a) Explain design of a machine guard.

Answer: Machine are dangerous because they are designed to change the shape and form of material which human strength cannot do. Whenever man and
machine meet, the possibility of accident is always there.
Moving machine parts have the potential to cause severe workplace injuries, such as crushed fingers or hands, amputations, burns, or blindness. Safeguards are
essential for protecting workers from these preventable injuries. Any machine part, function, or process that may cause injury must be safeguarded. When
the operation of a machine or accidental contact injure the operator or others in the vicinity, the hazards must be eliminated or controlled. This page contains
general information on the various hazards of mechanical motion and techniques for protecting workers.
Manufacturers usually make machine guards by combining CNC machining, extrusion, and post extrusion processes (rivet joining, bolts, nuts, screws, etc.) These
methods are explained below.
Extrusion Process in Making Machine Guards
 First Step: Extrusion Die Preparation and moving it to the Extrusion Press Firstly, a circle-shaped die made of H13 steel is machined. To help
maximize die life and ensure even metal flow, the die must preheat between 450 and 500 degrees Celsius prior to extrusion. After preheating the die, it can be
packed into the extrusion press.
 Second Step: Aluminum Billet is heated Before Extrusion. before extrusion, an aluminum billet is preheated. Following that, a solid, or billet,
cylindrical block of aluminum alloy is cut from a longer log of alloy material. It is heated up in an oven,
such as this one, to a temperature of 400-500 degrees Celsius. This makes it malleablebut not molten sufficiently for the extrusion process.
 Third Step: Transferring to Extrusion Process after preheating the billet, it is mechanically transferred to the extrusion press. Lubrication or release
agent is subjected to it before loading onto the press. To prevent the billet and ram from sticking together, the lubricant is also subjected to the extrusion ram.
 Fourth Step: Billet Material is Pushed into Container by Ram
The malleable billet is now packed into the extrusion press, where it is subjected to up to 15,000 tons of pressure from the hydraulic ram.
b) Explain duties and responsibility of a competent person in relation to safety. Competent Person: "Competent person" means one who can
identify and predictable hazards in the surroundings or working conditions, which areunsanitary, hazardous, or dangerous to employees, and who has
authorization to takeprompt corrective measures to eliminate them. The “competent person” designationrequires the individual to have the authority to
take prompt corrective action. Thisdesignation may be task specific or for the duration of employment. AuthorizedPerson: person authorized by
department and/or designated competent person ashaving the knowledge and skills to operate equipment and/or vehicle safely.
c) RESPONSIBILITIES: There are many circumstances where operation, inspection,maintenance and/or testing of appliances and equipment are
required to be carriedout by a “competent person”.
Some Occupational Safety and Health Administration (OSHA) standards have specific requirements for a competent person, including excavation work, working
at heights, when exposed to silica, daily crane inspections and demolition work. The competent person must be familiar with the hazards of the work and the
proper controls to use for employee protection. For example, if the jobsite includes workers being exposed to heights, a competent person must provide
training to workers on fall hazards and the equipment

d) Explain the benefits of good housekeeping.

Housekeeping in simple words means maintaining a house on a daily or long term basis or looking after its cleanliness, tidiness, upkeep and smooth running.
When you keep your house clean and well maintained, you would also like to make it as beautiful as possible. How do you make sure that everything in the
house is in usable condition? None of the objects are broken or chipped and fabrics are not torn. All the fixtures like taps, geysers, electric wiring, bulbs, tubes,
fans, plug points, are in good working condition, geysers are not leaking, electric wiring is proper
Helps to limit potential of slips, trips and falls from spills or cluttered floor areas.Increases production and efficiency of the operation. Time is not spent
maneuvering over or around someone else’s mess or looking for proper tools and materials.Helps to prevent a fire that could shut down a business and lead to
possible loss of jobs.Creates a good “first impression” of workplace environment and reflects well on the quality of work.Increases efficiency of workspace.
• Lightning Splash: A side flash (also called a side splash) occurs when lightning strikes a taller object near the victim and a portion of the current
jumps from taller object to the victim. In essence, the person acts as a “short circuit” for some of energy in the lightning discharge.
• Lightning Strokes: Lightning stroke is the direct discharge of an electrical charge between the atmosphere and the object of earth. It is a sudden
flow of electric charge between the electrical charge area of a cloud also called intra-cloud and another cloud called (CC lightning) or between the charged cloud
and the ground (CG lightning). The charge region of the cloud is equal to the electric discharge. When the cloud charge is discharged on the ground, then it is
called a strike, and if the discharge is hit on the object, then it is called flash. The lightning occurs in the form of the plasma and sound in the form of thunder.
e) What are the different hazards in handling on board operation of cargo?
Some of the most common hazards of bulk cargoes onboard ships are mentioned below:
Cargo shift: Cargo shift has always remained one of the greatest dangers on bulk carriers. This problem is greater for ships carrying grain cargoes. Grainsettles
by about 2% of its volume. Because of this settling, small void spaces exist on the top of the grain surface. These void spaces permit the grain to shift..
1. Cargo falling from height: Cargoes like iron ore, quartz and steel scraps are high-density cargo. There is a possibility of cargo falling from height during
cargooperations. Cargo may either fall from the conveyor belt of the ship loader or from the discharging grab onto the deck of the ship. People working on the
deck can get injured badly if hit by the sizeable lumps of the bulk cargo. It can be as bad as death. Cargo operation
2. Dust from working cargo: Dust is one of the most common hazards in bulk carriers. Many bulk cargoes are dusty by nature. Dust particles are small
enough to be inhaled and if inhaled can have disastrous effects on health. Anyone working on the deck can be exposed to high levels of dust. Dust can cause
sneezing and irritation of the eyes. Where possible it is always best to avoid exposure to cargo dust however if exposure cannot be avoided protective
3. Cargo Liquefaction: Liquefaction is a phenomenon in which solid bulk cargoes are abruptly transformed from a solid dry state to an almost fluid state.
Many common bulk cargoes such as iron ore fines, nickel ore and various mineral concentrates are examples of materials that may liquefy. Liquefaction occurs
as
4. Liquefaction results in a flow state to develop. This permits the cargo to slide and shift in one direction thus creating a free surface effect and reducing
the GM thereby reducing stability. Shippers’ declaration should be thoroughly examined by the chief officer before loading any bulk cargo. He must make sure
that the moisture content of the cargo to be loaded should not exceed the transportable moisture limit to avoid liquefaction during the voyage. Often shippers
declarations turn out to be faulty. Spot checks can also be carried on board ships to check the moisture content.
Explain NDT testing briefly.
Non-destructive testing (NDT) is the process of inspecting, testing, or evaluating materials, components or assemblies for discontinuities, or differences in characteristics
without destroying the serviceability of the part or system. In other words, when the inspection or test is completed the part can still be used. In contrast to NDT, other
tests are destructive in nature and are therefore done on a limited number of samples ("lot sampling"), rather than on the materials, components or assemblies actually
being put into service.
These destructive tests are often used to determine the physical properties of materials such as impact resistance, ductility, yield and ultimate tensile strength,
fracture toughness and fatigue strength, but discontinuities and differences in material characteristics are more effectively found by NDT.
Explain briefly “Buffing & Polishing hazards and their Preventive measures?

Both Buffing and Polishing Process is a common term and these are used in Manufacturing Processes or you can say manufacturing industry. Both processes are
finishing or super finishing processes used for enhancing the surface of the work piece in both ways (Physical and Aesthetic Properties).
The term Buffing is a super finishing process in which there is a buffing wheel (attached with abrasive disc) that is used to remove the bur or unwanted material from
the work piece for smoothing the surface of the work piece.
The other definition you can write is, -The buffing process is used to shine wood, metal, or composites using a cloth wheel impregnated with cutting compounds or
rouges. In the cloth, there is an abrasive disc that works is to remove or cut and get a better surface finish. This process is performed after polishing process for
providing a high luster to be polished surface. The buffing wheel used in this process is made up of cloth (Like, wool, flannel, cotton, muslin, or fiber which is charged
with loose abrasive grains.
Application of Buffing Process:
The following application of Buffing Process is:
The buffing process is used to remove scratches, oxides, coatings from the work piece surfaces. Used in the automobile sector, motorcycles, boats, bicycles, commercial
and residential hardware, and much more. Also used in the automotive sector (Component is Roller bearing, connecting rod, piston, and many more).
The process used to shine the work piece. It may be Tools, fixtures, or sports items. The buffing process also used in Household utensils and appliances.
Polishing Process:
The polishing process removes small elements of a surface and makes the work piece smooth and brighter. This smoothness of the work piece is obtained by rubbing
the surface.
Polishing is one of the best methods today to obtain the finest surface. There is ultra-precision technology is an indispensable ingredient for polishing today.
Polishing uses a larger number of multi-point for effective material removal.
The polishing process used in various components such as aerospace, automotive, mechanical seals, fluid handling, and many other precision engineering industries.
a) Explain safety in the use of CNC Machine & robotics.
In a now day’s machine apparatus are dynamic and produce chunks faster than ever before. As with any powerful piece of equipment, it’s important to
administer good security practices to reduce the risk of injury. To avoid tissue damage due to contact with cold or hot machine parts, hearing loss, eye damage
and stresses put on the body due to monotonous motions, enormous reaching or abundant lifting you should be fully aware about the doings of CNC machine.
Thankfully, leading edge machine tools are contriving with many safety features to help reduce these jeopardize. It is generally impossible to define the safety
requirements for CNC machine tools in the shape of distinctive measures. This may be because there are too lean adjustments and ideal explicit to the
equipment which administer concrete solutions. Safety requirements can be dogged only if the feasible hazards are identified systematically by conducting a
hazard analysis, specifically if
The two first general rules for CNC machine operation are:- You should never work with a CNC machine without the proper training or the equitable
operator’s manual. You should never endeavor to program a CNC machine without the decent training as well. These may include escorts and other defensive
devices, it is crucial that these safety devices are rigidly fitted in place at all times while the machine is in use.
Some of these safety devices may include:-
An Emergency Stop Button : The emergency stop button is used to push down the machine right away. This button is based on the handheld section, thecontrol
panel, and other places on the machine.
A Soundproof Casing : The soundproof casing dwindle the babble emitted by the operating section of the machine. It also safe guards the machine operator
from the risk of fluttering tool fragments and any other flying objects.
The Curtain Guards: The curtain guards are designed to shield the machine operator from the risk of tool fragments or airborne chips.
The Guard Fence: This part marks the superlative working area of the machine. This barrier carries the machine operator away from any moving parts.
The Contact Mats The operant uses this curb to stop the CNC machine instantly.
Robotic:-The use of robots and robotic systems in manufacturing has become mainstream in large manufacturing operations such as the automotive industry,
and their use in small manufacturing plants and niche operations will increase. Unauthorized entry into the working envelope of a robot exposes a worker to
the potential for serious impact or crushing injuries from the unexpected movement of the robot. The safeguarding of robots requires a systems approach to
safeguarding. It typically uses a combination of fixed barrier fences, interlocked gates, and presence-sensing devices such as safety mats and light curtain
devices.
b) Explain the concept of zero access guarding in detail.
No operator can touch harmful machine Parts. (Intentionally or Unintentionally) To find all problems you have to assume
They are there, until proven safe. Rules and behaviour do not give zero access. To be a guard it must require a tool to remove it or be interlocked.
Interlocks must be adjusted to prevent access until safe,Physical access is a bigger problem than interlock category
Interlock maintenance & adjustment is more important than interlock category. Not all moving parts, holes or unsecured doors pose a hazard.
What are the portable tools? Explain their selection criteria.
A portable tool is one that requires a power source to operate, such as electric, pneumatic, liquid fuel, hydraulic, explosive-actuated, and powder-actuated
device or power supply. Power tools can be hazardous if used improperly.

Portable Power Tools: Portable power tools can be divided into five groups.
Electric,Pneumatic,Gasoline,Hydraulic
4. Powder Actuated (Explosive)
The tools like saws, drills and grinders are common to the first three groups. Hydraulic tools are used mainly for compression work Powder actuated tools are
used exclusively for penetration work Cutting and compression.
Hazards -A portable power too! presents similar hazards as a stationery machine of same kind, in addition to the risk of handling. Bums, cuts and strains are the
main injuries..
• The cord or hose should not be kept lying on floor they will create a tripping hazard. they should be kept suspended over ais les or work area.They
should be stored properly and never be left encored on the ground.
Selection of tools :- Selection of a power tool replacing the hand tool for the same job will increase the degree of hazard. The hazard will be electrical or mechanical in
place of manual. Therefore, the safe design (safe condition) proper training (safe use) should be ensured before any power tools brought into use. Complete
information the job should be made available so that the tool selected should be most appropriate. The tool selected for intermittent use or light work are called "home
owners' grade" and those for heavy decay are called "industrial duty", provision of tool-proof training for the proper selection of tool is of Inspection and Repair
Periodic inspection is essential for the maintenanceof power tools A schedule be maintained, defective tool should be repaired or replaced.
Explain “in the use of Power & Grinding Machine”.
If your employees work with power presses, they face the greatest danger of injury at the point of operation where the stock is inserted, held and withdrawn by
hand. That is why effective machine guarding is crucial for keeping hands, arms or other parts of the body from Be.
Be sturdy and in good condition.
Provide protection against falling objects that could land in the machine and then fly out as dangerous projectiles.
Have no sharp edges that could cause injury.
Not interfere with the work.
.GRINDING MACHINE SAFETY:- Grinding machines are used daily in a machine shop. To avoid injuries, follow the safety precautions listed below.
Wear goggles for all grinding machine operations.
Check grinding wheels for cracks (Ring Test Figure 5-11) before mounting.
Never operate grinding wheels at speeds more than the recommended speed.
Never adjust the work piece or work mounting devices when the machine is operating
Do not exceed recommended depth of cut for the grinding wheel or machine.
Remove work piece from grinding wheel before turning machine off.
Use proper wheel guards on all grinding machines.
What is Built-in-safety? Explain its maintenance process.
The object of built-in safety device is to design and make the machine, equipment. method and environment so sale that the workers exposure to accident or
injury is eliminated or controlled automatically, It is well experienced that many a times the guards provided on the machines are removed, not refitted and
dangerous parts run without guards. Such unsafe practice leads to accidents. Therefore, it is always essential to incorporate built-in safety devices (guards) from
the design stage so that they become integral part of the machine and subsequent guarding is least required.
Benefits of Built-in Safety Devices:
They are more safe from accident prevention point of view.
They serve more than one purpose.
They are less costly in long run. Subsequent addition of guards requires frequent maintenance and they are usually costlier a nd less effective.
They provide better standard to the design and operation of the machine.
Need for training and supervision to control unsafe acts is reduced.
It helps for efficient production, high morale and less labour turnover..
Explain the difference between Destructive and non-destructive testing.Destructive testing:-

Tests usually simulate one or more service conditions. Consequently, they tend to measure serviceability directly and reliably.
Tests are usually quantitative measurements of load for failure, significant distortion or damage, or life to failure under g iven loading and environmental conditions.
Consequently, they may yield numerical data useful for design purposes or for establishing standards or specifications.
The correlation between most destructive test measurements and the material properties being measured (particularly under sim ulated service loading) in most
observers may agree upon the results of the test and their significance with respect to the serviceability of the material or part.
Destructive tests are not usually convenient to apply to parts in service. Generally, service must be interrupted and the part permanently removed from service.
Cumulative change over a period of time cannot readily be measured on a single unit. If several units from the same lot or service are tested in succession over a period
of time, lit must be proven that the units were initially similar. If the units are used in service and removed after various periods of time, it must be proven that each was
subject to similar conditions of service,

Non-Destructive Testing :-
• Tests usually involve indirect measurements of properties of no direct significance in service. The correlation between these measurements and
serviceability must be proved by other means.
Tests are usually quantitative and rarely quantitative. They do not usually measure load for failure or life to failure even indirectly. They may, however, reveal damage of
expose the mechanisms of failure.
Skilled judgement and test or service experience are usually required to interpret test indications. Where the essential corr elation has not been proven, or where
experience is limited, observers may disagree in evaluating the significance of test indications.
Non-destructive tests may often be applied to parts in service assemblies without interruption or service beyond normal maintenance or idle periods. They involve no
loss of serviceable parts.
Non-destructive tests permit repeated checks of a given unit over a period of time. In this way, the rate of service damage, if detectable, and its correlation with service
failure may be established clearly.
Computer vision Syndrome. 1) Computer vision syndrome (CVS), also referred to as Digital Eye Strain, is a condition resulting from focusing the eyes on a computer or
other display device for protracted, uninterrupted periods of time. Some symptoms of CVS include headaches, blurred vision, neck pain, fatigue, eye strain, dry eyes,
irritated eyes, double vision, vertigo/dizziness, polyopia, and difficulty refocusing the eyes.
Dry eye is a major symptom that is targeted in the therapy of CVS. The use of over the-counter artificial-tear solutions can reduce the effects of dry eye in CVS.
Asthenopia symptoms in the eye are responsible for much of the severity in CVS. Proper rest to the eye and its muscles is rec ommended to relieve the associated eye
strain Various catch-phrases have been used to spread awareness about giving rest to the eyes while working on computers. A routinely recommended approach is to
consciously blink the eyes every now and then (this helps replenish the tear film) and to look out the window to a distant ob ject or to the sky doing so provides rest to
the ciliary muscles. One of the catch phrases is the "20 20 20 rule" every 20 mines, focus the eyes on an object 20 feet (6 meters) away for 20 seconds. This basically
gives a convenient distance and timeframe for a person to follow the advice from the optometrist and ophthalmologist Otherwise, the patient is advised to close his/her
eyes (which has a similar effect) for 20 seconds, at least every half-hour
Carpel Tunnel Syndrome :- 1) Carpal tunnel syndrome (CTS) is a medical condition due to compression of the median nerve as it travels through the wrist at the carpal
tunnel. The main symptoms are pain, numbness, and tingling, in the thumb, index finger, middle finger, and the thumb side of the ring fingers.
Night time symptoms are very common. Because many people sleep with their wrists bent, symptoms may awaken you from sleep. During the da y, symptoms often
occur when holding something for a prolonged period of time with the wrist bent forward or backward, such as when using a phone, driving, or reading a book.
Explain the ergonomics of manual handling and storage briefly.
Ergonomics, human factors or human engineering is the study of human characteristics for the appropriate design of the living and work environment.
Limitations motivations. Human characteristics include capabilities and desires Hence, ergonomics is human-centered, trans-disciplinary and application
oriented science Scientific principles, methods and a variety of data are used to develop systems more suitable to people and successful application is measured
by improved productivity efficiency safety and acceptance of the resultant system design.
Improved facilities of good layout provide safe and efficient material transfer
Job or task design should consider stress on the worker and should decide whether to assign certain tasks to a person or a machine
Selection, use and improvement of equipment. machines and tools strongly affect material handling requirements Space requirement, control device, visibility, colour
and sign coding etc. should be considered
System must be designed for people as they are kingpins of material handling. Their body size,strength and energy capability should be considered.
Explain the safety precaution to be taken while handling industrial trucks.
Safety precautions to be observed in operation of forklift trucks
The capacity of every lift truck should be marked on the truck and they should not be overloaded.
Loaded or empty forks should be carried as low as possible but high enough not to strike a ramp.
Care must be taken to avoid jerking when tilting a load forward or backward, specially when the load is at a height.
Personnel must not be allowed to ride on the forks.
Forks should be driven well under the load, preferably full length or at least 2/3 of the length.
Other operational safety precautions for all types of power trucks are:
Selection and training of the operator. He should be provided with DOS and Don'ts of the operation, specialties of the work s ituation and layout, plant rules,
manufacturer's instructions etc.
While travelling fork should be in lowered position and it should not be moved for tilling.
Lift trucks should be driven in the reverse direction when the load obstructs the vision or while coming down from ramps or slopes.
If any rail track is to be crossed, it should be done diagonally and not at right angles.
Before crossing a bridge, plate operator should make sure that it is properly secured.
Operators should be instructed –
not to carry persons on the truck.
to check the conditions of the vehicle before starting e.g. tyres, brakes and safety devices.
not to leave the truck on aisle space, and to park at the place allocated. Parking brakes should be applied. Power should be shut off.
not to turn a truck on a gradient.
not to carry out unauthorized repair or adjustments.
Explain the principle of manual lifting of handling.
Principles of Safe Manual Handling – Assess the task :- The safest besttechnique for performing the task is determined by considering:
• the environment
the ability of the handler to perform the task e.g., size, age, state of health the nature of the load – i.e., animate or inanimate
Plan :-Ensure that the area is free from obstacles like debris on the floor which may interfere with the smooth implementation of the procedure. Wear comfortable
clothing, which allows free movement. Shoes should have flat heels, covered toes and provide good support to the feet.
1. Principles of Safe Manual Handling -Position the feet:- Feet should be comfortably apart to provide a wide base of support and to allow the handler to get as close to
the load as possible. Feet should be positioned in the direction of movement of the procedure
2. Get a secure grip:- Make sure that the grip is comfortable for both the child and the handler and that this is decided before commencing a procedure.
3. Keep the load close to the body:-Make sure the load is brought as closeas possible to the handler to minimize stress on the lumbar spine.
4. Maintain good posture throughout the procedure:- The vertebral column should be in correct alignment in the normal spinal curvature. The
handlershould keep his/her head up and neck straight, brace abdominal muscles to support his/her spine and avoid twisting.
5. Use the leg muscles:- Hips and knees must be bent to lower the centre of gravity and align the body correctly. The strong leg muscles are used to
reduce the stress on the spine.
6. Principles of Safe Manual Handling – Use body momentum:-Timing is essential so that the transfers can be performed smoothly and steadily.
Both client and handler should be fully prepared and the timing agreed e.g., one, two, three – lift. In team lifting, one person becomes the leader and directs the
procedure.
Explain safety features in the design of a hook & shackles.
Loads are based on a safety factor of 6 to 1. Size, work load, and trademark are permanently marked on all shackles. Any Deviations As Angular Lifts, Shock Loads,
Modification Of The Basic Forging, Etc., Will Result In Drastically Reduced Maximum Loads. Shackles can be made of Stainless Steel, Alloy Steel or regular Carbon Steel.
Shackles can be forged or Cast. Stainless Steel is much more expensive but does not necessarily offer greater strength, it offers supremely high corrosion resistance and
is suitable for underwater and marine type uses.
The design factor is generally expressed as a ratio such as 5 to 1. Also important to the design of hooks is the selection of proper steel. Quenching and tempering
assures the uniformity of performance and maximizes the properties of the steel. This means that each hook meets its rated strength and other properties.
Explain the safe working load for all mechanical material handling equipment.
Safe Workload Limit:- Safe Working Load (SWL) sometimes stated as the Normal Working Load (NWL) is the maximum safe force that a piece of lifting equipment,
lifting device or accessory can exert to lift, suspend, or lower, a given mass without fear of breaking. Usually marked on the
equipment by the manufacturer. It is a calculation of the Minimum Breaking Strength (MBS)aka Minimum Breaking Load (MBL) divided by its risk factor, usually ten to
one (10:1 or 1/10) for lifting equipment although depending on the application. SWL can also apply to other lifting devices or components of lifting devices, such as a
line, rope or crane The SWL is also sometimes referred to as Normal Working Load or Working Load Limit. It is the mass that lifting equipment can safely hold without
fear of breaking. The SWL or NWL is often a fifth of the Minimum Breaking Strength of the cable The SWL is determined by dividing the minimum breaking strength
(MBS) of a component by a safety factor assigned to that type and use of equipment. The safety factor generally ranges from 4 to 6 unless a failure of the equipment
could pose a risk to life, in that instance the safety factor would be a 10. For example, if a line has an MBS of 1,000 pounds and a safety factor of 5, then the SWL would
be 200 pounds 1000/5=200. Also called working load limit (WLL).
Making the Calculations: - To calculate the SWL, you need to know the diameter of the cable or of your three measurements as the diameter of the rope. Once you
know the diameter of the rope, you can apply it to the formula, which is SWL = D2 x 8. D represents the diameter of the rope in inches. If you're working with a 1.5-inch
diameter cable, for example, then the formula would be SWL = 1.52 x 8 or SWL = 2.25 x 8. This calculation means the SWL of a 1.5-inch diameter rope is 18 tons.
Explain the safety check list for buying new machinery for the plant.
Operation manual, Safety manual, Safe operating procedure. 4.Safety instruction. Start-up & shut-down procedure. Trouble shooting guide.
Do's & don'ts, Encasing or effective guards to: Set screw, bolt or key on revolving shaft Spindle, wheel or pinion Spur, worn and other toothed or friction gearing (while
in motion).Any projection that creates hazardous condition.Inbuilt safety: Trips, Interlocks, Auto controls.Maintenance manual (procedure & schedule).Details of
spares(availability).After sale-service.
Machinery Purchasing Safety Checklist
Do our intended manufacturers/suppliers have a good reputation withinthe industry?
Can the manufacturers/suppliers give us contact details of other users oftheir equipment?
Does the new machinery come with a CE mark?
Does the new machinery have a "Certificate of Conformity"?
Is full installation data provided?
Are full operating instructions provided?......
Can the manufacturer/supplier provide full safety information for the machine, e.g. a description of all risks associated wit h its use?.......
Can the manufacturer/supplier arrange safety and general training for our employees?
Does the manufacturer/supplier offer a maintenance contract"
Explain the hazards and safety measures for boiler operations.
Manufacturer's Instructions - Equipment manufacturer's instructionsshould be followed.
Training - Employees must be trained in safety prior to operation of the equipment. The training in safety should be a continuous process for the purpose of
educating employees to recognize and to keep safety in their minds throughout their careers. A training program should be established and maintained.
Housekeeping - Good housekeeping is essential for safety and good plant operation. Poor housekeeping results in increased safety hazards. A clean and orderly
environment will foster safety.
Clothing and Protective Equipment - Proper clothing should be worn at all times. Avoid loose clothing and jewelry. Protective equipment must be worn when
necessary (i.e.: hard hats, respirators, ear plugs, goggles, gloves, safety shoes, etc.). Never operate rotating equipment,.
Hot Surfaces - Many hot surfaces exist in a boiler area and even non- heated surfaces can become uncomfortably warm, therefore, employees, especially new
employees, must be made aware of these conditions. Refractory and insulation are typically provided to enc
Lockout and Tagout Procedures - Every plant should have a formalized lockout and tagout procedure that is strictly enforced.
Remote Starting of Equipment - Much of the equipment in plants are started remotely and/or automatically without warning; therefore, employees must be
alert to avoiding that equipment
Unexpected Noise - A sudden and/or unexpected noise may cause employees to move involuntary. Such reaction may result in injury. Precautions against this
are hard to take out but experience probably is the best teacher to prevent such inadvertent responses.
Unconventional Fuels - Sometimes unconventional fuels need to be burned in boilers. When this is done, particular attention should be paidto the hazards
that can result. Theses may from characteristics in the fuels, toxic chemicals in the fuel, and toxic chemicals
when making fuel-piping connections..
Electrical Hazards - Potentially hazardous voltages exist in control cabinets and electrically actuated control components. These components should only be
serviced when system power is removed and only by qualified electrical or instrumentation servicemen.
Explain “Development of a Plant Layout” in detail.
Typical Stages in the development of a plant layout.
Layout begins with the collection and assessment of flow sheet (which must show material of construction, size of piping and suggested elevations) Equipments
data sheet, result of site survey. topography, soil structure, weather conditions.
Plant items and buildings are laid out in plan, ensuring that all layout constrains (eg relating to operation maintenance, safety, environment and expansion) are
applied. A costing is made.
The selected plan and layout are now combined to determine possible position of supporting and access structures, and to study civil requirements Preparation
of piping, models are now commenced.
Preliminary Layout:- It is advisable to begin with a preliminary site layout. At this stage the layout may well be site-independent A number of layouts may be
done. The starting point is the flow sheet for the site. The layout of processes is then developed based on the flow principle, modified as necessary to isolate
hazardous processes or to prevent undesirable interactions. The principles for the addition of the central services (e.g. boiler house, effluent treatment plant)
include safety of location and for the ancillary buildings (e.g. laboratories, workshops, administrative offices) put, safely of location and minimization of
distances travelled by people. The road and rail systems are then in, observing such principles as access to all parts of the site and segregation of traffic.
a) Explain “5S” System of house-keeping.
5S is a systematic form of visual management utilizing everything from floor tape to operations manuals. It is not just about cleanliness or organization; it is also
about maximizing efficiency and profit. 5S is a framework that emphasizes the use of a specific mindset and tools to create efficiency and value. It involves
observing, analyzing,collaborating, and searching for waste and also involves the practice of removing waste. SS includes five terms that all start with the letter
"S."
What Does 5s Stand For?
5S, sometimes referred to as 5s or Five S, refers to five Japanese terms used to describe the steps of the 58 system of visual management. Each term
starts with an S In Japanese, the five S's are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke In English, the five S's are translated as Sort, Set in Order, Shine,
Standardize, and Sustain . There are five key practices involved in SS. They are as follows:
Explain the Procedure to dispose off scrap and other trade waste.
Disposal of Scrap and other Trade waste:- Material intended for reuse and storage at Physical Plant may only be accepted by the Central Stores Manager of
Physical Plant. A superintendent or Assistant Director must request the item(s) be stored and that person shall be the responsible manager assigned to that
material and/or equipment. The Stores Manager will create and maintain a record of these items deemed "Special Inventory" which shall list the following
minimum information: Description of the item. Quantity, original location obtained (IE Simpkins Hall), location stored (North Shed. South Bay #1), date stored,
superintendent or assistant director requesting storage (the responsible manager), description of how item would be reused. Generally historical building
components may be stored indefinitely at Physical Plant Items which are scavenged for use on existing operating obsolete equipment may be kept as long as
that equipment is still in use, but must be properly disposed of when the obsolete equipment is no longer in use or is scheduled for imminent
replacement Non-historical distinctive fixtures from restrooms, lighting, or other building components which are no longer available, may be kept as long as
those fixtures are still being used in a campus building. Most other building materials shall be reused in less than 12 months. Exceptions include new or almost
new building materials salvaged or not used on renovation or construction projects. These items as well as other new or almost new building materials being
stored at Physical Plant should not be included in the inventory described here. However, the physical limits for storage of surplus materials such as lumber,
plywood, piping, masonry, and electrical supplies shall be specifically defi ned by the Stores Manager Surplus materials shall not exceed the assigned storage
space allocated for them by the Store Manager.
items as well as other new or almost new building materials being stored at Physical Plant should not be included in the inventory described here However, the
physical limits for storage of surplus materials such as lumber, plywood, piping, masonry, and electrical supplies shall be specifically defined by the Stores
Manager. Surplus materials shall not exceed the assigned storage space allocated for them by the Store Manager associated with storage to include loss of
valuable space, risk of shrinkage,breakage, obsolescence, and the cost of continuous management of the special inventory.
Explain the hazards and control measures to be followed in ElectronicsIndustry.
The use of electronic items is day by day increasing in industry, at homes and many places. Their manufacturing should include.
Exhaust ventilation for fumes of lead, zinc, etc. and also for molten- soldertanks. Eye protection for organic peroxide hardeners and respirators for quartz
flour,epoxies with phenol compound and airborne concentrations. Prevention of flammable or explosive mixtures of solvents, and source ofignition .
Exhaust ventilation for printing process .Acid resistant and non-slip flooring, exhaust ventilation, eye bath and PPE inetching processes. Use closed containers
for etching liquids. Good industrial hygiene.
The electronics industry is diverse with a wide spectrum of processes. Its sectors include semiconductor wafer fabrication, manufacture of printed circuit
boards, the assembly of semiconductor devices and printed circuit boards, and assembly of the final electronic products. There are also many supporting
industries that produce materials and components necessary to make the final product. These include those which manufacture metal and plastic parts,
electrical parts such as storage media for hard disks, precision motors to run drives, transformers, switches, liquid crystal displays, and other electronic
component.
Explain lightening protection system.
lightning protection system is designed to protect a structure from damage due to lightning strikes by intercepting such stri kes and safely passing their
extremely high currents to ground. A lightning protection system includes a network of air terminals, bonding conductors, and ground electrodes designed to
provide a low impedance path to ground for potential strikes. Lightning protection systems are used to prevent lightning strike damage to structures. Lightning
protection systems mitigate the fire hazard which lightning strikes pose to structures. A lightning protection system provides a low-impedance path for the
lightning current to lessen the heating effect of current flowing through flammable structural materials. If lightning travels through porous and water-saturated
materials, these materials may literally explode if their water content is flashed to steam by heat produced from the high current. This is why trees are often
shattered by lightning strikes.Because of the high energy and current levelsassociated with lightning (currents can be in excess of 150,000 A), and the very rapid
rise time of a lightning strike, no protection system can guarantee absolute safety from lightning. Lightning current will divide to follow every conductive path to
ground, and even the divided current can cause damage. Secondary "side-flashes" can be enough to ignite a fire, blow apart brick, stone.
Explain Eddy-current method.
Eddy Current Testing: uses the fact that when an alternating current coil induces an electromagnetic field into a conductive test piece, a small current is
created around the magnetic flux field, much like a magnetic field is generated around an electric current. The flow pattern of this secondary current, called an
"eddy" current, will be affected when it encounters a discontinuity in the test piece, and the change in the eddy current density can be detected and used to
characterize the discontinuity causing that change. A simplified schematic of eddy currents generated by an alternating current coil ("probe") . By varying the
type of coil, this test method can be applied to flat surfaces or tubular products. This technique works best on smooth surfaces and has limited penetration,
usually less than
1. Encircling coils are used to test tubular and bar-shaped products The tube or bar can be fed through the coil at a relatively high speed, allowing
the full cross-section of the test object to be interrogated However, due to the direction of the flux lines circumferentially oriented discontinuities may not be
detected with this application.
Explain Earth fault Protection system. What is recommended earthing resistances?
Earth Fault Protection
Earth fault is the unintended fault between the live conductor and the earth. It also occurs, because of the insulation breakdown. When the fault occurs, the
short-circuit currents flow through the system, and this current is returned through the earth or any electrical equipment. This fault current damaged the
equipment of the power system and also interrupted the continuity of the supply.
The earth fault can be dispersed by using the restricted earth fault protection scheme. The earth fault protection scheme consists the earth fault relay, which
gives the tripping command to the circuit breaker and hence restricted the fault.
Earthing Standards: - Electrical Earthing or Grounding System for buildings to be carried out all in accordance with the international standards in conjunction
withthe local authority requirements and recommendations. Earthing standards and methods are highly depending on the nature of the utilities and equipment
installed / used at the premises. Simple earthing system we provide to the domestic connections while complex systems are being used in the power stations
and industries is recommendation earthing resistance?
Explain the main hazards of electricity.
This percentage is variable, but it indicates the areas of hazards need to be controlled. Main electrical hazards are:
Electric shock.Electric Burns.Fire and Explosion.Hazards due to Electric Welding and Cutting. Hazards due to static electricity6 Fall of lightening from the sky Shock and
burns are injury from direct contact. They cause accidents of three types (1) Hold-on type (2) Ventricular fibrillation and (3) Respiratory arrest. Injuries are possible
without current flowing through body, e.g. burns due to electric arcs, radiation, electromagnetic field, falling or injury due to sudden have low self-inductance.
An example of a structure vulnerable to lightning is a wooden barn. When lightning strikes the barn, the wooden structure and its contents may be ignited by the heat
generated by lightning current conducted through parts of the structure. A basic lightning protection system would provide a conductive path between an air terminal
and earth, so that most of the lightning's current will follow the path of the lightning protection system, with substantially less current traveling through flammable
materials.
ELECTROSTATIC DISCHARGE SAFETY
ESD protection for electronics parts and devices, ESD Safe, electrostatic sensitive device warning next to PCB over bubble wrap
Related Products : ESD Safe line of Cognex barcode readers ESD-Safe BarcodeReaders , ESD-safe barcode readers offer protection against electrostatic discharge
that can cause costly damage. starting of machine, equipment etc.Main protections are proper fuses, switchgears, circuit breakers, earthings and bonding. Such
electrical safety precautions are highly needed to prevent accidents due to electrical hazards.
Explain the health effects of lightning stroke on worker. How to protect it? Effect of lightning strike:- The effects of lightning are those of a high-strength
impulse current that propagates initially in a gaseous environment (the atmosphere), and then in a solid, more or less conductive medium (the ground),visual
effects (flash) caused by the Townsend avalanche mechanism,acoustic effects caused by the propagation of a shock wave rise in pressure) originating in the
discharge path, this effect is perceptible up toa range of around 10 km,thermal effect heat generated by the Joule effect in the ionized channel,electrodynamics
effects these are the mechanical forces applied to the conductors placed in a magnetic field created by the high voltage circulation They may result in
deformation.,electrochemical effects: these relatively minor effects are consisting in the form of electrolytic decomposition in accordance with Faraday's law-
induction effects: in a varying electromagnetic field, each conductor becomes the seat of an induced current effects on a living being (humanor animal): the
Explain the use and safety features of electrostatic discharge.
ESD can create spectacular electric sparks (lightning, with the accompanying sound of thunder, is a large-scale ESD event), but also less dramatic forms which
may be neither seen nor heard, yet still be large enough to cause damage to sensitive electronic devices. Electric sparks require a field strength above
approximately 40 kV/cm in air, as notably occurs in lightning strikes.
Explain the responsibilities of different agencies for the safety and health of dock workers.
National regulations for the protection of dockworkers, against accidents and injuries to health should clearly define the bodies and persons whose individual or
joint duty it is to comply with the different provisions of those regulations.
Bodies and persons that own or control workplaces on ships or on dock premises where dock work is carried on, or provide plant and equipment for use in dock
work, should provide and maintain such workplaces, plant and equipment in a safe condition.
Bodies and persons that employ dockworkers.
Co-operate with those bodies and persons in keeping workplaces and equipment safe; satisfy themselves that dockworkers are properly instructed in the
hazards of their respective occupations and the precautions necessary to avoid accidents and injuries to health, and in particular that newly engaged
dockworkers are properly instructed concerning hazards and precautions, and are adequately supervised; and ensure that dockworkers are fully informed in an
appropriate
Explain the various hazards and their control measures in Textile industry.
The textile industry consists of a number of units engaged in spinning, weaving, dyeing, printing, finishing and a number of other processes that are required to
convert fiber into a finished fabric or garment. There are several safety and health issues associated with the textile industry. This article aims at studying each
of these issues in relation to the US and Indian textile industries in detail, along with the possible solutions for these problems.
Exposure to cotton dust,Exposure to chemicals,Exposure to noise,Ergonomic issues
Explain the hazards and their control measures in sugar industry.
As outlined previously, the intent of this document is to identify industry specific hazards, suggest possible controls, and provide examples on the risk
management process which mill operators could adopt to assess and control risks specific to their operation. It is expected that mill operators would develop a
risk register as outlined in the How to manage work health and safety risks Code of Practice, assess the risks in their operation, implement controls and monitor
and review the systems implemented to control those risks. When managing health and safety in sugar mills, operators should consider the following issues as
key components of the management system:
•risk registers,risk management,consultation,training,emergency procedures.
Further details on these issues are provided in the following sections, and in theSugar Industry Code of Practice.
Risk registers The How to manage work health and safety risks Code of Practice recommends the development of a risk register for all hazards at a workplace.
Hazards can be classified under the following areas:
Biological hazards,energy and electricity,hazardous manual tasks plant,hazardous chemicals,work environment.
A number of hazards typical to the sugar milling process have been classified into these areas in the following sections and a range of possible controls
suggested for each hazard. There is also a section on general workplace hazards and possible control measures. As each mill operates
Explain the hazards and control measures to be followed in hot & cold rollingoperation.
Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they
recrystallize, which maintains an equiaxed microstructure and prevents the metal from work hardening. The starting material is usually large pieces of metal,
like semi-finished casting products, such as ingots, slabs, blooms, and billets. If these products came from a continuous casting operation, the products are
usually fed directly into the rolling mills at the proper temperature pieces, induction heating is used. As the material is worked, the temperature must be
monitored to make sure it remains above the recrystallization temperature. To maintain a safety factor a finishing temperature is defined above the
recrystallization temperature; this is usually 50 to 100 °C (90 to 180 °F) above the recrystallization temperature. If the temperature does drop below this
temperature the material must be re-heated.
Shape rolling design
Rolling mills are often divided into roughing, intermediate and finishing rolling cages. During shape rolling, an initial billet (round or square) with edge of diameter
typically ranging between 100–140 mm is continuously deformed to produce a certain finished product with smaller cross section dimension and geometry. Starting
from a given billet, different sequences can be adopted to produce a certain final product. However, since each rolling mill is significantly expensive (up to 2 million
Euros), a typical requirement is to reduce.
Explain Toxic & chemical handling hazards.
Chemical hazards and toxic substances pose a wide range of health hazards (such as irritation, sensitization, and carcinogenicity) and physical hazards (such as
flammability, corrosion, and explosibility). This page provides basic information about chemical hazards and toxic substances in the workplace.Asphyxiants-
Chemical asphyxiants deprive the body of oxygen; interrupting the transfer and use of oxygen by the bloodstream. Corrosives. ..., Irritants. ..., Sensitizers.
...,Carcinogens. ..., Reactive. ...,Flammable.
A toxic hazard may be defined as any substance which has the ability to cause harm or damage to living organisms. The term 'toxin' is often used synonymously
with any poison, but should be reserved to mean any toxic chemical which originates from a biological organism.
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