temporary cover over the pits

made for (exhaust, piping, wiring or
other purposes) to prevent accidents.

iii. Use specified tools those matches

with the job to be done.

S.2.2 During Installation

General points for installation work:

1) Always wear gloves wherever there is a

possibility of injury to hands or fingers.

2) Do not spill oil or grease on the floor, since

these can cause accidents due to
slippage.

3) Provide a stable platform or scaffold for

those jobs that cannot be done by
standing on the floor.

4) Never use gloves for doing jobs where

there is a possibility gloves being caught
in the rotating part of the machine.
 ‘e’ version

5) Please keep your tools, parts, devices

and instruments neatly arranged. Store
them in places where they are not likely
to fall down.

6) Whenever the tool is kept in standing

position or when it is kept inclined
against some support, adequate
precautions should be taken to ensure
that the tools does not slip and fall
down.

7) Never climb onto a heavy hoisted object

nor get under it.

8) Observe the following rules when

working in a group :
i. Choose a supervisor whose
instructions will be followed by all.
ii. Agree beforehand on words gestures
for giving and confirming signals.

iii. Be careful when handling heavy objects. If weight exceeds 20 Kg, two or
more workers should handle them.

S.2.3 Transport
1) Check out the transport route beforehand; to minimize the obstacles.
2) Before bringing in machinery, always prepare well-maintained carriers.
3) When unloading the machinery from a truck :
• Use a forklift with sufficient load capacity (2. 5 ton or more).
• Secure long packages with ropes or belts to prevent machine from falling
down or toppling.
4) Do not lift the load on the carriers to more than 200 mm from the floor.
5) Do not stand in narrow space between
the load and wall during transportation.
6) Always assign a guide and transport
according to his instructions. The guide
should pay sufficient attention to avoid
obstacles in the transport route.
7) Always push handcarts while carrying
loads. Never pull them.
8) When transporting the intermediate units
with a forklift, be sure to check that the
fork holds the skid and balances it
properly.
9) Fix the load with a rope or other means if
necessary, to prevent the load from
falling down during transportation.
10) While inserting wooden blocks under the
load, take care to avoid fingers from
getting caught in between the load and
the floor.
11) Always lift the GE using ropes or belts
from the front door side (since the center
of gravity lies at the front door side), This
will prevent the frame from falling down.
12) When using a dedicated hoisting carriers or transporting tools, make sure
that the transporting beam holds the spindle rail of the intermediate units and
balances them securely.
S.2.4 Assembly and adjustment

1) Rough assembly

• When removing skids from the GE head, OE head and intermediate

units, communicate with co-workers to avoid injury to hands.

• When using the dedicated transporting tools for approaching the

intermediate units to the adjacent units or GE/OE heads, move the
intermediate units slowly and carefully. Link the middle block as a team
and communicate with co-workers to avoid damages to the machine.

2) Leveling the machine

• When using straight edges, parallel rulers, or levelers, be careful not to drop
them onto the workers below, who are busy with the adjustment bolts.

• When moving straightedges, parallel rulers or levelers, be sure to do so

together with the aid of co-workers. Never attempt to move these devices
alone or in a strained position
 ‘e’ version
3) Installing the creel parts
• Use platforms that are stable and sturdy.
• Do not install the creel rails or bobbin hangers, when people are busy
working in the lower areas of the machine since dropping parts or tools
can cause injury to those working below.
4) Installing the roller parts
• While connecting two rollers, fix the connecting tools securely to avoid
slipping of the tools on the fluted rollers.
• When installing the bottom rollers onto the roller stands, do so as a
team and assign a leader, communicating with words or gestures.
5) Heat-bonding the spindle drive belts
• For belt bonding, use a heater, which can attain temperature in the
range of 110° to 130° C.

6) Wiring

Never allow untrained workers to connect or disconnect primary power

lines.

• Before starting wiring work,

be sure to check that the
main circuit breaker is open
and the warning notice
(tag) is put up.

• Before starting wiring work,

ensure that there is no
power supply in the line.

S.2.5 Before trial running

1) Area around the machine

• Remove all unnecessary things lying on the machine and also around
the machine.

• Check that all sections of the machine are securely tightened and the
safety covers are in position.
 2) Electrical components
• See that grounding wires in the
control box are connected properly.
• Check the routing, connection and
insulation of the wiring.
• Check the direction of rotation for
the main motor, and suction motor.
• Check the functions of each of the
stop motions.

S.2.6 During trial running

1) Rotate the drive belts on each of the
drive sections manually to check for
fraying or other damage. Communicate
with co-workers to avoid injury resulting
from the hand getting caught in running
belts.

2) When starting the machine,

communicate your intention to co-
workers, and wait for them to confirm it.
Then, check that the machine starts and
stops normally.

3) For adjusting the contact pulleys or tape

tension pulleys while they are rotating,
do so in a careful, comfortable position.

4) For centering of the spindles, stop the

machine and center them. Never
attempt to do the spindle centering when
the machine is in operation; it is
extremely dangerous.
 ‘e’ version

S.3 Rules for safe operation

S.3.1 General Rules

1) Absolute precautions

• Never allow non-qualified workers to connect or disconnect the primary

power lines.

• Never try live wire operation when changing the wiring on the machine.

• Never start the machine without communicating your intention to co-

workers or without confirming their answer to your signal.

• Never touch rotating or operating parts until the machine comes to a

complete stop.

• In the automatic doffing operation, be careful if those moving parts seem

to have stopped. The machine may stop temporarily, but it is still
dangerous.

• Never operate the machine by wearing loose clothes as this can get
entangled with the rotating parts.

• Never remove a warning notice, caution plate or instruction plate from the
machine.

2) Handling abnormal situations

• Always turn the power off before making any adjustments or repairs to
correct abnormalities that may occur during operation.

• If you turn off the machine, be sure to put up the warning notice on the
power switch.

• The temporary warning notice should be removed only by the person who
put it up, once it is not needed.

3) Other precautions

• The supervisor should make sure that each employee observes all safety
rules.
S.3.2 Precautions for spinning
1) Starting

• When two or more persons carry out work, they must always
communicate with words or gestures before starting the machine.

2) During spinning

• In case of any malfunction or problems in control box, only the

trained person must take corrective action.

3) While the machine is in operation

• Never touch the running portion.
• Never open or remove any of the safety covers
• Never try to remove yarn or fly.
• Do not operate the machine wearing
- Loose fitting clothes.
- Long sleeves with buttons.
- Work clothes with large buttons sticking out in front.
- Sandal type shoes.
• Keep long hair up under your cap to prevent it from getting caught
in the machinery.
• Never restart the machine without permission of
- A person in charge of maintenance.
- Other people responsible for stopping the machine.

4) Other precautions

• When removing fly or fleece entangled around the top rollers,

remove the top roller from the machine or hold it in one hand.
Take necessary care so that fly or fleece removed from the top
roller does not fall on the rotating section.

• Clean the machine as explained below to prevent fire:

- Periodically wipe off fly or fleece accumulating around the

motor.

- Clean the main motor periodically to avoid clogging and

ultimately to avoid burning of main motor.

- Periodically clean the control panel and inverter panels to

avoid failure of electronic and electrical components.
 ‘e’ version
S.4 Safety Rules for Maintenance

S.4.1 Before maintenance work

1) Checking the work procedure

• Check the work procedure with co-workers in advance. Be sure to

inform the spinning operators that the frame is to be stopped, and
always put up the maintenance notice on the power switch.

• Checking the tools

• Select and inspect the tools for required for doing the job. Use
spanners and wrenches of suitable sizes.

• Keeping things neat and tidy

• Determine the storage location for disassembled parts, making

sure that passages are clear for frame operators.

S.4.2 Precautions for Maintenance personnel

1) If you stop the machine for maintenance, be sure to put up the warning
notice saying “DON’T TURN THE SWITCH ON”.

2) Do not keep tools or any items on top of the machine, whether it is in

operation or stopped. Otherwise they may fall into the frame, causing
damage or bodily injury.

3) Do not use compressed air for cleaning your skin since it may cause
infection at an open wound.

4) Lubricant, paint, bond, sealing agent or detergent are harmful to skin and
eyes. Always wear suitable protection such as safety gloves and goggles
when using such materials to avoid injury to skin and eyes.

5) If any of these come into contact with skin or eyes, wash them with water
immediately and seek medical treatment.

6) When using any washing solution, always ventilate the room sufficiently.

7) Follow the instructions provided by the material manufacturer or supplier.

8) Wear safety goggles while doing works, which are likely to cause injury to
eyes.
S.4.3 During Maintenance work

1) Maintenance

• Installing or removing the parts inside the GE ASSY (Gear End

Assembly)

- Since the GE ASSY incorporates a variety of automatic devices, be

sure to stop the machine in the reference position, so that parts
need not have to be forced in or out.

- Parts can become slippery due to grease, oil, fly or fleece, so clean
them thoroughly and hold them securely to avoid dropping.

• Installing or removing the motor pulleys, timing pulleys and driving

pulleys

- When installing or removing the flat belts or timing belts, be careful

not to get your hands caught in the belts.

- Since pulleys are heavy, install or remove them in a comfortable

position.

• When removing the motors and impellers from inside the filter box, do
so in a comfortable position, communicating with co-workers.

• When adjusting the tape tension pulleys or contact pulleys during

operation make sure that your hand does not come into contact with
the rotating section and work in a comfortable position.

• When replacing broken spindle tapes, be sure to stop the machine;

otherwise, those tapes will get entangled in the tin pulleys.

• Installing or removing tin pulley shafts require the workers to operate

in a difficult squatting or bending position; communicate with co-
workers during the job to avoid injury and damages to the machine.

S.4.4 Lubrication

1) Make sure that the machine has been stopped before greasing of the bearings
or gears.

2) Always wipe up oil spilled on the floor after filling the oil in the oil bath.

3) Waste oil drained from the oil bath should be disposed off in containers.
 ‘e’ version

S.5 Rules for Operating or Checking the Electrical Devices

(% & ) *+, !
%
- .(/ 0 %

1) All operating and checking jobs must be carried out by responsible persons only
(e.g. duly trained persons or electrical experts).

2) Always turn off the main switch before opening the control box.

3) After turning off the main switch, be sure to put the warning tag
“DON’T TURN THE SWITCH ON” on the main switch.

4) Prior to checking or servicing the electrical components or parts, use a voltmeter

to make sure that there is no power inside the electrical cabinets.

Turning off the Main switch “a1” will put off power and control circuits.

5) Take extra care when switching on the machine during work in order to check the
control system. Ensure 220V , 24V DC supplies in control circuit before switching
on the control circuit

6) Use the measuring devices and tools, which are maintained in proper condition.

7) During electrical installation work, an authorised responsible person should

supervise the work.