Hazards during

Repairs &
maintenance
What is a Maintenance?
All activities by which the expected life of
the material/ machinery/ capacity etc. are
achieved is called a maintenance.
What is a hazard ?
The potentiality to make an accident/
Loss/damage/injury/environmental
damage
 Hazards from which
activity

• Mechanical
• Electrical
• Chemical
• Physical
• Biological
 Electrical Hazards
• Shock & burn
• Fire & explosions
Prevention:
Correct permit & follow up, Good
communication
Earthing/ grounding, Proper isolation, floor
insulation
ELCB, 24 V to avoid shock in confined
location
Proper equipment, PPEs
Inspection, permit system
Training
Supervision
Physical Hazards
Heat stress
Radiation (UV, IR)
Lighting
Ionizing radiation
Prevention
 Heat stress: Acclimatization, Water with
Salt and sugar, design protection
 Radiation: Usage of anti UV anti IR
glasses, design protection
 Lighting: No glare, no reflection, correct
lighting according to job and age
 Ionizing radiation: Protection by PPEs,
avoid from that zone, remote operation
 Biological hazard
Some industry may manufacture biological
material like vaccines etc.
 Some may use it
 Some may un intentionally get in contact with
biological hazard material like anthrax in leather
industry. Some may get in contact with HIV who
are working in medical and research lines.
 Prevention: PPEs, Isolate the danger, Transfer
Knowledge to employees, Proper way of
destroying.
 Mechanical Hazard
• Caught between the objects
• Fall of materials/tools etc
• Fall of persons due to slip/ trip etc
• Striking against object like scaffolding
• Rigging jobs lifting, placement of heavy objects
• Failure of lifting equipments
• Wrong working in hand tools
• Working in confined locations
• Working at heights
• etc
 Mechanical hazards
• Tooling:
Manual Tools:
 Use right tools for right job.
 Don’t use worn out / broken tools.
 Don’t use makeshift arrangement on non matching tools.
 Remove mushrooms in chisel as on the hit, may pierce
on body.
 Use standard company tools.
 Use tool holders while taking tools to other places, Use a
bag or tool box for taking tools.
 Count the tools on return and don’t leave any tool on the
place where you worked.
 Keep the tools clean away from oil and dirt.
 Use proper PPEs; Know the place, material, area you are
working and the hazards. Contd..
 Power operated Tooling:

• Inspect tools/ power cords, electrical fittings for damage prior to

each use. If found any fault repair/ replace damaged equipment.
• No jewelry, gloves, loose clothing while using revolving power
tools.
• Power OFF the switch of the tolls before connecting to electrical
power supply.
• Ensure the connection is with 3 pin supply and earthing system
is working.
• Do not use the machine with direct insertion of electrical
connection to plug hole.
• Do not use the machine in wet condition / damp locations unless
tool is connected to ELCB (Earth leakage circuit breaker).
• Do not clean tools with flammable or toxic liquids/ solvents.
• The equipment should not be operated in area containing
explosive vapours/ gases.
• The power cord should be clear of tools while in operation.
• Do not suspend the cord in hot lines.
• Use proper rated plugs/ cables.
Do not carry the tools with the help of electrical cord.
If electrical cord is hot then check the cord by an electrician.
Do not connect many connections from one source (Octopus
connection).
Do not pull the plug connection with cord for disconnection.
Do not use extension cords as permanent wiring.
Keep the power cords away from heat/ chemicals/ water/ oil etc which can
damage the cord insulation.
Wear safety goggles / face shield while working.
Keep drill vents clear to maintain adequate ventilation.
Disconnect the supply of the machine before changing or adjusting tools
etc.
Do not leave tool key in the chuck.
Secure work piece before drilling.
Drill a small hole (pilot) before drilling larger hole.
Do not use defective tools.
Do not exceed the manufacturer’s recommended maximum speeds.
Do not over reach. Keep proper footing and balance at all times.
Contd…
Follow manufacturer’s instructions.
Use lubricants while cutting metals.
Do not stop the momentum of the machines by
rubbing the tools on floors or other surfaces.
Do not touch the tool on stock before machine is
started.
For operating circular saws use both hands.
Use designated sharp tools.
The saw should have proper guards.
Keep the saw on properly designed tool rest bench.
Always study and follow the instructions of
manufacturer for operation and maintenance.
Pneumatic driven:
Air powered tools are generally use in grinding/ drilling ,
hammering, chipping riveting etc. They are used where
there is no electrical supply is either not available or can
not be used. Some points to remember
Take care of pneumatic hoses laid, can be a trip hazard
Connect the hoses with proper connections and fit
properly.
Preferably connection be made with Quick release
coupling keeping male end to the tools and not to hose.
Turn off air pressure to hose when not in use or when
changing tools.
Check the sped of the tools to suit the machines speed.
Choose air pressure hose rating which should be 150%
of air pressure supplied. Contd…
Do not use air for cleaning debris/ dust from cloths etc.
Use goggles/ face shield safety shoes and ear
protection.
Maintain tools carefully.
Replace worn out / defective tools.
Dress mushroomed heads of striking tools.
Carry tools in a sturdy toolbox to & from the work site.
Always study and follow the instructions of manufacturer
for operation and maintenance.
Welding safety
Welding safety- hazards:
Gas welding:
Flame/ Hot surface
Back up of Oxyacetylene / back flash
Leakage of Gases from Hose & all joints
Acetone carryover with gas
Ingress of oil/ grease into oxygen system.
Incompatible of acetylene with copper and
copper alloys.
Spitting of molten metal during welding/cutting.
Welding fumes – Health hazard (poisonous
Metal oxides)
Radiation hazard
PROTECTION/PREVENTION
Frequent inspection & cleaning of gas nozzles.
Maintenance / inspection of Cylinder Pressure Gauges/
Regulators/ performance observation of Torch mixing
chambers/ Back flash arrestors / NRVs.
Periodical inspection of hoses/ fittings
Use always single continuous hose
Keep DA (acetylene) cylinder always vertical position.
Ensure no oil/ grease used at any point of time in making
oxygen connection.
Never use copper /alloys of copper and do not use
incompatible pressure gauges.
Use of approved welding goggles/ apron/ leg and hand
protection
Ensure surrounding area is clear of flammable material.
Local exhaust ventilation or dispersion by forced draft.
Electric Arc welding:
Hazards- Shock, Fire, Exposure to metal fumes
Area of work to be free from flammable material,
Proper connection of return earthing
Proper cables not any metal rod or piping
Inspection of cables and equipment, receptacles by
authorized electrician.
Supply of power on plant location by permit.
Operation of welding in plant area by approved
permit.
Welder- trained person only.
Proper PPEs to be used like leather gloves, leg
guards, welding shield approved, cotton dress.
Switch off machine on non-use. Speciall care on
confined location.
 Working at height
( any work above 10’ or 3 M)
Jobs like:

Painting,
Work at fragile roof,
Scaffold fabrication,
Repair on hoists, EOT cranes,
Repair work on flare stalk, etc.
WORKING AT HEIGHTS AND ON FRAGILE ROOFINGS

1) Before starting the work at height or on a fragile roofing, permit to

work at height & fragile roofing must be obtained from concerned
Area In- charge through Executing engineer of company. Any job
above 10’ (approx 3 mts) to be considered as critical job
2) For working at height, make use of proper platform or Scaffolding. Do
not use makeshift arrangements for climbing and do not work
standing on pipelines.
3) Scaffolding should be firm with proper approach and work platform.
4) While working at height on structures, use of safety belt (harness) is a
must. Safety net may also be required in certain critical areas.
5) If only ladder is being used for working at height, then ladder should be

properly secured and do not lean from ladder, better shift the ladder
and use proper type of ladder in right way.
6) While working on fragile roof either for maintenance or for fixing new
sheets or any other purpose, sheet may break & worker can fall down.
Hence crawling board (Roof ladder) must be used
 Working at confined locations
If it is a vessel check for:
Cleanliness- fit to enter
Check for toxic, flammable, Oxygen levels
Positive isolation (Blinds) of all inlet/out let lines
Check in & around area for any release or any other type of
hazards expected from that location.
Availability of standby who is knowledgeable on his duty
Equipments/ tools and tackles on their fitness
Isolation of power (Electricity, Pneumatic power)
Isolation of moving parts and choking
Standard Safety harness with lifeline
Illumination
Availability of 24V fixtures for lighting & work
ELCB connection if 24V Machinery for work not available
 If it is a pit/underground :
Electrical cables
Pipelines- get clearance from elec./ instrument deptt.
Leached chemicals/ leaked chemicals-inform in-charge
Digging be careful for first 1 M
Depth more than 5’(1.5M) take extra precautions as earth can
cave in
Loose soil/ wet soil area and more depth –shoring/ slope cut &
Timber bracing and shift removed soil away from pit.
Look for any vibrating location like compressor/ road location
etc.
Arrange for emergency escape- ladder or make steps in the pit
Employ minimum required manpower
Be careful while digging near compound barrier walls.
Use proper PPEs
Constant supervision as most of the workers are illitrate.
In case of emergency/siren- stop work and come to safer
location.
Chemical Hazard
Toxicity
Flammability
Reactivity
Corrosive
Radioactive
NFPA Signals

Ratings for Health, Flammaability & for Reactivity;

1- low
2- Medium
3- High
4- Extreme
H=Blue: Health
F=Red: Flammability
R=Yellow: Reactivity
Green: For Corrosive, Radioactive or special
requirement mentioning.
The numbers are given in the correct slot
HEALTH:
Toxicity data is to try & determine the potential
effects of a material on humans. The toxicity of
materials as reported is derived after variety of
studies.
Acute oral; acute inhalation; Acute dermal
Lethal dose: LD50 ; Lethal concentration: LC50
Lethal dose: LD50 is the amount of material given
to a population in a single dose that results in the
death of 50% of the population.
Lethal concentration: LC50 It is an indicator of the
potential danger to human from inhaling airborne
amount of the material. The amount of material
given to a population in a single exposure that
results in the death of 50% of the population with
in one hour (usually)
Both studies on rat /monkeys done.
TLV: Threshold Limit Value: it is laid down by the
ACGIH (American Conference of Governmental
Industrial Hygienists. The value is time weighted
average concentration for a normal 8 hour work day.
STEL: Short Term Exposure limit: a 15 min. time
weighted average exposure which should not be
exceeded at any time during a work day and should
not be repeated 4 times a day with at least 60 min
interval between successive exposures.
IDLH: Immediately Dangerous to Life & Health: It is the min
concentration to which one could be exposed for 30 mi. without
impairing the ability to escape or having irreversible health
effects

Flammability:
LEL: Lower explosive limit/ Lower flammable limit
UEL: Upper explosive limit/ Upper flammable limit
Reactivity:
It is the instability rating, and indicates the energy
released if the material is burned, decomposed or
mixed.
0- stable & not reactive with water
1- unstable if heated, changes or decomposes on
exposed air, light, or moisture.
2- Violent chemical change: reacts violently
3- Shock & heat may detonate; reacts explosively
with water without heating or confinement.
4- May detonate
Corrosive material:
Use compatible material (Eg. No SS for Cl / HCL)
Use correct PPE Special PVC for HF etc.
Know the material/ Properties and act
Use Face shield for Caustic, acid service, Proper
apron, Rubber/PVC gloves, Rubber gum boots.
Caustic area- PVC soled shoes, PU bottom not
suitable.
In case of splash in eye wash for not less than 15
min for caustic. So know the location of shower/
eye water fountain.
Inform any accident or abnormality immediately to
In-Charge and call for help.
Our aim is zero accident