SAFETY

HAND-BOOK

NAVAL DOCKYARD
MUMBAI

CONTENTS
PREFACE
TEN COMMANDMENTS OF SAFETY
AMENDMENTS
PART : 1

SAFETY MANAGEMENT SYSTEM

CHAPTER

DESCRIPTION

CHAPTER 1)
SAFETY POLICY
CHAPTER 2)INSPECTION OF CENTRES
CHAPTER 3)SAFETY ORGANISATION
CHAPTER 4)SAFETY SYSTEM
CHAPTER 5)LIST OF IMPORTANT DOCKYARD
SAFETY ORDERS
CHAPTER 6)ACCIDENT REPORTING /
INVESTIGATION/FOLLOW UP
CHAPTER 7)SAFETY CODE - SUB CONTRACTORS
CHAPTER 8)
ACTION PLAN FOR EMERGENCY
HAZARD CONTROL

01
02
03

PAGE NOS
04
05
10
16
21
24
29

PART : 2

SAFE

CHAPTER 9)
CHAPTER 10)
CHAPTER 11)
CHAPTER 12)
CHAPTER 13)
CHAPTER 14)
CHAPTER 15)
CHAPTER 16)
CHAPTER 17)
CHAPTER 18)

FIRST AID
MEDICAL SURVEILLANCE
HOUSE KEEPING.
PERSONAL PROTECTIVE EQUIPMENT
WORKING AT HEIGHT
WORKING IN CONFINED SPACES
NOISE & VIBRATIONS
MATERIAL HANDLING
FIRE FIGHTING
HANDLING OF DANGEROUS
SUBSTANCES
COMPRESSED AIR/GASES
SECURITY
GEN. PRECAUTIONS
WORKING ON MACHINES
WORK PERMIT SYSTEM

CHAPTER 19)
CHAPTER 20)
CHAPTER 21)
CHAPTER 22)

31

ENVIRONMENT
34
43
45
51
56
60
64
67
75
82
85
91
92
94

PART : 3
CHAPTER 23)
CHAPTER 24)
CHAPTER 25)
CHAPTER 26)
CHAPTER 27)
CHAPTER 28)
CHAPTER 29)
PART : 4
CHAPTER 30)
CHAPTER 31)

ENGINEERING PRODUCTION OPERATIONS

FITTING/MACHINE/PIPE SHOPS
ICE SHOP
FOUNDRY
RUBBER MOULDING
REFRIGERATION, AIR CONDITIONING
BOILER SHOP
TEST HOUSES

96
100
102
105
108
109
117

ELECTRICAL PRODUCTION OPERATIONS

CHAPTER 32)
PART : 5

SAFE USE OF ELECTRICITY

CARDIO PULMONARY
RESUSCIATION
ELECTROPLATING
WEAPONS PRODUCTION OPERATIONS

CHAPTER 33)
CHAPTER 34)

H.P.AIR/HYDRAULIC SYSTEM
RADIATION

119
130
132

135
138

PART : 6 CONSTRUCTION PRODUCTION OPERATIONS

CHAPTER 35)
CHAPTER 36)
CHAPTER 37)
CHAPTER 38)
CHAPTER 39)
CHAPTER 40)

WELDING AND CUTTING

PLATER/BLACK SMITH/
SHEET METAL WORK
PAINTING
DOCKING, UNDOCKING OF SHIPS
STAGING
WOOD WORKING MACHINES

146
152
154
158
161
165

PREFACE
The objective of this hand book is to develop safety consciousness among all
workers, supervisors and officers of the Naval Dockyard, Mumbai, to ensure that each

and everyone in the yard is familiar with the general rules, procedures and practices for
safe conduct of his work. I sincerely hope that this compilation will serve as a ready
reference for safe work practices to be followed by one and all in the yard.
Rules, procedures and practices for the prevention of accidents are neither based
on any one injury/accident nor are they compiled from the experience of one man, one
plant or one industry. These rules and procedures have been formulated based on the
contributions of the men who have had years of practical experience in diverse industries
working with men and material and machines.
I would like all employees of Naval Dockyard, Mumbai to abide by the instructions
contained in this booklet, to ensure safe and healthy working conditions. These
instructions are by no means exhaustive, and as additional measures, I expect everyone to
go beyond these procedures in their safety efforts and exercise even further degree of care
at all times.
Heads of Departments are to ensure that the contents of this Handbook are
brought to the notice of all personnel working under them.

(P C Bhasin)
Rear Admiral
Admiral Superintendent
Naval Dockyard
Mumbai
04 Mar 97

TEN COMMANDMENTS OF SAFETY

1.

SAFETY IS A WAY OF LIFE, LIVE SAFELY.

2.

YOUR SAFETY MEANS THE SAFETY OF YOUR FAMILY.

3.

SAFETY HAS NO HOLIDAY.

4.

SAFETY IS THE CONCERN OF EVERY BODY.

5.

WORKING SAFELY IS AS IMPORTANT AS WORKING

6.

MAKE SAFETY YOUR SIXTH SENSE.

7.

NEGLIGENCE ALONE CAUSES ACCIDENTS. MOST

ACCIDENTS ARE PREVENTABLE.

8.

SAFETY AND PRODUCTIVITY GO HAND IN HAND.

9.

ALWAYS AIM AT HIGHER DEGREE OF SAFETY.

10.

SAFETY IS SOLD NOT TOLD.

PROPERLY.

AMENDMENTS

Amendment Authority
Date of Initial Remark
Number
Insertion
---------------------------------------------------------------------------------------------------

PART : 1
SAFETY MANAGEMENT SYSTEM

CHAPTER 1

SAFETY POLICY
Naval Dockyard ( Mumbai)
1.
The management of the Naval Dockyard believes that safety
of the employees is of greatest importance and ranks it no way less
important than production and quality of work. The management
is of the firm belief that observance and maintenance of safe operating procedures, can result in preservation of vital human
resources, plant and machinery. It is also the firm conviction of the
management that observance of industrial safety means higher
productivity resulting in best turn out of the fleet at sea.
2.
It is, therefore, imperative that all personnel, be it the
Managers, Asst. Managers, or Supervisors who manage the
workmen, should recognize, accept and give top priority and
importance in implementing safe work procedures and ensure safe
and healthy working conditions.
3.
It is the prime duty of workers representatives to educate the
workmen to adopt safe work procedures and use the necessary
means for protection religiously.
4.
The workmen shall not endanger theirs and their fellow
workmen's lives by adopting unsafe means and shortcuts. It
should be understood that any violation of safe work practice
endangers their own lives, causing undefined hardship to self and
families for years.

CHAPTER 2

INSPECTION OF CENTRES
2.1

SAFETY INSPECTION :

Safety Officers are authorised to carryout surprise safety inspection of any area
in the yard including workshops, dry-docks, jetties and contractor work sites. In
addition, they are also to carry out regular Safety Inspection of all the workcentres, drydocks, jetties, powerhouses and other sites of the yard. The points to be covered during
inspection are as give in para 2.4. During the regular safety inspection, the concerned
centre Asst. Manager and the Senior Foreman are to accompany the Safety Officer. The
inspection reports of such inspection are to be forwarded to the concerned Asst/Dy.
Manager, Manager and DGM for taking necessary corrective measures. Safety Officers
are to recheck again after a reasonable time to ensure that all the shortcomings have been
eliminated. In case of non-compliance of any points, the same is to be brought to the
notice of the Chairman Apex/Local Safety Committee.
2.2

ASDS INSPECTION OF CENTRES

ASD will inspect all the centres of the yard on a regular basis. Prior to
ASDs Inspection the following Officers are required to inspect the concerned centre and
submit inspection report to MIES in duplicate for onward submission to ASD:a)
c)

Concerned HOD/AGM/DGM
PMO

b)
d)

e)

MLOG

f)

AGM(TS)
Chief Security and Fire
officer
MHRT

g)

MPC

h)

MMIS

j)

Personnel Manager

k)

Safety Officer

l)
2.3

MIRW
REGISTERS FOR SAFETY INSPECTION

Following registers connected with the safety are to be maintained by all the
centres and submitted for Safety Officers Inspection:
i.

Accident Register

ii.

Safety Officers Inspection Register

iii.

Departmental Safety Committee Meeting Register

iv.

Record of Earthing of Electrical Equipment

v.

Record of Personal Protective Equipment

vi.

Lifting tackles testing registers

vii.

Fire Fighting Equipment Register

viii.

First Aid Kit Register

ix.

Family Planning Register

2.4

CHECK LIST FOR SAFETY INSPECTION

AREA OF INSPECTION

i.
ii.
iii
iv
v
vi
i.
ii.
iii
iv
v
vi

FIRE PREVENTION
Extinguishing equipment
Training of personnel
Storage of flammable material
Disposal of flammable scrap
Exits and other signs
Fire protection
HOUSE KEEPING
Work area
Aisles, stairs, floors
Lighting & ventilation
Material/component stacking
Waste disposal
General neatness/ cleanliness
MATERIAL HANDLING

i.
ii
iii
iv
v
vi
vii
viii

Statutory records / Log books

Cranes & gantries
Chain /slings , rope, lifting
tackles etc.
Fork lifts
Chain / pulley blocks
Power trucks & tractors
Hand carts
Manual handling equipment.
STORES AND STORAGE

i.
ii
iii
iv
v
vi

Location
Storage racking
Access means
Stacking & piling
Dangerous substances store
Loading / unloading

GOOD

AVERAGE

POOR

MACHINERY
i.
ii.
iii.
iv.
v.

Drive motors & controls

Operation point guards
Drive mechanism guards
Material flow
Dust, vapor, chips, fumes,
sparks.
PRESSURE EQUIPMENT

i.
ii.
iii

Compressor & pump sets

Air receiver & air lines
Test records
POWER SUPPLY

i.
ii.
iii.
iv.
v.

Switch gears & control

High voltage supply lines
Domestic supply &
connections
Temporary lighting/
connection
Earthing records
FIELD WORK

i.
ii.
iii.
iv.
v.
vi

Dry docks & under water work

Ship side work
Scaffoldings/ staging, ladders
Work in ships compartment
Work in confined spaces
Work in pits and culverts
TOOLS

i
ii
iii
iv.

Power tools
Hand tools
Jigs and gadgets
Use & maintenance of tools

i
ii.
iii.
iv.
v.

PERSONAL PROTECTIVE EQUIPMENT

Goggles, face shields ,screens
Helmets,
Gloves
Footwear
Respiratory protective equipment

vi. Other protective equipment

vii. Procedure of PPE maintenance

i.
ii.
iii.
iv.
v.
vi.

MISCELLANEOUS
First aid boxes & training
Safety posters and signs
Accident register & records
Safety awareness
Accident investigating records
Any other relevant records

i.
ii.
iii

WELDING EQUIPMENT
Electric welding set and earthing
Electric holder & line earthing
Gas welding set

i.
ii.
iii.
iv.
v.

WELFARE
Drinking water
Washbasin & toilet
Change & work room
Showers & eye wash fountain
Pest control records
vi. Stretchers

Note:
1. The above check list must be used by Safety Officers, Safety Committee Members,
departmental officers, senior shop supervisors while taking safety rounds in their
department.
2. Any shortcomings observed are to be brought to the notice of the concerned
HOD/DGM/Manager for taking necessary corrective measures.

CHAPTER 3

SAFETY ORGANISATION AND SAFETY COMMITTEES

DOCK YARD SAFETY ORGANISATION

A S D (M B )
G M (T )
D G M )H R )
M IE S
SR SO
S O -I

S O -II

S O -III

NOTE:MIES = Manager Industrial Engineering and Safety

SR SO = Senior Safety Officer
SO = Safety Officer
DUTIES/RESPONSIBILITIES AS REGARDS SAFETY ORGANISATION
3.1

Admiral Superintendent

Formulate the policy and give guidelines for efficient, safe and healthy environment
in the dockyard.

He will be the Ex-officio President of Safety Committees.

3.2

General Manager (Tech.)

Ensure the promulgation of Dockyard Safety Policy and implementation of safety
norms, rules and procedures , so that there is optimum usage of available men and
material with highest quality and reliability .
Train and develop the existing human resources in safety.


3.3

3.4

3.5

3.5

He will be the chairman of the Apex Safety Committee.

Deputy General Manager (HR)
Ensure development of human resources , conduct of Industrial Safety Training
and application of industrial engineering and safety standards in the dockyard.
Ensure implementation of safety measures in all dockyard activity.
He will be the chairman of Dockyard Local Safety Committee.
Manager (IES)
Render advise to all officers and instruct all workers, in application of measures to
prevent accident / occupational hazards with reference to Factories Act.
Act in as advisory capacity when work is being carried out which requires wearing of
PPEs.
Maintain liaison with local Director of Industrial Safety and Health and accompany
him during visit to the Dockyard.
Senior Safety Officer
Regular and frequent inspections of
Departments for ensuring safe
practices/procedure and drawing attention of a responsible officer for any unsafe
acts .
Investigation of accidents in conjunction with Departmental Officer concerned.
Compilation and promulgation of accident statistics .
Maintain accident records.
He is to apprise MIES regarding any unusual feature of the reports/records affecting
safety of the personnel .
He will be the member secretary of the Dockyard Apex Safety Committee.

Safety officer
Regular and frequent inspection of departments , centers, dry docks and jetties to
ensure safe practices, conditions and acts.
He is to draw the attention of concerned Departmental Officer in case of any unsafe
conditions and acts.
His inspection is to cover applications of machine guarding , maintaining clean
passages, use of proper staging etc.
Examine various safety periodicals and publications calling the attention of MIES to
any method which in his opinion are worthy of adoption in the dockyard.
Implementation of Safety Handbook contents as applicable.

3.6

Arranging for distribution and display of posters, calendars, stickers etc. at

appropriate places on receipt from National Safety Council /other sources.
He will be the member secretary of the Dockyard Local Safety Committee.
SAFETY COMMITTEES

In keeping with the provisions of Factories Act 1948 (as amended up to 1987) and
the Maharashtra Factories Rules 1963 (as amended upto 1982), Dockyard Safety
Committees are constituted as contained in the succeeding paragraphs.
3.7

DOCKYARD APEX SAFETY COMMITTEE

The composition of this committee will be as follows :

a)
GM((T)/(Q) -Chairman
b)
AGM(PR)
--Member
c)
A/DGM(TS) -Member
d)
A/DGM (MAT) -- Member
e)
PMO
--Member
f)
CHSFO
-Member
g)
COY
--Member.
h)
Sr. Safety Officer -- Member Secretary
j)
Equal numbers of elected representatives from staff side.
This committee is to meet once in a quarter to discuss/resolve major
related to safety aspects in the dockyard.

3.8

issues

DOCKYARD LOCAL SAFETY COMMITTEE :

Composition of this committee will be as follows :

a)
b)
c)
d)
e)
f)

A/DGM(HR)
-- Chairman
All Managers of Production,
Maintenance, Material and Quality
control departments
-- Members
Medical Officer
-- Member
Fire Officer
-- Member
DCOY
-- Member
Safety Officer
-- Member Secretary

This committee is to meet once every quarter and resolve the points for
which actions are pending in the Departmental Safety Committee.
3.9

DEPARTMENTAL SAFETY COMMITTEE

Composition of this committee will be as follows :-

a)
b)
c)
d)
c)

Manager of the Department

One Officer From each centre
One Supervisor From each centre
One worker-- From each center
One Safety Member From
concerned Department

------

Chairman
Member
Member
Member
Member secretary

These Departmental Safety Committees are to meet once in two months to

discuss and resolve shop level problems related to safety and health. Copies of the
minutes recorded are to be forwarded to concerned HOD and MIES to enable issue of
safety advice/instructions as applicable.
3.10

FUNCTIONS OF APEX SAFETY COMMITTEE :

The primary functions of the Apex Safety Committee are as follows :-

Assisting and co-ordinating with the management in achieving the aims and objectives
outlined in the Health and Safety Policy of the yard.
Dealing with all matters concerning health, safety and environment and to arrive at
practicable solutions to the problem encountered.
Creating safety awareness amongst all workers.
Undertaking educational, training and promotional activities of health and safety.
Deliberating on reports of safety, environmental and occupational health surveys,
emergency plans, safety audits, risk assessment and implementation of the
recommendations made in the reports.
Carrying out health and safety surveys and identify causes of accidents ; maintenance
of house keeping records.
Looking into any complaint made on the likelihood of an imminent danger to the
safety and health of the workers and suggests corrective measures; follow up action
thereof.
Reviewing the implementation of various recommendations.
Any other points related to safety and health of the worker are to be brought up and
remedial measures will be discussed during the
meeting.
Promoting accident prevention and safe methods of performance within the work
areas.
Encouraging employees to use PPEs where necessary/ desirable.

3.11

FUNCTIONS OF DEPARTMENTAL SAFETY COMMITTEES

The Departmental Safety Committee will perform the following functions at the
departmental level :

Organise talks/lectures on safety in every center by the qualified personnel on regular

basis once in a week preferably on every Saturday.

*
*
*
*
*
*

Carry out bi monthly Internal Safety Inspection of the center covering (Team of one
officer/senior supervisor & workers representative/ safety committee member) the
following aspects :-* House Keeping
Lighting and ventilation
Adequacy/ functionality of first aid, fire fighting equipment .
Protective clothing and safety gears etc.
Electrical wiring and equipment.
Material handling equipment, gear and methods employed.
Training of personnel in handling fire fighting equipments and
appliances
Detailed checklists (2.4) are available with the safety department for inspection on
above subjects and can be utilised by the centre.
Shop level safety meetings are to be held once in a month and the record of
proceedings/points is to be maintained in a register indicating the actions taken and
follow up. If the point does not get resolved within two months, the same should be
taken up at departmental level in Departmental Safety Committee meeting which is to
be held once in two months.
The Manager accompanied by the Safety Committee Member of the shop will carry
out monthly Safety Inspection of every centre.
Safety committee meeting at departmental level comprising of nominated members of
centres will be held once in a two months to resolve points on safety which could not
be resolved at shop level .
The points in Apex Safety Committee (Quarterly meeting ) meeting will be only those ,
which could not be resolved at the shop/ departmental level and which are relevant to
the safety of personnel in general.
All nominated members of the safety committee will be trained in-house by the safety
organization.
The Safety officers, during their periodic inspection of centres, will examine the
records pertaining to shop/ departmental safety committees and will advise the centres
on concerned points.

3.12

PERIODICITY OF MEETINGS :

The above committees shall meet as often as necessary but at least as per the
periodicity indicated above. The minutes of the meetings of safety committees are to
be preserved for inspection of the Factory Inspector on demand.
The above committees have been constituted to fulfill statutory requirements and to
serve an important role and functions effectively for purposeful worker participation.
Maximum encouragement will be given by the management to all representatives of
Safety Committees to participate fully in the discharge of their duties. The
Committee members at all levels are expected to work in a united and dedicated
manner for betterment of the Dockyard.

CHAPTER 4

SAFETY SYSTEMS
4.1.

SAFETY DEPARTMENT

The primary function of the Safety Department is to advise in maintaining

and promoting a safe and healthy working environment. The Naval Dockyard safety
system is managed by the Safety Department which is headed by GM(T) and eighteen
management staff. Various Safety committees assist the Safety Department in the
formulation and execution of safety policies and procedures.
4.2

TEN POINT SAFETY & HEALTH MANAGEMENT PROGRAM

The Dockyard has a 10-point safety program aimed for educating employees and
preventing accidents on board ships and in yard. These safety programs have been
formulated over the years based on experience and are regularly reviewed and
upgraded to meet safety requirements of this yard. The comprehensive 10 point
program is planned to ensure a total Safety Management System
Safety Committees
Safety Education and Training.
Fire prevention
Safety Inspection
Safety Handbooks
Promotional activities
Medical surveillance
Protective equipment
Emergency Preparedness

Accident Reporting Investigation and Analysis

4.3

SAFETY COMMITTEES
Committees are set up at various levels to spearhead and coordinate all safety
activities in the yard. The various committees include :
Apex Safety Committee
Local Safety Committee
Departmental safety committee
In addition, safety matters are also discussed at senior management level, at meetings,
which are chaired by the Chairman of the Safety Committee.
Group discussions are also held regularly both formal and informal various
committees, safety meetings and discussions are held to highlight problem areas and
recommend remedial measures.
4.4 SAFETY EDUCATION AND TRAINING
Comprehensive and structured safety education programs are provided to
Dockyard employees. Courses are customized for different work levels. A three days
course in basic inductive safety is conducted for all dockyard worker and supervisors.
Courses on first aid and handling of chemicals are also imparted for concerned
individuals with the help of the faculty drawn from expert institutions outside the yard.
4.5

FIRE PREVENTION

This yard is equipped with a well equipped fire fighting system in the premises .
Fire prevention in the work areas is being taken care of by the employees them selves
who are trained to handle all first aid fire fighting systems/equipments. Regular updating
of knowledge, practical demonstration in fire fighting is conducted by the fire-fighting
department of the yard to enhance the capability of fire prevention. This yard has a
main fire station with one sub fire fighting station to cater to the needs of entire yard in
fire fighting with well-trained manpower.
4.6

SAFETY INSPECTION:

Identification and rectification of unsafe conditions are two critical preventive

measures of unsafe acts. For maximum effect, these unsafe acts should be identified and
remedied immediately during work processes. Safety inspections are carried out
regularly and stringently.
Daily Inspections by Safety personnel are carried out both on board vessels and
workshops to identify unsafe conditions and unsafe practices. Immediate measures are
taken to rectify any unsafe condition and practice observed.
Departmental Safety Committee Inspection is carried out on a bi-monthly basis.
Jobs of sub-contractors engaged by the departments are also checked during these
inspections.

4.7

SAFETY HAND BOOK :

The Safety HandBook is a reference book which must be followed by everyone for
reducing the number of accidents in the yard by following safety norms as per safety
policy. The safety norms are not exhaustive since work in this yard is of different types.
This publication is to enhance safety consciousness amongst management, supervisors
and workers, and to follow set procedures in reducing work related accidents.
4.8

SAFETY PROMOTIONAL ACTIVITY :

Safety awareness is promoted by means of the following.

Safety Posters :

Safety posters depicting various hazards, safety rules and regulations, safe work
procedures are displayed at various strategic locations throughout the yard.
*

Safety Exhibition :

To instill and promote safety awareness, exhibitions are organized annually.

*

Safety Slogan Competition :

To promote participation of employees in Safety management, Slogan Competition is

being held during Safety Week Celebration.
*

Safety Suggestion System :

Safety Suggestion System is to encourage participation of all employees in the prevention

of accidents in work places.
* A accident Free Trophies :
Departments are awarded rolling trophies during the safety week on completion of
maximum accident free periods during the year.
4.9

MEDICAL SURVEILLANCE :The yard is fully equipped to meet any medical emergency and medical surveillance
is part of the management system in reducing work-related injuries.
Pre-employment, periodic and post retirement medical surveillance is part of the
management strategy in reducing the occupational injuries due to various processes
/work.

A full fledged medical team is in attendance during normal work hours and a medical
officer with requisite staff during off hours for attending to any work related injuries
with full fledged dispensary .
Further medical assistance is requisitioned from nearby government/municipal
hospitals within a reach of 2 km from the yard.
An ambulance is in attendance at all times .

4.10

PERSONAL PROTECTIVE EQUIPMENT :

All employees are issued with the necessary personal protective

equipment, items like helmet, shoes, gloves, earplugs and overalls. Other personal
protective equipment such as safety belts, welding shield, goggles, life jacket, apron and
facemasks are issued to certain trade employees who are exposed to special risks. Subcontractors are required to wear similar protective equipment for their jobs.
4.11

EMERGENCY PREPAREDNESS :

For processes like Chemical Cleaning, Battery Charging, Electroplating,

High pressure system, Test houses and Docking/ Undocking emergency preparedness
system is operated by respective departments and the drill is being conducted
periodically.
4.12 ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS
All accidents are to be reported to the Safety Department and to the Factory
Inspectorate through Personal Department vide Factories Act 1948.
All major accidents, incidents are being investigated and suitable remedial measures
suggested for implementation to prevent recurrence.
All the accidents are analysed causes identified and remedial measures suggested to
prevent future accidents .
For maximum effect, unsafe acts should be identified and remedied immediately
during work processes. Safety inspections are carried out regularly and stringently on
a bi-monthly basis .
Sub-contractors engaged by any department, are also to be inspected during in these
inspections.
All accidents, dangerous occurrences and fires are thoroughly investigated by Safety
personnel so that suitable remedial and preventive actions can be taken. The
recommendations are communicated to the departments for compliance.
4.13

INVESTMENT IN SAFETY

The high commitment and priority accorded to safety by the Dockyard is

demonstrated by the willingness to invest much time, effort and money in improving
safety in the Dockyard.
There is a constant look out for new safety equipment so that the standard of safety
preparedness in the Dockyard is kept at a high level.

4.14

THE FUTURE

The Dockyard is committed towards achieving the highest possible safety

standard involving all employees with
whom the personal responsibility and
accountability for safety is vested. As such, time, effort and resources will continue to be
invested in ensuring that Naval Dockyard, Mumbai
provides the safest work
environment and employees effectively practice safe work procedures . The Dockyard is
convinced that only through such a philosophy and policy, a high level of safety can be
provided for the employees.

CHAPTER 5

LIST OF IMPORTANT DOCKYARD SAFETY

ORDERS
Sl.No.
(1)
1.
2.
3.
4.

5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

(1)

DSO No.
(2)
44/74
GMs Note
28/82
GMS Order
17/82
DYD Ord.
05/83

Dated
Subject
(3)
(4)
01/07/74
Safety Inspections.
07/04/82
Safety in Dry dock
08/10/82

Maintenance of Dry Docks

Procedure regarding
injuries sustained by
dockyard employees
while on duties.
GM Ord
13/12/84
Prevention of accidents
20/84
use of helmets, maintenance of Dry dock
DY.S. Memo 10/04/85
Compulsory wearing
01/85
of helmets in Dry Docks
GM Ord
17/04/85
Upkeep of first-aid
09/85
boxes
04/85
02/05/85
Parking of material
handling equipment
GM Ord
23/07/85
Test and periodical
17/85
Inspection of lifting
appliances etc.
DYD Safety 12/09/86
Material handling
Memo 02/86
equipment
10/87
01/09/87
Implementation of
safe practices
DYT/SAFETY/
07/12/87
Safety Policy
8551
GM(T)
15/12/87
Safety Organisation
Ord.11/87
& its duties
DYD Memo
19/01/88
Duties of DDO
02/88

(2)

Jul. 83

(3)

(4)

15.

GM(T)
Ord.02/88

16/08/88

16.

01/88

16/08/88

17.

02/88

26/09/88

18.

02/90

20/02/90

19.

06/90

06/10/90

20.
21.
22.
23.

07/90
GM(R)s
Ord.07/90
GM(T)s Memo
11/91
GM(T) TY
Memo 25/91

25/10/90
21/12/90
22/07/91
26/08/91

24.

01/92

16/01/92

25.

31/01/92

26.

GM(R)s TY
Memo 16/92
06/92

27.

07/92

23/07/92

28.
29.
30.
31.

(1)

15/07/92

08/92

21/08/92

MIES Cir.
07/92
12/92

24/08/92
19/10/92

DTM 166/92 04/11/92

(2)

(3)

Implementation of
safety measures /reporting
of accidents.
Unsafe traveling in
platform trucks.
PPEs for dockyard
personnel.
High incidence of fire
in fitting out wharf.
Unsafe practices in
Dockyard.
Safety in Gas welding
and cutting
Maintenance of Dry
Docks.
Improvement in Safety
Management.
Earthing of electrical
system & equipment
in ND(MB).
Use of safety helmets and
other protective gears
Testing of chain, pulley
blocks and lifting appliances
Safety of personnel in Drydocks
Mandatory safety
requirements to
of personnel from hazardous
heights.
Enhancement of safety
awareness in dockyard
personnel,
Use of PPEs by workers
Safety measures hazardous
processes .
Procedure for reporting
fatal accidents/deaths
to civil authorities.

(4)

prevent

fall

32.

13/92

16/12/92

33.

03/93

25/01/93

34.

DTM 40/93

17/03/93

35.

06/93

20/05/93

36.
37.

07/93
10/93

29/05/93
31/08/93

38.

11/93

06/09/93

39.
40.

12/93
MIES Circular
33/94

14/09/93
30.09.94

41.

02/95

26/07/95

42.

03/95

12/08/95

43.

04/95

23/08/95

44.

05/95

16/09/95

45.

03/96

29/05/96

46.

04/96

13/06/96

Use of safety gear by

personnel
and
conduct
of safety training in centres
by trained supervisors.
Testing/Examination of
lifting equipment /gear
Encl. : i) Form 12
ii)
Section 29 of Factories
Act and 64 of M.F.R.
Procedure for reporting fatal
accidents/deaths to civil
authorities.
Unsafe practice leading to
fatal/serious accidents.
Safety in Dry Docks
Handling of Acids /
Chemicals Safety
Precautions.
Implementation of Safety
Measures in Dockyard
Electrical Safety
Safety measures during
hauling in/out of ships in
Dry docks.
Safety precautions for
handling HP/LP gases.
Safety precautions in the
use of lead lamps.
Painting in confined
spaces Safety measures.
Safety Measures for
DocksideCraneOperations.
Use of Safety Helmets
and Other protective
gears.
Safety during monsoon.

Note :- The list of all the above orders / instructions is contained in this hand book.
Master copies of all are held in MIES Department for reference of those interested.

CHAPTER 6
ACCIDENT REPORTING, INVESTIGATION AND ANALYSIS

6.1
An accident is an unplanned and unpleasant event, which may or may not
cause injury. All accidents can be attributed to one or more of the following :
*
Unsafe Act. It is an act by the employee, which is not in line with safety norms,
instruction and procedure.
*
Unsafe condition : It is a situation, which could potentially lead to an accident
unless corrected by some one.
*
Uncontrollable condition : Accident occurs due to unsafe act and prevailing unsafe
condition in which both the act and condition when cannot be controlled result in an
unpleasant incident causing material damage or injury to personnel.
*
Employment Injury : Means a personal injury of an employee caused during the
course of his employment.
*
Serious Nature Accident : means an accident, which may result in following.
Immediate loss of any part of body or any limbs or parts thereof.
Any injury by which body part gets affected and is leading to
fatality.
Unconsciousness.
Severe burns or scratches due to chemical, steam etc.
Fatal.
The Dangerous Occurrences :

6.2

are defined as

Bursting of a vessel used for containing steam under pressure greater than
atmospheric pressure, other than plant, which comes within the scope of the Indian
Boilers Act?
Collapse or failure of a crane, derrick winch, (lift), hoist or other appliances used in
raising, lowering persons, goods, or any part thereof, or the overturning of a crane.
Explosion, fire, bursting out, leakage or escape of any molten metal, hot liquid, or gas
causing bodily injury to any person or damage to any part or portion of the factory in
which persons are employed or damage to any plant /machinery /material.
Explosion of a receiver or container used in any process, or for storage at a pressure
greater than atmospheric pressure, of any gas or any gases (including air) or any
liquid or any solid).
Collapse of any floor, gallery, roof, bridge, tunnel, chimney, wall or building forming
part of a factory or within the compound of factory.

ACCIDENT REPORTING PROCEDURE

*
In case of an accident, following statutory requirements must be complied under
the Factories Act 1948.

Rushing the individual for immediate medical aid with form NSO.7 (Specimen at
appendix A to this chapter)

Reporting to civil police, District Magistrate etc. in the event of serious accidents or
death due to accident and completing various formalities as per regulations and the
Factories Act.
Reporting to the Director of Industrial Safety and Health (DISH), Maharashtra.
Submitting detailed report to the Director of Industrial Safety and Health,
Maharashtra on Form 24 . ( Specimen at appendix B to this chapter )

The responsibilities with regard to the above actions are as defined in the
succeeding paragraphs.

Immediate Medical Aid. : On occurrence of an accident the following action should

be taken by the in-charge of the team to save the life of the individual :Rush the individual to the Dockyard Dispensary for First aid, treatment, and transfer
of the case to the civil hospital at the earliest, if required.
Inform the concerned Manager of the Centre or Departmental Officer in charge .
The Manager or Departmental officer should inform the GM/HOD concerned and
GM(R) who in turn will inform the ASD.
Obtain necessary financial assistance as required from A/DGM (P&A) from nonpublic funds for any emergency treatment.
Reporting to Civil Police.

The Manager/Departmental Officer concerned shall inform the Chief

Security Officer immediately on occurrence of the accident who will arrange for civil
police to come to the scene of accident and complete all necessary formalities such as
filing FIR, Panchnama etc. The Chief Security Officer will also subsequently obtain
copies of these documents from the civil police and forward them to the concerned
Manager for appropriate action.
*

Reporting to the Director of Industrial Safety and Health.

It is mandatory that all serious incidents, fatal accidents be reported to the Director of
Industrial Safety and Health within "four" hours of its occurrence. This is a statutory
requirement and has to be complied with. Following procedure will be followed in future
to ensure compliance with this requirement:

The Manager /Departmental Officer will send a telegram to the Director Industrial
Safety and Health (DISH) Commerce Center, Tardeo, Mumbai-400 034, and at the
same time inform him on telephone No 4942230 also regarding occurrence of the
accident.
The Managers/Departmental officers will also inform the PM, A/DGM(P&A),
A/DGM(HR) and MIES of the above occurrence for similar action as above by them.
The PM would also verify with the concerned Managers that the information has been
communicated to the DISH. There may be duplication of effort, but it will ensure that
there is no slip up in dealing with statutory regulations which could otherwise lead to
strictures and legal proceedings.

After the above initial action has been taken by the Managers / Departmental Officers,
all other actions will be coordinated by the Personnel Manager.
The Manager will furnish a detailed report on the accident to PM on Form NSO 7 and
Form 24 in accordance with Factories Act.
The Personnel Manager will take necessary action in accordance with Rule 115 of the
Maharashtra Factory Rule 1963 to inform all concerned authorities. Further follow
up action on such cases will be initiated by the PM and the Manager/Departmental
officers will render any assistance required by PM in expeditiously dealing with such
cases.
Visit by the Director of Industrial Safety and Health.

The Director of Industrial Safety and Health or any officer deputed by him
will visit the yard for investigation into the cause of the accident and ascertain as to
whether all safety measures have been followed. It is important that their visits are well
coordinated within the yard and they are received and seen off with due courtesy. This
aspect is to be coordinated by the MIES in consultation with the Chief Security Officer.
The officer will be taken to the site of the accident by the concerned HOD and Manager.
*

Visit of Officials from Directorate of Industrial Safety and Health.

The Chief Security Officer is to instruct his staff to permit the

Director/Inspectors to enter the Dockyard on proper identification and after expeditious
completion of security procedures such as issue of ty. pass etc. The visit of these officers is
a statutory requirement as per the Factory Act. In case of any assistance required A
/DGM(HR.)/,A /DGM(P&A),/MIES may be contacted.
*

Follow up Action :

All administrative action pertaining to payment of compensation ex-gratia as

applicable, pension benefits ,intimation to the next of kin etc, due to death/permanent
disability are to be taken by the PM on priority basis.
All administrative personal information regarding the accident victim is to be
intimated by the PM to the Board President in the event of a Board of Inquiry .
*
Conduct of Routine Inspection/Investigation of accidents by the Director of
Industrial Safety and Health.
MIES is to organize/liaise the visit/inspection by DISH of the work
centres/work sites during the annual inspection and accident sites. The CLO and the
Senior Safety Officer are to accompany them. Managers of the concerned centers are
required to provide the necessary assistance as required .
*

Transport.
Dockyard Transport officer is to provide necessary transport on receipt of
requisition from the Chairman Safety Committee/MIES at short notice with reference to
inspection / visit by DISH

Miscellaneous Requirements :
Renewal of factory license and maintenance of all statutory records with reference to
the Factory Act will be the responsibility of the Personnel Manager who will act as
Manager of the Dockyard for the purposes of the Act.
DGM(RP) / MCM/ MPLS while off loading repair/refit to trade/private agencies is to
ensure that all the statutory requirement vide section 2(iii) of the Factory Act viz.
registration, submission of various returns ensuring safety measures / precautions
and maintenance of records with reference to the above requirements are brought to
the notice of the contractor prior to awarding of the contract. A clause to this effect
be included in the contract.
Action Outside Working Hours.

In amplification of para 0118 of DYSO 92, the DDO is to ensure that the
steps indicated in para 3 to 5 above are reported for action by the respective
departmental officers and a written report rendered to ASD through A/DGM (P&A) the
next morning.
6.3
INVESTIGATION :
*
All accidents are to be investigated and report forwarded to the Safety
Department by Manger/Sr. Supervisor as per Dockyard Standing Orders.
*
Accidents of serious/dangerous nature must be intimated to Safety Department to
carry out investigation without disturbing evidence.
*
A special board for fatal and serious accidents is to be ordered for investigation.
Report shall be rendered to ASD for implementation of recommendations to avoid future
recurrence.
*
The Safety Department shall
maintain all record of investigation and
recommendations.
6.4

ANALYSIS
All accidents with details, reported to the Safety Department are analysed for the
causes due to which the accident took place and remedial action suggested for bringing
down the accidents and advise in better work methods by utilizing Safety equipment.
6.5
FOLLOW UP
The Manager must ensure that the recommendations are promptly implemented.
Safety Committee is to ensure that recommendations are complied and implemented
at the earliest so that recurrence of similar accidents will not take place in future.
All accidents shall be entered in the accident register.

CHAPTER 7
SAFETY CODE FOR SUB- CONTRACTORS
7.1
Dockyard offers sub-contract jobs to a contractor when the infra structure and
man power of the yard, are overloaded to carry out such jobs
7.2
In the event of any accident occurring in this yard resulting in loss of lives or
otherwise damage to any part of the property, the contractor shall be required to provide
compensation to this yard and shall be responsible for all consequences that follow, from
loss or injury to the person involved in such accident.
7.3
It is ential to follow standards of working and procedures for accident free
working by the contractor and his men in the premises and also to instruct his men in the
observation of safe work procedures, utilizing safe tools and equipment.
7.4
DGM(RP) / MPLS/MCM while off-loading repair/refit jobs to trade/private
agencies are to ensure that all the statutory requirements vide section 2(iii) of the Factory
Act viz. registration, submission of various returns and maintenance of records and safety
regulations with reference to the above requirements are brought to the notice of the
contractor prior to awarding the contract. A clause to this effect is to be included in the
contract.
7.5
Following are the general guideline for safe sub-contracting of jobs.
Every contractor must observe all safety precautions in connection with the work to
be performed by him, his agent or labourers.
All rules, regulations, codes and ordinance of the Government of India, Government
of Maharashtra, and Local bodies regarding the Safety and Health will be applicable
to the contractors.
The contractor or sub contractor shall be required to provide their workman with
relevant safety gear . The work overalls should have suitable color with the name of
the contractor printed on it with prominent letters. It shall be ensured by the

contractors supervisor that the workers wear the overall and safety gears throughout
their work duration in the premises of the dockyard.
The contractor or his agent of labourers must ensure that the place of work is kept
reasonably clean and all scrap / waste is transferred to nearby scrap bin/waste boxes,
on completion of work in any location / compartment.
The management of Naval Dockyard reserve its right to suspend the work in the
event of the contractor not complying with the safety rules, instructions with regard to
safety and health practices for which no claim of any kind will be entertained.
All accidents occurring to the contractors personnel must be reported promptly and
immediately by the contractor or his agent to the MIES (safety department) and PMs
department in addition to the concerned Manager and this should be followed by an
accident on report form No. 24 supervisors report form, and Form NSO 7.
A representative of the contractor should maintain appropriate contact with MIES in
addition to concerned manager of offloaded jobs concerning safety conduct.
All contractors should go through the safety manual and follow safety procedures
wherever applicable to their work.
The contractor should be fully responsible for the cleanliness and house keeping of the
Job site.
The contractors should ensure that adequate fire extinguisher arrangements are
provided, where property is exposed to the hazard of fire. Open fire will not be
permitted unless prior approval from concerned manager is obtained.
Tarpaulin used should be of fire retarding type.
Inflammable liquids must be handled in safe cans approved by Naval Dockyard (MB)
and shall be stored in the locations allowed byND(MB). All such containers or cans
must be clearly labeled.
The Contractors working in confined spaces or pits below ground level must acquaint
themselves and advise their employees of hazards of gas or liquid levels and take
proper precautions as per laid down procedures (work permit etc).
The Contractors should ensure that first aid boxes are provided at work spot and they
should ensure proper medical care of injured persons.
All employees of contractors should wear approved safety helmets and other safety
gear while working in dry docks and other areas.
Carrying, storing, consuming intoxicants in the yard is strictly forbidden. Entering
the yard in an intoxicated state is also an offense.

PART : 2
SAFE ENVIRONMENT

CHAPTER 8

ACTION PLAN FOR EMERGENCY HAZARD

CONTROL
An emergency occurs when the operator at a unit can not cope up with a
potentially hazardous incidence and needs to call for assistance i.e. loss of control causes
the unit to go beyond its normal operating condition thus creating danger .
The first few minutes after an emergency situation occurs are generally the most
critical. Any wrong action or a few seconds delayed action in a crisis can make all the
difference. A quick and effective response at that time can have tremendous significance
on whether the situation is controlled with little loss or whether it turns into a
catastrophic or disaster.
8.1.
The following emergencies have chances of occurring in our yard:
Accident
Fire
Electrocution
Acid/Alkali Burn
Acid Fume Release
8.2

ACCIDENT

On occurrence of an accident , the in-charge of the team should take the following action
to save the life of the individual :-

If possible give first aid/CPR as required.

If required and possible call for ambulance.
Alternately shift individual (injured) to Dockyard dispensary for first aid / treatment
by Medical Officer on duty .
Inform the concerned Manager of the centre / Dept. immediately.
Concerned Manager should inform details of the accident to GMs/ HOD/ MIES for
onward transmission of information to ASD.

8.2.

FIRE:

Asst. Manager of the concerned Department will be the group coordinator for
tackling the emergency due to fire. Following are the action to be taken:
Switch off Electrical Supply and shout Fire,Fire, Fire to attract attention
Extinguish fire with appropriate fire extinguishers
Inform Fire Brigade (Ph No. 1440/1441)
Evacuate personnel trapped in the fire
Inform Medical Officer
Put barrier near flammable material
Inform Manager and Senior Officers
8.3

ELECTROCUTION:

Assistant Manager of the concerned Department will be the group

coordinator for tackling the emergency due to Electrocution. Following are the
actions to be taken:

8.4

Switch off Electrical Power Supply

If necessary administer CPR (Cardio Pulmonary Resuscitation)
Inform Medical Officer
Evacuate victim to dispensary
Inform Manager and Senior Officers.
ACID /ALKALI BURN :

Assistant Manager of the concerned department will be the group coordinator for
tackling the emergency due to Acid /Alkali Burn. Following are the action to be taken:

8.5.

Drench victim with copious water on the affected portions

Isolate the victim from chemicals
Inform Medical Officer
Evacuate victim to Dispensary.
Inform Manager and Senior Officers

ACID FUME RELEASE:

Assistant Manager of the concerned department will be group coordinator for

tackling the emergency due to Acid Fume release. Following are the actions to be
taken:

Use PPEs and isolate chemical

Isolate victims
Dilute chemical before allow to drain
Take all precautions to handle chemicals
Inform Medical Officer
Inform Manager and Senior Officers

CHAPTER 9

FIRST AID
GENERAL
First aid is primarily a temporary measure to arrest the deterioration of the
victims condition till the victim gets the proper and timely medical attention in the event
of an accident. This first aid is no substitute for treatment by a qualified doctor who must
be sought at once.
9.1

INSTRUCTIONS TO RENDER FIRST AID

9.2

Gather information as to how the accident or illness came about.

Look out for signs such as swelling, bleeding, immobility etc.
Check whether the victim feels thirsty, nausea, cold pain, numbness etc.
Pay special attention to severe bleeding, failure of breathing and shock.
Arrange for speedy removal of the victim to a proper medical care unit .
DO'S AND DON'T S OF FIRST AID

Do first things first quickly, quietly and without panic.

Stop severe bleeding, if any.

Administer artificial respiration, if required, and continue till the doctor arrives.

Treat for shock.

Boost up the morale of the victim to lessen his anxiety and to reassure him.

Avoid crowding around the victim as fresh air is essential.

Do not remove clothes, unless essential.

Do not try to achieve too much.

9.3
*

FIRST AID FOR SPECIFIC ACCIDENTS OR ILLNESS

TREATMENT FOR SHOCK

Reassure the casualty.
Lay victim on back with head low and turned to one side unless there is an injury to
the head, abdomen or chest when the head and shoulders should be slightly raised and
supported.
Loosen clothing about the neck, chest and waist.
Wrap victim in a blanket or rug to keep warm.
If, victim complains of thirst, sips of water, tea, coffee or other liquid (but not alcohol)
may be given.
Do not give anything orally if an anesthetic is required to be given to the casualty for
surgery.
Do not apply heat or friction to the limbs. Hot water bottles should not be used.
Remove urgently to hospital (Severe cases).

TREATMENT FOR SPRAINS

Ensure absolute rest for the victim till the arrival of doctor.
The affected joint should not be kept loose.
If possible elevate the affected joint.
Expose the joint and apply a firm bandage.
Wet the bandage with cold water and keep it wet.

*
TREATMENT FOR WOUND ACCOMPANIED BY BLEEDING
Place the causality in a suitable position, bearing in mind that blood escapes with less
force when the patient sits and still less when the patient lies down.
Elevate the bleeding part, except in the case of fractured limb.
Expose the wound, removing as little clothing as possible.
Do not disturb any blood clot already formed.
Remove any foreign particles which are visible and can be easily picked out or wiped
off with a piece of clean dressing.
Apply and maintain pressure directly with the thumb, fingers or Indirectly
compressing an artery at pressure points or by the use of constrictive bandage.
Apply a dressing, pad and bandage.
Immobilize the injured part.

TREATMENT FOR BURNS AND SCALDS

Avoid handling the affected area more than necessary, keep your hands clean by
washing them.
Do not apply lotions of any kind.
Do not remove burnt clothing and do not break blisters.

Cover the area with ready made burn dressings if available, otherwise clean gauze or
lint or freshly laundered linen or some similar material may be used.
Bandage firmly except when blisters are present or suspected in which case bandage
lightly.
Immobilize the affected area by suitable means.
Treat for shock.
In a major case, remove the patient to hospital as quickly as possible.
In a minor case, give large quantities of warm fluids preferably weak tea sweetened
with sugar.
TREATMENT FOR ACID AND ALKALI BURNS
Thoroughly wash the burnt part with water.
If burn is due to acid, bathe the part freely with an alkaline solution such as two
teaspoons of baking soda or washing soda in a pint of water. If burn is due to alkali,
bathe the part freely with a weak acid solution as vinegar or lemon juice diluted with
an equal quantity of water.
Apply the general rules for the treatment of burns as above but remove any
contaminated clothing immediately or prevent further injury. Take precautions
against burning yourself with contaminated clothing.
In the case of unconscious victim and difficulty in breathing, administer artificial
respiration at once.
Turn the face to one side, see that the air passage is free, remove the scrotum, if any,
by gauze or cotton.
TREATMENT OF AN UNCONSCIOUS PERSON
Ensure an abundant supply of fresh air and that the air passages are not obstructed.
Remove from harmful gases or impure atmosphere. Open windows and doors. Keep
back crowds and remove false teeth (if possessed).
If breathing has stopped or appears to be failing, turn the casualty into prone position
and start artificial respiration.
If breathing is not noisy lay the casualty on his back with the head and shoulders
slightly raised and support, and turn the head to one side. Be prepared to modify the
position, if breathing becomes difficult or obstructed.
If breathing is noisy (bubbling through secretions) turn the casualty into the threequarter prone position. Support him in this position with a pad in front of the chest or
draw up the upper knee. If the casualty is on a stretcher, raise the foot of the stretcher
to help to drain secretions from the lungs.
Undo all tight clothing about the neck, chest and waist.
Apply the specific treatment for the condition that has caused unconsciousness.
Wrap in a blanket but do not apply heat.
Do not leave the casualty until the casualty has been placed in charge of a responsible
person. Keep a continuous and careful watch for any change in his conditions.
Do not attempt to give food or fluids while the causality is unconscious.
Remove to shelter on a stretcher soon as possible.

9.4.

When casualty returns to consciousness moisten the lips with water. Unless an
abdominal injury is suspected sips of water may be given if victim complains of thirst.

TREATMENT FOR POISONS

General rules for the treatment of poisoning are:Removal of the poison
Skin or eye: Continuously flush with water the contaminated area. While
removing clothing wash the skin with soap or detergent. For eyes flush out with water.
Do not use chemical antidote.
Respiratory tract (Inhaled poisonous gases or fumes): Remove the casualty from
the contaminated atmosphere, clean out the air way, use artificial respiration and
oxygen, If necessary stimulate with smelling salts.
Gastro-Intestinal Tract (swallowed poisons):
Induce vomiting
(Only for
conscious patients). Stimulate vomiting with finger or spoon against the back of the
throat or if it fails give an emetic (two table spoon of salt to a tumbler to tepid water).
General remedies

Neutralize the poison by giving an antidote (a substance which reacts with the poison
and makes it harmless) For some poisons there are special antidotes. If the poison is
not known universal antidote may be used consisting of:
i. Two parts of powdered charcoal.
ii One part tannic acid and
iii. One part magnesium oxide
Home made substitute for Universal antidote is:
Two parts burnt toast.
One part strong tea and one part of milk of magnesia.

Dilute the poison by giving copious drinks of water. This will help to lessen the
irritating effect and to delay absorption in strong concentrations. It will also replace
fluid lost by vomiting.
Give soothing drinks- such as milk, barley water, raw eggs or flour beaten up with
water.
Symptomatic treatment and general measures to prevent collapse

a.
b.
c.
d.
e.
f.

Cover with a light blanket.

Do not use hot water bottle.
Raise the foot of the bed.
Give strong tea or coffee.
Smelling salt inhalation.
Injection of caffeine, adrenaline etc. depending upon requirements.

g.

Intravenous fluids like 5% glucose, normal saline, glucose saline or plasma,

plasma expanders or blood transfusions.

Preserve for examination

i.
ii.
iii.

Any remaining poison.

Any box, carton, bottle or other container which may help to identify the poison.
Any vomit matter.

9.5.

TREATMENT OF SPECIFIC POISONS

ACIDS

Do not make the casualty vomit. Give plenty of water or milk dilute the acid. Do
not use stomach tube as perforation may occur.
ETHYL ALCOHOL
Observe the general rules.
METHYL ALCOHOL
Observe the general rules.

ALKALIS/AMMONIA
Do not make the casualty vomit. Give plenty of milk or water to dilute the alkali. If
necessary give vinegar or lemon juice, citric acid, well diluted in water to neutralize the
alkali. Later, give about 100 ml. of edible oil or butter. Relieve pain and treat shock.
ALKALOIDS
Observe general rules. Use universal antidote.
BENZENE AND DERIVATIVES

If inhaled, remove casualty from contaminated atmosphere. If breathing has ceased,

give artificial respiration followed by administration of oxygen on resumption of
breathing.
If swallowed, give gastric lavago with 10-2-% sodium bicarbonate solution. Emetics
may be used.

CYANIDES

Place in open air in recumbent position.

Remove contaminated clothing.
Maintain artificial respiration.
If ingested, induce vomiting by tickling the back of throat by finger.
Give amylnitrite inhalation for 15-30 seconds every 2 minutes.
Combat shock.
Administer oxygen by forced ventilation.
CARBON MONOXIDE

Immediately remove from toxic atmosphere and keep the patient warm. Ventilate
the area fully. Loosen the clothing around neck, chest and waist. Give oxygen and/or
artificial respiration.

FLUORIDES (INSECT POWDERS)/ HYDROCHLORIC ACID

Lavage with lime water or with large quantities of milk or solution of any soluble
calcium salt.
Sodium or magnesium sulfate 30 gm. in 200 ml. of water.
Give white of egg beaten in milk.
Treat shock and give supportive treatment.
HYDROFLUORIC ACID BURNS

Immediately flush skin with lot of water spicily skin under the nail. Immerse in a
mixture of ice and alcohol. Remove contaminated clothing. Antidote is magnesium oxide
or calcium gluconate.
FORMALDEHYDE (FORMALINES)

Give milk freely or water with baking soda (once teaspoon in a glass of
water). Then induce vomiting.
MERCURY/BICHLORIDE OF MERCURY

Give egg white and charcoal powder followed by milk and make the patient vomit.
Give demulscents (raw egg and milk )
METHYL CHLORIDE (REFRIGERANTS)
Administer oxygen and/or artificial respiration. For skin contact flush with cold
water. Do not use oils or grease.

NAPTHALENES

Induce vomiting with salt.

Use demulcents- milk, egg white
Use Stimulants
Use Laxatives
PHOSPHORUS

Inorganic (Fire works, matches and some rat poisons).

i)
ii)
iii)

Make the casualty vomit

Give water copiously with if possible, a few crystals of permanganate of potash.
Do not give oils.

Organic (Oregano-phosphates, pesticides & sprays)

i)
ii)
iii)
iv)
v)

Antidote is atropine injection 2 mg. atropine I.M. every half an hour until
symptoms are relieved and signs of atropinization appear.
Induce vomiting and wash the stomach if ingested.
Sodium or magnesium sulfite 3- gms., in 200 ml of water
Give Oxygen if pulmonary edema and difficulty in breathing.
Give artificial respiration if necessary.
SILVER NITRATE

Gastric lavage with large quantities of salt solution ( 2 table spoonful) in 250 ml of
water.
Magnesium sulfite (Epson salt)/ 30 gms in 200 ml of water
Demulcent such as white of egg demulcents beaten in milk. In case of burns- soak in
salt solution.
SULFUR DIOXIDE
Administer oxygen and/or artificial respiration in case of breathing failure.
ZINC SALTS

Emetic rarely needed.

Soda bi-carb or pot bicarb 15 gms in 300 ml. of water
Milk and strong tea.
TREATMENT FOR GAS POISONING

In all cases of gas poisoning, call the doctor.

Remove the victim to fresh air.
Put the victim on a bed in a comfortable position.
Turn the face to one side, see that the air passage is free. Remove the sputum if any by
gauze or cotton.
In case of unconscious victim and difficulty in breathing, administer artificial
respiration.

CHAPTER 10

MEDICAL SURVEILLANCE
10.1

General:

The recommendations of this chapter are intended as medical guide lines.

Occupational physicians may wish to supplement these provisions to meet local needs
and to assist in proper evaluation of individual cases.

The PMO of Dockyard is responsible for the medical examination of workers.

10.2

Structure of the medical examination:

The pre-assignment medical examination of workers whose work is likely to involve them
in exposure to such environment should include:
A case history which include the occupational history of the worker
with
an
emphasis on the respiratory system andprevious occupational exposures.

A general physical examination.

Additional tests as necessary for diagnostic purposes, particularly in high risk groups
of workers.

The periodic medical examination for exposure should include:

A brief medical and occupational history.

A physical examination.

Additional test as necessary, for diagnostic purpose, particularly high risk groups of
workers.

The PMO/MO of Dockyard Dispensary should maintain a register in which all cases of
work related diseases are to be reported.

10.3

Frequency of medical examinations:

The periodic medical examinations shall be carried out once in a year.

The results of all medical examinations and supplementary examinations and tests
should be placed in the individual worker's medical file and be held in medical
confidence.

Under certain circumstances, it may be desirable to prescribe appropriate measures

or conditions in order to certify the worker's fitness for a particular job.

CHAPTER 11
GOOD HOUSEKEEPING
11.1
A clean and orderly work environment sets the tone for the entire
establishment. Good housekeeping encourages good work habits and boosts up
morale. It is also a big factor in accident prevention. Poor housekeeping promotes
poor morale and carelessness. Housekeeping plays a big role in recognition of hazards.
Plan to have a place for every tool, appliance and material. Avoid junk piles.
Have maintenance of equipment properly attended to.
Enforce reasonable rules about keeping the place in order. Train new employees, in
particular, to keep their work place clear and orderly.
Provide suitable and separate containers for scrap, oily rags and waste.
Keep the floor stairways, walkways dry and clean.
Enforce reasonable standards of sanitation.
Give full co-operation to all concerned in maintaining good house keeping.
11.2

UNSAFE PRACTICES

The following list represents the most frequently found unsafe practices in
industrial establishments. A large proportion of industrial accidents can be directly
traced to one or more of these practices.
Operation of machines at unsafe speeds.
Removal of machine guards
Use of defective or makeshift tools or equipment
Overloading, overcrowding bad storage or handling
Working under suspended loads, near open hatches, riding loads creating plant traffic
hazards.
Repairing or adjusting equipment in motion, under pressure, electrically charged or
containing dangerous materials.
Failure to use personal protective equipment s (e.g. helmets, respirators, safety
glasses).
Poor housekeeping and failing to remedy unsanitary or unhealthy conditions.
Horseplay

11.3

PERSONAL CONDUCT OF EMPLOYEES

All employees shall wear personal protective equipment as appropriate while working.
Every effort shall be made by the employees to maintain them in good condition.
Loitering around operating units is prohibited at all times.
Report promptly any situation affecting the safety of yourself or fellow employees.
Employees should train themselves to be on the lookout for regulatory signs and
should observe them at all times.
Bringing /consuming intoxicants inside the dockyard is strictly forbidden.
Jumping on or off the trucks, automobiles or other moving vehicles is prohibited.
Employees should wait until the vehicles stop before attempting to enter or leave.
Regular type barrel or drums are not to be used as supporting devices. Barrels or
drums should not be used to stand on or for supporting scaffolds or for any other
make shift purposes.
Employees should never use compressed air to clean the clothing they are wearing and
must never point air hoses toward a fellow employees.
Drive very cautiously in the yard within the specified speed limit. Go slow and sound
horn when approaching a blind corner.
Any person sustaining an injury on the job, however minor it may be, should avail of
first aid facilities in the centre and then report to the dockyard dispensary for
treatment as per laid down procedure. Where the injury is of a serious nature and the
employee is unable to report, the supervisor or others on the spot must arrange timely
medical aid and also promptly inform the immediate supervisor of the injured
employee.
Conduct which may be termed as horse play or playing the fool is strictly forbidden.

11 . 4

ENVIRONMENTAL
FRESH AIR

The following functions are very important and are required to be achieved by all
concerned to ensure healthier and better working conditions:

To supply sufficient quantity of fresh air at all work places.

To uniformly distribute the air throughout the work centres and other work places.

To ensure that atmosphere around is reasonably comfortable.

To remove the contaminants from the work environment.
To ensure that the room temperature shall not increase beyond acceptable units, air
movement of least 80 meters per minute is to be provided

To achieve the above working conditions the following may be ensured in work places
Natural Ventilation

Pressure head through wind action.

Thermal head
Chimney effect.

The easiest and effective method is to orient buildings for prevailing winds and
to have sufficiently large openings on the windward and leeward walls. Roof
ventilation is necessary when span exceeds 20 meters.
Mechanical Ventilation
Mechanical ventilation can be employed when natural ventilation is inadequate to
maintain reasonable conditions of comfort. Wall mounted oscillating fans to be preferred
to ceiling fans. The amount of fresh air supplied by means of mechanical ventilation in an
hour
shall be at least six times of cubic capacity of work place/room and shall be distributed
evenly throughout the work place/areas.

Extraction Systems

Exhaust ventilation by propeller fans

The inlet openings should be at least 3 times disc area of fans.
The openings near the exhaust fans should be closed to prevent short circuiting.
Suitable shields should be provided for exhaust fans to protect from rains etc.
Combined plenum and extraction systems are used to have better control.

Local Exhaust Ventilation

Local exhaust ventilation must be ensured in work-centres where
electroplating/surface preservation work is carried out. This is to be ensured by adequate
provision, maintenance of exhaust system by a hood closer to the source(tanks), ducking
and exhaust fans.

ILLUMINATION.

Work centres are to be suitably illuminated depending upon the type of work being
carried out. However, natural lighting is to be preferred to the artificial lighting. This can
be effected by introducing translucent plastic / acrylic sheets in A.C. sheet roofing.

Recommendations as per Factories Act 1948/Rules of Maharashtra state

SR.NO. AREA/WORK ROOM
ILLUMINATION IN LUX
(1)
a.

(2)
Stock room, Main entrance, exit,

MINIMUM

INTENSITY

(3)

OF

b.

c.

Roads, Catwalks of outdoor plants,

Storage areas.
Passageways, Corridors, Staircases
Warehouse, stockrooms of large
material, Platforms, outdoor plant,
Basements.
Engine room / Boiler room, Elevator
Conveyor, Store room for fine
material, Lock room , toilet, and wash basin

20
50

100

In addition to the above followings is recommended

SR.. Nature of work
Illumination in lux
(1)
(2)
1. where discrimination
of details is not
essential

Example

minimum

(3)
Handling of material
of coarse nature grinding
of clay product.

intensity
(4)
50

2.

Where slight
discrimination of
detail is essential

Product of semi finished

iron parts rough assembly,
milling, grinding,

100

3.

Where moderate
discrimination of
detail is essential

Medium assemblies rough

bench work, inspection &
testing products

200

4.

Where close
discrimination of
details is essential

Medium and bench work,

floor grinding ,welding sub
assemblies, drilling, riveting.

300

5. Where discrimination
Fine assemblies, fine bench
of fine detail is involved
& machine work, fine inspection
under fair degree of
fine polishing , fine wood working
work for long period
6. Where discrimination
Extra fine assemblies. Fine
of extremely fine
inspection, & testing , fine
detail is involved under
instrument, watch repairing
conditions which give
final packing, proof reading.
Extremely poor
Contrast for long period

500

1000

CHAPTER 12
PERSONAL PROTECTIVE EQUIPMENT
Employees working in hazardous areas will be required to wear protective
equipment such as gloves, safety shoes, overalls, helmets, goggles etc.
It is important that statutory requirements for the wearing of protective clothing
and equipment in certain hazardous occupations be observed. Necessary instructions and
orders are published collectively from time to time, and advice of Factory Inspectors,
whenever applicable should be sought as appropriate. In order to ensure adequate
protection for workers employed in enclosed compartments or in other sheltered places or
during oxy-acetylene or other welding operation or lead and lead painted surfaces, where
noxious fumes are given off, they are to be provided with and to wear appropriate face
masks / shields / breathing apparatus.
The attention of Managers is drawn to the fact that where factory orders and regulations
made under the Factory Act provided for the issue to employee of items of protective
clothing and equipment for use when engaged on specific processes, it's not enough that
the items are provided for use. In addition, all steps must be taken to ensure that the
worker uses the equipment provided for his protection. Strict orders should be issued
regarding the use of protective clothing and equipment and must be exercised to ensure
that the instructions are complied with.
12.1.
Safety Belts - In general, all employees shall wear safety belts to give
protection in performing jobs at elevated location where adequate protection against
falling is not available.
12.2
Head Protection - All employees shall wear safety helmets while working in
areas where the job/environment demands head protection. Safety helmets for such
personnel have been provided by the Dockyard. All effort must be made by employees to
maintain them in good condition.
12.3
Eye Protection
Because of the seriousness of eye injuries, it is vitally important that employees use
appropriate eye protection equipment when eyes are exposed to possible hazard.
Industrial safety goggles, should also be worn while working on the metals and their
alloys, with the machinery running at high speeds.
No one, unqualified shall try to remove a foreign body from the eye prior to reporting
to the Dockyard Dispensary. Prompt treatment by the medical centre is essential.
There are several types of eye protection equipment available in the yard, and it is
important that employees use the proper type for the particular job. It would be
difficult to compile a list, which would include all the possible jobs requiring eye
protection. The following types of work, however, can be classified requiring eye
protection.

12.6

CUP TYPE / CHIPPERS GOGGLES.

Using hammer or doing any other work involving metal to metal or impact between
any hard objects.
Using grinding wheels, buffing machines, or any other abrasive tools (Goggles are
required even though glass guards are provided.)
Chipping, cutting, shearing, breaking or drilling metallic materials or masonry.
Scraping or buffing metal surfaces.
Cutting or handling spring wire and scrap steel.
Driving rivets, or doing other types of rivet work.
Chipping and caulking metal with either hand tools or mechanical tools.
Using anvil and other blacksmith tool, either mechanical or the hand type.
Operating any power machine tools, including those at the mechanical shops.
Working in cramped quarters under equipment such as motor vehicles, machines etc.
Using a pick ax or other such tool on roadways or hard surfaces.
Cleaning bricks and other masonry.
Cutting, breaking or chipping glass.
Melting, pouring or handling any molten metal, asphalt etc.
Cleaning tubes of fired coils, heat exchanger equipment etc.
Handling loose asbestos of insulating material.
Operating cement guns.
Using paint spray guns.
Working where rust, dust, sand or other foreign objects are blowing about, specially
in foundry complex and shot blasting on ships hull prior to painting.

Work requiring use of Goggles with special colored lens

Welders, gas cutters and employees having to work near them shall wear goggles
equipped with the approved colored lens to avoid eye injuries from the harmful rays.

12.7

RESPIRATOR PROTECTION

Personnel shall equip themselves with proper gas masks whenever it is necessary to
work where toxic gases or vapors are present.
It should be remembered that all gases, other than air, are harmful to humans being
if inhaled in high concentrations. The action of these gases may be classified as either
asphyxiating or irritating. Asphyxiating gases may cause death by replacing air in the
lungs or by reacting with the oxygen carrier in the blood. Irritating gases may cause
injury or death not only by these methods but also burns, both internal and external.

In order to guard against the inhalation of harmful gases employees should:

Secure necessary permission before opening or entering equipment/compartment.

Provide positive ventilation as required.

Wear dust or fume respirator as required.

Employees should know where gas masks are located in work areas, and should learn
how to use them properly.
It is essential that employees do not work in oxygen deficient atmosphere.
In
general, to sustain life, the oxygen concentration of any atmosphere must be over 16
percent by volume. To achieve this ,positive and effective ventilation must be ensured,
few hours before entering such spaces.

12.8

OBLIGATION OF WORKERS :
No worker in a factory:--

Shall willfully interfere with or misuse any appliance, convenience or other thing
provided in a factory for the purpose of securing the health, safety or welfare of the
workers;
Shall willfully and without reasonable cause ,do anything likely to endanger himself
or others; and
Shall willfully neglect to make use of any appliance or other thing provided in the
factory for the purpose of securing the health or safety of the workers ;

12.8
If any worker employed in a factory contravenes any of the provisions of
this section or any rule or order made thereunder, he shall be punishable with
imprisonment for a term which may extend to three months, or with fine which may
extend to one hundred rupees, or with both.
12.9
PRINCIPLE: The working environment in a factory needs to have
protection to the body parts due to hazards in the work. For the purpose of protection of
the body parts special safety devices have been designed and are in use. To reduce the
effect on the injury as well as to reduce the number of accidents in the industry personnel
protective equipment is one of the means.
12.10
GOVERNMENT SANCTION: The Government of India has given
sanction for the required number of PPEs which needs to be utilised by concerned
people in the yard.
Present inspection in the yard by Safety professionals indicates a large amount of
defaulters in the utilization of the basic minimum of safety gears by majority of work
force. Inspite of availability in the required quantum the personnel are taking chances to
work near hazards by not wearing the safety gears.
12.11

RESPIRATORY PROTECTIVE EQUIPMENT

(RULES FOR PROPER USE)

Personnel required to use respiratory protective equipment should be familiar with its
capabilities, limitations and care.

Only respiratory protective equipment approved and prescribed for a specific purpose
should be used.

Air purifying type canister gas masks should not be used in oxygen deficient
atmosphere, or for gases whose concentration is unknown or great enough to over
helm the canisters capacity.

Personnel should be familiar with proper method of fitting, testing, and maintaining
protective equipment. Supervisors should institute courses of instruction to familiarize
users with equipment, and scheduled practice session to maintain their proficiency.

Personnel should make certain that their equipment is fitted and working properly
before entering in to hazard area.

Protective equipment should not be removed while the user is in the hazard area.

The user should leave the hazard area as soon as a warning device indicates that the
protective equipment is near exhaustion. No attempt should be made to exceed time
limitation.

A person wearing protective equipment in a contaminated atmosphere should

immediately leave the area if he feels sleepy, detects any unusual odor, or feels any
irritation of the eyes, nose, or throat.

No attempt should be made to use equipment for a purpose for which it was not
designed or for which it is unsuitable.

Equipment that is poorly fitted or in poor condition should not be utilized. If

protective clothing is damaged while the person is in the hazardous area, he should
leave immediately.

Personal protective items which seriously reduce vision, unduly reduce mobility or dexterity,
or create other difficulties should be reported to the supervisor or Safety
Department.

PART : 3
ENGINEERING

PRODUCTION OPERATION

CHAPTER 13
STAGING AND WORKING AT HEIGHT

Sufficient supply of requisite material and appliances shall be available in a

convenient place for the construction of staging.

All planks and other materials and appliances intended to be used or reused for
staging shall be carefully examined by a senior supervisor/Asst.Manager before being
taken into use in any staging.
Staging plank should be of good wood or of any equivalent quality and should not be
less than 27.5 CMS width and 6.5 CMS thickness.
Trestles, planks and ladders are to be kept in good condition, and if found defective
after use, should be replaced.
Staging planks must be laid evenly in the same horizontal plane, and the ends must be
securely lashed.
Due to the nature of work, alterations to the staging may become necessary. Great
care must be taken at this stage to check the condition of the staging to ensure that it is
safe before the work recommences.
Staging should not be less than the width of two planks (55 CMS) for simple jobs like
load-line marking, painting, drilling test holes, burning of rivets, cutting of the plates
or ring welding the rivet heads.

 For difficult jobs like handling of the shipside plates (removal or renewal), caulking of

the seams and riveting etc. the staging width should not be less than three planks
width (75 CMS) along the parallel portion of the ships hull.
The places where the ship's contours change rapidly near the bow and the stern of the
ship for all difficult handling of job the staging should be at least of four planks width
(110 CMS). It may be more depending on the job in hand.
Whenever staging is required to be suspended from the ship's main railings, special
attention should be paid to the length of the suspended support shores for the staging
planks. These shores must firmly rest against the ship side plates. The planks should
be lashed up firmly with shores. The materials used for lashing of the staging is of
utmost importance, and the supervisor in charge should ensure that standard lashing
material which would take the strain is supplied to riggers to use along with outer
staging material. All supervisors must ensure that worn out material is not used, even
if it is supplied.
Particular care needs to be exercised while preparing the type of staging, popularly
known as "MARY PARANJA' used near the ship's bow. No adjustment in the "Mary
Paranja" should be carried out while the work men are on the staging. If minor
adjustment is found necessary, the workmen on the staging should be properly
cautioned before shifting the guy ropes and they must have their safety belts on. A
ladder giving access to this staging must be properly secured and must be in good
condition.
Not more than two workmen should go on the staging described above. Under no
circumstances, the workmen on this staging should be left unattended especially when
the vessel is in dry dock.
For any type of staging the gap between the work face and the staging should not be
more than 25 CMS unless in cases where the configuration of the work place is such
that the gap should necessarily be more for the convenience of the work. In such cases
greater vigilance and safety precautions all round, are necessary, such as lifelines etc.
Staging should be lashed firmly to prevent it from swinging.
When the shipside plate is required to be dislodged from its position, for its renewal, it
is essential that the plate be anchored with a nut and bolt not more than 15 / 20 CMS
long in order to prevent it from springing out suddenly and striking against any part
of the staging, thereby endangering the workmen on the staging.
Lighting - Maximum visibility is essential both for good workmanship as well as for
safety. All officers should ensure proper lighting on the staging. This is particularly
important when the staging is used in dry docks.
Safety belt and life lines: - Safety belts and helmets have been provided in sufficient
quantities and it is the duty of all officers and supervisors to ensure that these safety
belts are in good condition and are used where required. The requisite number should
be maintained in stock for use at all times.
While using a safety belt, the length of the cord should be adjusted to keep it shorter
than the height of the operation, which is to be carried out.
Whenever ropes are used on suspension staging they should be revved through pulley
block or fairlead roller guides to prevent the ropes from being chafed or damaged by

coming in contact with sharp edges. Under no circumstances must the ropes
suspending the staging on ship's side pass over edges of sharp /shearing edges.
In case any alteration in the staging work is necessary as the work progresses, it
should be done properly with safety consideration in view and any makeshift
arrangements should be avoided.
During prolonged jobs, frequent checks must be made on the condition of the staging
to ensure that it is safe.
In ship repair work, it is not always possible to provide firm railings all around the
plank staging. However, all possible efforts must be made to tie guard ropes on the
outer edge of the shipside staging, to provide protection. Particularly when work is
being carried out on board submarines proper railings or guard ropes to be rigged all
around on the upper deck area to prevent any person falling over.
While working on air ventilators of ships under repair, proper staging shall be erected
to reach the place of work, regardless of the size, nature and the extent of work.
If the contingencies are such that either making or standing on plastic translucent
roofing shade becomes imperative, a wooden plank of at least 30 CMS width and 2
mtrs. Length shall be used to walk or to stand on such plastic sheets or on any other
brittle material.

Note: This will distribute the load evenly over wider area and chances of a worker falling
through due to cracking of the sheets will be prevented.

If the wooden plank used is of shorter length, care must be exercised to see that it
spans adequately and well over at least two parallel members of the steel structure,
supporting such roofing.
All the above precautions shall also be observed while doing pre-monsoon cleaning of
the A.C.C. roofs/other roofs of all shops in Naval Dockyard premises.

When ship side painting and repair work is going on, the worker working at heights
must not be required to hold the tools, paint can etc. with his hands. These equipments
and accessories should be independently suspended so that the working hands are free
for safeguarding and supporting him in an emergency.
When work is required to be carried out on the mast of a vessel, electric supply to the
mast must be switched off and when work is done at night, portable hand lamps must
be made available.
While working at heights the extent of hazards and the magnitude of its consequences
should not be judged from the minor nature of work or short duration for which the
job is required to be done or for the technical importance of the job. Any false notions
along these lines could lead to unsafe makeshift arrangements, leading to lack of
consideration of safety and accidents.

CHAPTER 14
SAFETY IN CONFINED SPACES
14.1 A confined space is any area that is not designed for continuous human occupancy.
It has limited accesses and ventilation. It is also susceptible to hazard such as inundation
of water, gas or solid particles or it may have slopping side such as a bin or hopper that
leads to a crusher, auger or restriction. Other hazards are oxygen deficiency, radiation,
toxic gasses or vapour, fire and explosion, electric shock etc.
14.2 Therefore, it is necessary to identify confined spaces, carefully review the
operation and decide the line of action to be carried out. Secondly, identify the potential
hazard and method of elimination. Finally, develop a work permit system/form to
carryout work safely. The danger should be well defined and known to all persons
involved in such operations.
14.3

`WORKING IN CONFINED SPACE / ENCLOSED VESSEL

Assistant manager/ supervisor of the department should personally see the

following: -

Ensure continuous ventilation before and during the work.

Approve the work to be accomplished which necessities entering in tank, confined or
other hazardous spaces.
Notify and co-ordinate activities with safety officer, industrial hygienist and other
concerned people.
Approved procedures and work methods to be followed.

No naked light shall be taken in a tank or confined space where flammable

liquid/gases are present.
Examine and approved PPE to be worn and rescue equipment available on hand.

Determine that the personnel are familiar with the task to be accomplished,
procedures to be followed, hazards involved, equipment to be used, precautions to be
taken and signals in emergency to be observed.
Determine that the personnel are physically capable of accomplishing their assigned
task.
Determine methods and manner by which confined space or tank will be isolated.

Ascertain that space has been suitably prepared for entry.

Make sure that the space or tank is clean and is fit for work.
14.4

ENTRY IN CONFINED SPACE OR TANK

Following shall be carried out: -

 Isolate all incoming product lines, interconnected vent lines and cross connection lines.

This shall be done by blanking then off with blind flanges or by disconnecting them.
Shutting off valve generally will be unsuitable, since valve may leak. Tag them
properly. Check list should be provided for this purpose.
Gasket shall be used with blind flanges to prevent damage to valve piping and tank
fittings.
Tank / confined space shall be emptied to the maximum possible extent, before
disconnecting lines, valves.
Check, tank/space visually and verify. Ventilate with copious supply of air through
blowers at least for 24 hours.
If required clean it by water or purge with air, steam, nitrogen or any other
neutralizing agent/solution or blanketed with inert gases which will depend upon the
material in tank/space, before hot work is conducted.
The manhole on tanks or space should be kept opened until prescribed work has been
completed.
No person should enter in tank/space without his immediate supervisor's permission
or without taking necessary precaution indicated.
The buddy system must be used, when one man enters tank/confined space, one
should remain out side. The outside man should be physically able and equipped to
remove man from inside the tank if necessary.
The outside safety man should remain in position at all times where he can either see
the man in the tank or receive communication at all times during work. If he cannot
see or communicate with the man in tank, he should investigate immediately and
obtain assistance, if necessary.
Personnel entering a tank or confined space should be sure that there has been an
adequate air purge of the tank. Canister masks (respirator) should not be used in a
tank or confined space where possibilities of toxic gases may be present or may occur.
A worker should not enter a tank if his PPE clothing is torn or damaged in any way. If
the clothing is torn while entering tank, he should leave immediately.
Bulk breathing apparatus such as large backpacks should not be removed to enter a
tank through restricted openings. Equipment that is more suitable should be used in
such situation.
The outside man should keep a record of time that the other worker spends in the
tank. If the tank worker is issued with a self contained apparatus, he should be
warned, when the air supply approaches the point where it should be replenished.
A worker entering a tank should be equipped with a suitable body harness to which a
lifeline is attached. The free end of lifeline should be secured to a constrained fixture
outside the tank so that it cannot be drawn or dropped through manhole.
A block and tackle should be provided to the tank, which can be used by the
safetyman in extreme emergency. If there is no other suitable structure outside, a
tripod should be erected over the manhole and the block and tackle should be
attached or hung to the tripod.

 Rescue equipment should be kept outside the tank, ready for use at all times.
In an emergency, the outside man should not enter the tank or confined space, until he
has been relieved by another qualified person. To attract other worker's attention,
prearranged signals, whistles or some types of electrical communication can be used.
If more than one man are to work in a tank or confined space, the number should be
kept to the absolute minimum possible.
14.5
Following instruction shall be strictly followed while welding and cutting in
a confined space: -

Welding and cutting operation should not be permitted in or near the places, which
contains flammable or combustible vapours, liquids, dust or inside the tanks or other
containers which have held such materials, until all fire and explosion hazards have
been eliminated.
All the surroundings should be thoroughly ventilated, and frequent gas testing
provided.
Local exhaust system should be provided for removal of hazardous gases, vapours and
fumes.

The accepted method for preparing tanks for any hot work is :

a) Remove all sources of ignition i.e. open flames, unguarded electric lights etc. from the
vicinity of the tanks/confined spaces.
b) Test the tank/confined space for the presence of flammable vapour with a gas
indicator. Test for toxic contaminant and for oxygen sufficiency or enrichment if
personnel are to enter.
c) Make similar tests when welding repairs are performed. If the operations extend over
an appreciable period, make repeated tests.
d) Respiratory Protection If gases, dusts and fumes cannot be kept below the Threshold
Limit Value, welders should wear respiratory protective equipment certified for the
exposure. Where Oxygen is also deficient, self-contained breathing apparatus with
hose masks and blowers are necessary.
e) Medical Control: A replacement medical including chest X-ray and lung examination
is recommended for all persons engaged in welding and periodic check shall be
carried out and record maintained.
f) Eye Protection: Goggles, helmets and face shield that give maximum eye protection
for welding and cutting process should be worn by operators, welders and their
helpers.
g) Disconnect the power on arc welding and remove the electrode from the holder. Turn
off the torch valves on the gas welding or cutting units, shut off the gas supply at a
point outside the confined space, remove the torch and hose from the area.
h) Keep away all personnel from the job since it will be hot.
i) Follow the safe Housekeeping principles. Do not throw electrode or rod stubs on the
floor. Discard them in proper waste container.
j) Use equipment in accordance with manufacturers instruction and practices.

CHAPTER 15
NOISE AND VIBRATIONS
15.1

Elimination of Vibrations and Noise:

In industry, noise and vibration are some of the causes for accidents as also for
occupational injuries. These are to be controlled to eliminate unpleasant after effects.
Some of the control procedures are enumerated below.

Determine whether an operation, process or piece of equipment that is noisy can be

avoided or eliminated by use of a quieter one. Use press instead of drop hammers.
Select and operate rotating and reciprocating equipment such as pumps, fans, motors,
and presses. Use large, slow operating machines instead of small fast ones with the
same capacity.
Mount equipment that could vibrate, on firm, solid foundations, which do not permit
it to vibrate. Make certain that foundation bolts are kept tight.
If equipment vibrates, determine whether its characteristics can be changed by use of
such devices as dynamic dampers, rubber or plastic bumpers, flexible mountings and
couplings, or resilient flooring.
Keep velocity of fluids, such as air flowing in ducts and jets or liquids in piping, at the
lowest speeds possible. Avoid sudden direction and velocity changes in pipelines and
ducts.
Do not use quick acting valves in liquid system, which could cause water hammer. If
water hammer does exist, replace with slow acting valves or install accumulators to
eliminate the problem.
Make certain that the piping is firmly secured to prevent rattling.
Provide noise absorbent lining on air ducts and mufflers on openings through which
air must pass.
Ensure that periodic maintenance minimizes vibration and noise which might be
generated by keeping the equipment in condition where it is free of chatter, impact
and similar noise generating motions. Replace, adjust and tighten worn, loose or
unbalanced machine parts.
Locate noisy activities and equipment far from other operations.

15.2

ELIMINATION OF NOISE & VIBRATION BY ISOLATION

Locate noisy activities, such as individual machines, in sound absorbing enclosures, or

provide barriers between such activities and other locations where personnel are
present.

Ensure that floors, walls and other structural features do not vibrate and transmit
vibrations and noise to other locations.

Where vibration of fixed equipment cannot be eliminated, mount it on vibration

isolators to prevent transmission of motion.

15.3

ELIMINATION
PERSONNEL

OF

NOISE

&

VIBRATION

BY

ISOLATION

OF

If only one or two workers must remain in a large, noisy area, determine whether they
can be isolated in an acoustically quiet booth or any other enclosure.

If the noise level cannot be reduced to a maximum of 85-dB (A), provide workers with
hearing protection devices.

Attempt to schedule personnel so that they remain in high noise level areas for
periods, which are as short as possible.

Ensure that areas where hearing protection devices should be worn the workers are
warned of the hazard and the necessity to use protective devices.

Ensure that workers who must wear hearing protection devices such as ear defenders
be initially advocated medical advice.

All supervisory personnel should ensure that workers wear their protective equipment
at all times while they are in high noise work areas.

Arrange work schedule so that work at high noise levels for extended period is divided
among two or more persons.

Since Noise Induced, Hearing Loss is an occupation disease as per Factories Act 1948.
Following permissible exposure limit shall be followed through out working hours.
--------------------------------------------------------------------------------Sound pressure level
Total time of exposure per
in dB(A)
day in hours
---------------------------------------------------------------------------------

90
92
95
97
100
102
105
107
110
115

8
6
4
3
2
1.5
1
0.75
0.5
0.25

No exposure in excess of 115 dB(A) is to be permitted.

Pre employment, periodical audiometry survey shall be conducted for all worker who
are involved in noisy areas
Effective hearing conservation programs shall be carried out and record of all
workers working in such areas. Records of the same shall be maintained.
Effective ear protectors shall be provided and ensured that workers involved in such
areas wear it.
Audiometry test shall be conducted by certified surgeon and if required rehabilitation
of such worker shall be done.

CHAPTER 16
MATERIAL HANDLING
Unsafe ways of material handling are major contributing factors for occurrence of
accidents particularly in handling of materials. The natures of injuries resulting from
accident because of unsafe material handling are as under:

Object slipping or dropping down on foot or other part of the body.

Pressed in between the object and lifting tackles.

Cuts due to sharp edge of material or sharp corner of stack.

Burns due to hot or corrosive substance.

Sprains while lifting materials by wrong method.

16.1

PROCEDURE FOR SAFE MATERIAL HANDLING

If the load is too heavy to lift by one person ask help from other.

While shifting heavy materials by more men from one place to another, the job
should be carried out under the direct supervision of a responsible person on site,
While carrying or lifting long material on ladder (pipes etc.) two or more men
should be similar in size and physique. They should keep the front and the material above
the height of any person to avoid any body injury.
The material should be gripped firmly and then lifted with proper posture and
sure footing.
Leather hand gloves should be worn while handling sharp materials or steel plates,
rubber gloves for corrosive liquid and acids, asbestos hand gloves for hot material, hand
pads or shoulder pads while lifting or carrying heavy objects.

16.2
DO'S AND DON'T FOR HANDLING OF MATERIAL BY
MECHANICAL MEANS

DOS

The operator must be physically and medically fit and officially authorized for
operation of crane.
Regular inspection and proper maintenance must be carried out in conformity with
safety rules and Factory Act.
Overloading must be avoided.
Everybody must keep themselves away from the load during lifting or lowering the
load or during swinging the boom and the cab.
Only one person should give signal during lifting or lowering or transporting the load
etc.
DONTS

Heavy load should not be lifted beyond safe working load of the crane.
The load as well as the crane should not be moved /shifted unless the floor and
pathway are clear.
The load should not be allowed to swing fast.
Nobody should be allowed to work under the suspended load.
The boom of the crane should not touch overhead H.T.lines during the operation.
The slinger should not keep hands or fingers near the pinch point of the load.
The operator should be strictly instructed not to carry the load over men working on
the shop floor/dry dock floor.
The operator should not perform more than one operation at a time to avoid
confusion during slinging etc.

16.3

SAFETY of IMPORTANT PARTS.

The following important part of crane must be regularly inspected taking the
minor details into account by the operator and the maintenance personnel.
Brakes - (normal/emergency)
Hoisting cables and hook block
Wire Drums
Limit switch (it should be checked against maximum safe height of pulley block can go
beyond which limit switch lever must cut off the power supply to the lifting motor)
Controllers (electrical or mechanical defects which give faulty operations)
Alignment of bridge (scratching or squalling wheels indicate that the bridge is out of
line)
Broken or cracked or chipped rails, trolley or runway.
Condition of gears (grinding or swiveling) indicates lack of lubrication or foreign
material in gear teeth.
Safety guards, foot walks associated side rails and toe holder (bent, broken or lost)
End stops on trolley or bumper on bridge

Frequent tripping of power , overload relay

Mechanical parts loosened by vibration(loose nuts, cover etc)
Bumpy riding(worn wheel)
Collector shoes or bars(worn out, fitted loose or broken)
Warning or signal lights
Lubrication
Couplings or bearings

16.4

SAFETY RULES TO BE OBSERVED IN WORK CENTERS

Hand gloves must be used while handling materials with sharp edges (i.e. steel, timber
cutting tools, wire wound boxes etc)
Helmets must be worn while handling materials on board ships, in the dry dock,
under E. O. T. Cranes/in shops/in stores sections having elevated racks. Safety shoes
must be used while handling steel, timber and scrap.
Tight fitting goggles, respirators or filters and protective clothing that fits tight at the
neck, wrist and ankles must be used while handling cement. They must also use hand
gloves.
Delivery of heavy materials, from and to, stores should be made with the help of
trolleys and forklifts. Regular check up, repairs and maintenance of the trolleys and
forklift should be carried out.
All ropes, shackles, slings, ladder etc must be checked thoroughly so as to ensure
soundness of the same before they are used. The defective items must never be used
but sent for necessary repairs/test in C. No. (13/17). Proper records should be
maintained in regard to history of every item. Only the correct size of ropes, shackles
should be used.
In case of racks, the light material should be stacked on the upper shelves and heavier
material in the lower shelves.
While using the ladder, it should be ensured that top and bottom of the upright
members are secured properly. If necessary, a person should be stationed at the base
of the ladder. The man using the ladder should not carry anything in his hands. He
should hold the rung with one hand and upright with the other. The material should
be hoisted and handled by suitable equipment (pulley blocks, chains, rope etc). The
ladders must be periodically examined and proper records maintained.
The workman should be at a safe distance from the handling area while the crane/fork
lifts are in operation.
While using chain pulley blocks, rope shackles etc for lifting of items, load limit must
not be exceeded.
While unloading gas bottles of Carbon dioxide, Acetylene, Oxygen, and Freon from
the truck, coir mattress must be used. The cylinder should be stored in upright
position and should never be dropped or used as rollers. The cylinders must be always
with caps without which the cylinders should not be accepted.
Stacking must be done on the ground in lots with a minimum of 60 CMS of passage.
Never throw a box or package upon a high pile. The whole pile may topple over.

Bags of material should be piled so that the layers cross each other at right angles and
as far as possible piled with the bag mouth away from the aisle where it may get
caught on something.
The floor of the stores must be kept clear and absolutely free from oils grease,
lubricants, paints etc by good housekeeping. Empty packing cases, packing materials
such as straws, paper shreds etc. should be removed daily.
While EOT cranes are in motion, in the process of handling materials, warning alarm
bells should be used so as to keep man / material / equipment clear off the handling
area.
If the lighting arrangement fails in any of the work centers it must be immediately
brought to the notice of the yard services department for restoration.
Saw dust, fire wood, sludge oil and other material which are potential hazards for fire
must not be allowed to accumulate and should be disposed off quickly.
While stacking the materials in the stores and godowns, the load bearing capacity of
different floors must be taken into consideration. Stacking heights should not be more
than 210 CMS other than for ground floor and below 75 CMS from the ceiling.
While using cargo lifts the capacity of the lift should never be exceeded.
Timber and paint must never be stacked together.
Accumulation of scrap material especially in and around dry dock area is not
permissible; arrangement for removal and disposal of scrap is to be done on priority
basis.

16.5

USEFUL HINTS - LIFTING GEAR

Lifting Gear - Ropes, Chains, Slings, Chain Block, Pulley Blocks, Hydraulic Jacks,
EyeBolts, Shackles, Beam grabs, Plate lifting clamps.

Keep Lifting Gear in a rack when not in use.

Avoid dragging Lifting Gear along the floor.
Avoid trapping Lifting Gear under a load.
Always protect Lifting Gear by using padding over sharp covers.
Always keep Lifting Gear away from welding or cutting operations.
The minimum radius around which a wire sling should be bent is three times its
diameter.
Alloy steel chain slings can be safely used in extremely low temperatures. It is
unnecessary to heat them, in fact, heat treatment is detrimental to the quality of chain
and exposure to any source of heat must be avoided.

16.6

Safe use of Lifting Gears

All Lifting gears shall be marked with their maximum SWL safe working load in tons
or kilograms and their diameter in millimeters.

Always select the correct size and type of lifting gear for the load.
If there are any obvious defects or any doubt of fitness for use, a sling should not be
used but replaced at once.
Take into account the maximum included angle between the sling legs and the
possibility of unequal loading.
Never take chances; the result may cause serious or fatal injury and damage to
materials.
Slings must not be twisted, kinked or knotted.
Make sure that the load is properly supported in the bowl of the hook.
Make sure that eyebolts are not loaded beyond the safe working load
Avoid snatch or sudden loads.

16.7

SAFETY POINTS :-Rope slings, Wire slings, Chain slings, Rope blocks, Chain blocks, Pulley blocks,
Eye bolts, Shackles, Beam grabs, Plate lifting clamps, and Hydraulic jacks.

Do not use the lifting gear if in worn out /defective condition.

All lifting gear must be tested once before using.
All lifting gear must be tested for its SWL and marked on it with the future date of
testing.
Any distortion /crack on any lifting gear found during inspection is to be rejected for
material handling.
Storage of all the lifting gear is to be done in a proper place and should be accessible
for use at all times.
The maintenance of the lifting gears should be done by the trained personnel.
Certification of load to be lifted is to be issued by a competent person.
Keep all lifting gear away from fire, acids, alkalis, oil, and grease.
Regular maintenance with approved procedure followed for the upkeep of the lifting
gear.
Over loading of the lifting gear should be avoided to reduce accidents.
All lifting appliances should be marked with its S.W.L. on the lifting appliance itself,
and a chart showing the safe load that can be lifted should be displayed at prominent
locations of the work places.

16.8
SAFE LOADS FOR SHACKLES
SWL Large bow mild steel shackles per BS 825 (1949)
Safe working
dia of Shackle
Dia of Pin
Load in Tons
in CMS
in CMS
(W)
(d)
(D)
O.4
O.6
1
1.5
2

9
12
15
19
22

12
15
19
22
25

2.8
3.4
4.2
5.5
6.5
7.2
8.8
10
11.5
14
17
20
25
30
35
40
50
60
80
Notes: a.
b.

25
28
31
34
37
41
44
47
50
56
63
69
75
84
87
97
106
109
115

28
31
34
37
44
47
50
53
56
63
69
75
81
90
97
103
115
125
144

Proof load =2 x safe working load (w)

Always check SWL stamped on shackle before use.

16.9

SAFE LOADS FOR EYEBOLTS

(BS 4278 1968)

Single vertical lift Non vertical lift per pair in tons

Isometric
In tons Included Angle Between Legs
Thread Dia.
In degrees
30
60
90
In mms
-----------------------------------------------------------------------------------------------------0.32
12
0.63
16
1.2
1.6
1
0.63
20
2
2.5
1.6
1
24
3.2
4
2.5
1.6
30
5
6.3
4
2.5
36
8
10
6.3
4
45
10
12
8
5
52
12
16
10
6.3
56
16
20
12
9
64
20
25
16
10
70
SAFETY NOTES

Always check the SWL stamped on the eyebolt and its test date

Only use eyebolts with collars for inclined loads and ensure they are screwed down
firmly to the collar
Always keep inclined loads in the plane of the eye
Adjacent to isometric tapped holes should be stamped thread details to identity the
thread and the max. Safe vertical load for the size of thread.
Eye bolts as per BS 5259 (1944) with BSW are still in use and care should be taken to
prevent threads being damaged by misuse.

PART : 4
ELECTRICAL PRODUCTION
SYSTEM

CHAPTER 17

FIRE FIGHTING AND FIRE FIGHTING

AGENTS
17.1

THE FIRST FEW MOVEMENTS ARE VITAL

In all cases of fire, speed in raising the alarm and immediate use of suitable fire
extinguishers in the incipient stage is very essential. Fire fighting equipment and
appliances should be checked frequently and should always be maintained ready for
immediate use. Responsibility of periodic checks and inspections must be clearly defined
and individuals be made accountable.
17.2

THEORY OF FIRE FIGHTING

Fire requires a combination of fuel , oxygen and a source of heat. Combustible or

flammable substances, when heated, gives off vapour which will burn if ignited, when
mixed with an appropriate quantity of oxygen, from the air.
Fire can be controlled and extinguished by the removal of any one of the elements
such as heat, fuel or air. The main aim when fighting fire must therefore, be to
reduce the temperature or remove the fuel or exclude the supply of air with the
greatest possible speed.

17.3

TYPES OF FIRE

Fires may be divided into three classes which require different extinguishing
agents and different fire fighting techniques. These are:

Combustible Material Fire

Common examples of combustible materials are bedding, clothing, cleaning rags,
canvas, ropes and paper etc.
Cooling by large quantities of water, or extinguishing agents containing a large
proportion of water, is of primary importance when fighting fires in such ordinary

combustible material. Cooling of the source and surrounding area should be continued to
ensure that no re-ignition is possible.

Flammable Liquid Fire

Common examples of flammable liquid fire are petroleum, cargo or bunkers,
paint, vegetable oil, etc. Cut off the flow of liquid from the source if possible. Exclusion of
air by smothering or blanketing is necessary for fighting such fires .This is achieved by
the use of foam, steam or water. The other method is by inhibiting the propagation of
flame by using vaporizing liquids and dry chemical powder.

Electrical Fire
A non conductive extinguishing agent is essential when fighting fires in electrical
equipment like carbon dioxide, bromochlorodifloromethane which is a vaporizing liquid
or dry chemical powder.
Highly sensitive electrical equipment may be damaged by the use of dry chemical
powder.
17.4

IGNITION SOURCES
There are many sources of ignition, some of them are :--

Careless disposal of lighted match sticks and lighted cigarette butts.

Open flames including smoking ,lighted matches and cigarette lighters.
Hot flying particles such as burning items, welding and cutting sparks.
Sparks from mechanical and friction sources.
Sparks or arc from electrical equipment
Hot surfaces such as hot machinery and high temperature steam lines, oils and lignite
when heated above their auto ignition temperature.
Static electric discharge due to charge generation and accumulation on refined
petroleum and on electrically isolated conductors. Static electricity generation
could also result from using carbon dioxide, direct from pressurized cylinder to pump
room and tank spaces.
All possible sources of ignition should be subjected to strict inspection. The
maintenance on and under the jetty in hose handling gear, in decks and in pump rooms
and electrical switch rooms, should at all times be strictly observed. Pools of oil and other
potentially combustible material should be removed immediately. Surplus and spare
equipment and tools should be removed or properly stowed away from the working area
with due regard to fire prevention measures.
17.5

SPONTANEOUS COMBUSTION

Some materials when damp or soaked in oil are liable to ignite without the
application of flame, through the build up of heat produced during oxidation. For this
reason, cotton waste, rags, jute sacking or any similar absorbent material specially with
oil impregnated should not be left lying on the floor, on deck or around hot pipe lines in
pump rooms and electrical switch rooms etc. Metal bins with proper lids should be

provided for collecting oily rags and waste. Strict vigilance and careful disposal of oily
rags and waste etc are the only precautions against spontaneous combustion.

17.6

EXTINGUISHING AGENTS

Cooling water.
Water is the most common cooling agent .This is largely used because water possesses
very high heat absorbing qualities and at shops and on ships is available in ample
quantities. A water jet, although excellent for fighting fires involving combustible
material ,should not be used on burning oil or in galley fires, on cooking oil or fat
,because of the danger of spread of the fire.
Water spray and water fog may be used effectively against oil fire and for making a
screen between the fire fighter and the fire.
Owing to the danger of electrical shock, water should not be directed towards any
electrical equipment.
Smothering.

a) Foam: Foam has a limited heat absorbing effect. Foam is aggregation of small
bubbles ,of lower specific gravity than oil or water, which flows across the surface of
burning liquid and forms a coherent smothering blanket. It will also reduce the surface
temperature of the liquid by the absorption of some heat.
b) Water :- Water supply may be used as a shield to permit closer approach to the seat
of the fire with foam apparatus but the effectiveness of foam is reduced
if water is
allowed to fall on it and it could then be ineffective against fire.
Foam intended for use against petroleum fires will not normally be effective under
conditions where it will not be widely diffused. In an open deck or jetty area

it has limited effect. carbon dioxide is effective in enclosed areas such as

machinery spaces, pump rooms and electrical switch rooms where it can
penetrate into places that cannot be reached by other means.
c) Carbon dioxide (Co2) :Carbon dioxide does not damage delicate machinery or instruments . Being a non
conductor, it can be used safely on or around energized electrical equipment.
Carbon dioxide direct from pressurized cylinders should not be introduced into
and tank spaces due to possibility of static electricity generation.
Carbon dioxide gas is asphyxiant. No one should enter a confined or partially
confined spaces when Carbon dioxide extinguishers have been used unless supervised and
protected by suitable breathing apparatus and lifeline. Canister type respirators should
not be used.
d) Steam

Steam may be used to smother fires in enclosed spaces on board ship or tanker
such as, in cargo tankers, holds or machinery spaces, by excluding air. Due to the steam
condensation, a substantial delay may occur before sufficient air is displaced to render the
contents of the space incapable of supporting combustion.
e)

Sand
As a smothering agent, sand is useful only against small fires on hard surfaces.

17.7

FLAME INHIBITORS

Dry chemical powder

Dry chemical powder is discharged from an extinguisher as a free flowing cloud, and
is most effective in dealing initially with a fire, resulting from an oil spill on a jetty or
on deck of a tanker. It is especially effective on burning liquids, escaping from leaking
pipelines or joints. It can be used in confined spaces but is not effective in the presence
of hot metal surfaces because of the risk of reignition. It is a non conductor and thus
suitable for use in dealing with electrical fires. After use of dry chemical powder,
special precautions should be taken to prevent re-ignition.
Certain types of dry chemicals can cause a breakdown of a foam blanket. Only those
extinguishers labeled " foam compatible" should be used in conjunction with foam.
Dry chemical powder clogs and becomes useless if it is allowed to become damp when
stored or when extinguishers are being filled.

VAPORIZING LIQUIDS :
An example of these is Bromo chloro di fluro methane(B.C.F)
Vaporizing liquids, like dry chemical powder, have a flame inhibiting effect and in
addition also have a little smothering effect.
All vaporizing liquids have some degree of toxicity, but B.C.F. is only slightly toxic.
However, all vaporizing liquids produce toxic fumes when in contact with flame and
hot surface, and anyone entering a compartment after these have been used should
wear suitable breathing apparatus.
17.8

GENERAL

Considerable damage has been caused to the ships/dockyard work centers by fire
in the past. Most of these fires were caused due to carelessness on the part of the
individuals/department in not taking adequate precautions against fire. "Prevention is
better than cure" is an adage that need no emphasis, particularly in regard to fire
hazards.
It is therefore, essential that the following fire precautions are scrupulously
observed in offices, workshops and store houses:

Do not smoke in areas marked : "NO SMOKING".

Do not throw lighted cigarette/bidi butts indiscriminately; use ash trays/receptacles
half filled with water.

Used cotton waste/rags contain oil/paints and are liable to ignite spontaneously, hence
throwing them indiscriminately in workshops and on board ships ,is highly
undesirable.
Used cotton waste to be collected after securing of work and soaked in water in
containers.
Do not store cotton waste/rags near oil/paint drums.
Electric power supply in workshops must be switched off before closing of workshops.
Do not keep electrical appliances unattended when in use. Switch off the electrical
supply / disconnect before leaving the work bench.
Electrical wiring should be checked periodically and replaced immediately when
found defective.
Use only correct gauge of fuse wire, when renewing.
All joints in the electrical cables, carrying supplies to ships from junction boxes,
rectifiers, load tanks etc must be properly insulated,
Accumulation of waste and other inflammable material in shops/working areas must
be avoided and no hot work in any circumstances must be carried in the near vicinity.
All rotating electrical machinery should be of spark proof type and must be protected
from moisture and dirt.
All electrical machinery/equipment should be provided with proper earthing.

17.9

FIRE ORDER
Adequate quantity of appropriate fire extinguisher, water and sand buckets must
be provided in every office, & workshop. Every effort has to be made by concern
departmental officers / supervisors to ensure that these are maintained in serviceable
condition at all times and a layout plan of shop indicating location of equipment etc, is to
be clearly displayed . In cases where these are not provided or are insufficient. the
Dockyard Fire Officer should be informed and action for procurement must be initiated.
The following guidelines are to be followed for extinguishing of fire in case, it breaks out.
The senior supervisor of each center is to organize a small fire fighting squad
(numbers to be decided based on area of the work center and types of fire hazard
present) from the personnel deployed inside the workshops in order to take
immediate action, when a fire occurs.
Each centre has to arrange first aid fire fighting training of the squad through
dockyard fire brigade organization and fire fighting exercises are to be carried out
regularly.

In case the fire breaks out, the following steps are to be followed immediately.
The person discovering the fire should sound the nearest fire alarm or shout fire! fire !
fire !
The members from the fire fighting squad should attempt to extinguish fire with the
first aid fire fighting appliances available in the center or near vicinity.
Simultaneously ,another person must rush to inform dockyard fire brigade in
telephone number : 1444 and in addition a person must run to dockyard fire brigade
to inform about the fire.

Under instructions from the senior supervisor ,the balance member of the squad
should cordon off the area where fire fighting operations are going on and remove
inflammable material away from the site immediately.
On arrival of fire station staff, the members of the squad must assist them at site .In
case of electric fires, all supplies are to be switched off immediately and then only any
fire fighting operation to be carried out, and water is never to be used.
In addition, the pump houses in the vicinity are to be informed immediately to ensure
pumping of water in fire main / fire hydrants.

USE OF FIRE EXTINGUISHING AGENTS

Ordinary fire:
In case of ordinary fires, use soda acid fire extinguishers or buckets filled with
water.

Electrical fires:
Use carbon dioxide fire extinguishers or sand, after switching off the power supply,
use water.

Oil fires:
Do not use water in oil fire. Use foam extinguishers and remove the items from
surrounding storage. If possible ,cover the container with metal lid or wet asbestos to
suffocate the supply of oxygen to the fire.
17.10

HOW TO USE EXTINGUISHERS

SODA ACID TYPE

Strike the plunger, lift the extinguisher invert and direct the jet to the seat of fire.

FOAM TYPE
Lift the cap nozzle and turn to your right, to engage it in the gap. Lift the
extinguishers, turn upside down and direct the inner side of the container.

CHAPTER 18
HANDLING OF DANGEROUS SUBSTANCES
18.1

GENERAL

Dangerous substances should be handled and stored under the supervision of a

competent person who is familiar with the risk and the precautions to be taken.
Labeling of every container for identification of substances must be done before
storing.
Signs and posters in conspicuous places should be placed about the hazards and
control.
In case of doubt, as to the nature of the risk or the precautions to be taken, necessary
instructions should be obtained from the competent authority.
When dangerous substances are to be handled or stored, the workers concerned
should be given adequate information concerning their nature and the special
precautions to be observed in handling them.
Special precautions, such as the provision of mats, sling nets, boxes and high sided
pallets, should be taken to prevent breakage of or damage to containers of dangerous
substances.
All metal containers of flammable solvent should be kept in isolated location with
proper grounding and precaution to avoid out break of fire.
Different classes of chemical should be stored separately.
If containers of dangerous substances are broken or damaged to a dangerous extent,
work should be stopped and the workers concerned removed to a safe place until the
danger has been eliminated.
When highly flammable materials are being handled, special measures should be
taken to ensure that unincipient fire can be controlled immediately.
Non sparking tools should be provided and used in explosive atmosphere.
Where corrosive substances are handled or stored, special precautions should be
taken to prevent damage to the containers and to prevent any spillage. Use of PPE
must be encouraged.
Ventilation should be on at all times.
Allow escape of accumulated gasses before entering the shop after a long closure.
Workers handling harmful substances should thoroughly wash their hands and face
with soap before taking any food or drink.

18.2
ACIDS:
Whenever acids are stored a dike wall about 25 cms high is to be provided all around
the area so as to restrict the direction of flow of the liquid all over the area.

The flooring is to be of acid proof tiling and even in level without any cracks etc.
In work centers where acid is being handled a source of fresh water at a height of two
meters secured from a pipe 25 mm dia and fitted with a quick acting valve must be
provided so as to flood the injury with water in case of accident.
Transportation of acids must be done under supervision of competent person.

18.3
GASOLINE
Always store gasoline in a safe place by itself.
Drums and small containers should never be exposed to direct rays of the sun.
Insist upon the use of gloves to protect the hands. Lead poisoning may result if leaded
gasoline comes in contact with cut or scratched hands.
Never allow smoking near gasoline storage, Explosive power of the vapour of gasoline
is far greater then dynamite.
Always provide an exhaust pipe to and beyond the outer wall when using gasoline as
fuel for a compressor, pump, welding machine, hoist, etc.
`Ground' all gasoline containers.
Do not permit gasoline to be used to start a fire.
Do not permit gasoline to be placed in the tankers of machines unless the engine is
stopped.
Safety cans should be provided.
Never force gasoline out of a drum or other container by means of compressed air.
Never store gasoline near an engine in actual operation.
18.4

ASBESTOS

The general precautions as enumerated above to be followed and in addition the

proper respiratory equipment must be used. The handling of asbestos is a possible factor
in the incidence of lung diseases along with other air pollutants and pleural calcification
observed in non occupational exposure. The lungs may also will be affected for persons
who handles asbestos

CHAPTER 19

COMPRESSED AIR AND GASES

19.1

GENERAL RULES

Never indulge in "Horseplay" with compressed Air.

Never use compressed air to dust yourself, direct the stream towards another person,
or to clean machinery or to blow metal particles or sharp cuttings from the machines.
When not using the air hose, turn the valve off at the receiver or pipe line connection.
Do not leave the air hose lying across walkway, etc. suspended from above.
Always wear adequate eye protection when using or working, near areas where
compressed air is being used,
If the air hose parts at the coupling connection, turn the air off at the main valve
before reconnecting.
Make sure that the air hose and its fittings are in good condition. Always store in a
clean dry place or roll up on a reel.
Remember that clothing does not protect your body from being affected by a stream
of compressed air.
Compressed air must never be used for ventilating an enclosed compartment or for
dusting clothes.
Never direct a compressed air hose nozzle towards your own body or that of your
fellow worker. The ear drum can be easily punctured thereby causing permanent
deafness, or serious damage can be caused to the eyesight if a stream of compressed
air is directed to any vulnerable part of human body.
Never try to blow dust from hair or that of fellow workers using compressed air.
Skin aberrations or slight skin punctures are sufficient to permit normal air pressure
to enter blood stream. Once air enters in it finds its way into the minute blood vessels
of the brain, causing severe pain and even sometimes, death.

19.2
PRESSURE PLANT
If any plant or machinery or any part thereof is operated at a pressure above
atmospheric pressure, effective measures shall be taken to ensure that the safe
working pressure of such a plant, or machinery ,or part is not exceeded. Pressure
plant means pressure vessel, piping ,and its associated fittings. Safety measures for
pressure plant and vessels operated under pressure over atmospheric pressure as per
Maharastra Factory Rules are given under :
All pressure plants should be properly maintained.
Competent person should conduct a through examination and pressure tests, as
required on a pressure vessel or plant and make a full report on its condition.
All pressure plants should be fitted with:
Safety valves, pressure gauges with dial indicators, stop valves, nipples and globe
valves with test pressure gauges, drain cocks, reducing valves with pressure gauges,
additional safety valves,

All pressure plants in service shall be thoroughly examined by a competent person.

(a) externally in every six months,
(b) internally, once in every twelve months, &
(c) hydraulic test once in every four years.

Note: If however by reason of construction of the pressure vessel or pressure plant a

thorough internal examination is not possible, it may be replaced by a hydraulic test,
which shall be carried out once in every two years:

The maximum safe working pressure and the date of the last examination shall be
plainly marked on every pressure vessel or pressure plant and no pressure plant or
pressure vessel shall be operated or used at a pressure higher than the maximum safe
working pressure.
No pressure plant or pressure vessel which has been previously used or has remained
isolated or idle for a period exceeding 6 months or which has undergone repairs or
alterations shall be used in a factory unless it is examined and tested by a competent
person.
No pressure vessel or pressure plant shall be taken into use for the first time in any
factory unless
A certificate specifying the maximum safe working pressure and the tests to which it
was subjected to, is obtained from the maker; and
It is thoroughly examined by a competent person in the premises where it is used.
If during any examination, any doubt arises as to the ability of the pressure vessel or
plant to work safely until the next prescribed examination, the competent person shall
enter in the prescribed Form, his observations, findings and conclusions with reasons
therefor and other relevant remarks any, may authorize the pressure vessel or
pressure plant to be used and kept in operation, subject to a lowering of maximum
safe working pressure, or to more frequent or special examination or test or to both
of these conditions.
Where the report of any examination under this rule specifies any conditions and
suggestions for the working of a pressure plant or pressure vessel the same shall not
be used except in accordance with those conditions and suggestions.

The manager shall maintain a register of pressure plant or pressure vessels showing Name and make of the pressure plant or pressure vessel.
Identification mark.
The reference number and date of the report of examination by competent person.
The report of the result of every examination made shall be completed in Form 13.
The competent person making a report of any examination under this rule shall,
within seven days of the completion of the examination, send to the Inspector, a copy
of the report in every case where the maximum safe working pressure is reduced or
the examination shows that the part cannot continue to be used with safety, unless
certain repairs are carried out immediately or within a specified time or where he
has specified frequent or special examination or tests.
Inspector may by an order in writing ,direct the production unit within the time
specified in such order, of a report of examination made, by a competent person who

shall not be an employee of the factory in which the pressure plant or pressure vessel
is in use.
All certificates, reports and registers required to be obtained or maintained under this
rule shall be complete in all respects and duly signed by the maker or competent
person, and these shall be produced for the perusal of the Inspector.

19.3 The provisions of this rule shall apply to pressure plants and pressure vessels as
defined , except the following: Vessels having an internal operating pressure not exceeding atmospheric pressure by
1 kg/cm or 15 lbs. sq inches absolute;
Steam boilers, steam feed pipes and their fittings , coming under the purview of Indian
Boilers Act, 1923 (V of 1923).
Metal bottles or cylinders used for storage or transportation of compressed gases or
liquids or dissolved gases under pressure covered
by the Gas Cylinder Rules 1981, framed under the Indian Explosive Act 1884(IV of
1884);
Vessels in which internal pressure is due solely to the static head of liquids;
Working cylinders/casings of the machinery such as pumping sets, compressors and
prime movers;
Vessels for nuclear energy applications.
FORM 13
Report of examination of Pressure Plant/Vessel
1. Name and address of factory
2. Name, description and distinctive
number of the Pressure Plant/Vessel.
3. Name and address of maker
4. Nature of process in which it is used.
5. Particulars of Plant/Vessel (a) Date of construction
(b) Thickness of walls
(c) Date on which it was first taken
into use.
(d) Safe working pressure recommended
by maker.
6. Date of (a) Last external examination
(b) Last internal examination
(c) Last hydraulic examination
(d) Last ultrasonic test
7. Whether lagging was removed for purpose
of examination.
8. Description of examinations carried out
and findings (a) External examination (give reasons
if it is not carried out six monthly).

(b) Internal examination (give reasons

if it is not carried out annually).
(c) Hydraulic test (give reasons if
this is not carried out at interval
of 2 years or 4 years).
(d) Ultrasonic test (please quote number
and date of the certificate issued by
Chief Inspector, permitting ultrasonic
test in lieu of internal examination &
hydraulic test).
9. Safe working pressure calculated as per
methods given in sub-rule 5(c)(ii) for
sizing cylinders (1)
(2)
(3)
10. Condition of Pressure Plant (a) Vessel
(b) Piping
11. Conditions of fittings and appliances (a) Pressure gauges
(b) Safety valves
(c) Stop valves
(d) Reducing valves (give reasons if not
necessary).
(e) additional safety valve (required in
case reducing valve is necessary)
(f) Other devices (please specify particularly in case of jacketed vessels).
12. Safe working pressure recommended after
examination (specify the allowances made for
conditions of working such as heat, corrosion
etc).
13. Specify repairs if any and period within
which they should be executed.
14. Specify reduced working pressure pending
repairs.
15. Other observations/conditions subject to which
the plant is to be operated.
I certify that on _______________the pressure plant/vessel described above was
thoroughly cleaned and (so far as its construction permits) made accessible for thorough
examination and for such tests as were necessary for through examination and that on the
said date - I thoroughly examined this pressure vessel/plant including its fittings and that
the above is a true report of my examination.
Name

Address :
Qualification :

Signature
(Competent person)

If employed by a Company or Association give name and address

CHAPTER 20

CHAPTER 21

GENERAL PRECAUTION WHILE

WORKING ON A MACHINERY
21.1
The concept of elimination of hazard is by providing safe guard to every
occupational safety and health program and is enumerated below.

Carry out job analysis of every machine and task, identify the hazards, and provide
sufficient and adequate protection .
In most of the operation the hazards or associated with machines, equipment or in the
point of operation. Identify these hazardous potential for accident and eliminate
them.
Find a new method or system to carry the same task / job which is less hazardous.
If possible, change the physical condition of the machine or job that create the
hazard.
Find out or change the work procedure with new standard .
Reduce the frequency of material handling which create hazard.
Provide adequate guarding to the point of operation, energy source which is a
potential danger.
Built in safeguarding concept must be applied for new purchase of equipment /
machinery. This will increase the production and reduce the hazard.

21.2
POINT TO BE KEPT IN MIND WHILE DEVELOPING/ DESIGNING
THE SAFE GUARDING

Guarding should be well constructed , durable and strong.

It should be able to accommodate work piece feeding and ejection.
It should be protective .
It should be easy to maintain and inspect.
It should be fool proof.
It should not create any new hazard.
It should not interfere with production and do not cause discomfort to the operator.

21.3

MATCHING THE MACHINE TO THE OPERATOR :

All work place machine / equipment should be provided and arranged in such
away that the operator does minimum amount of traveling, lifting and physical work .
The work height should be minimum in relation to stand up or sit down position of
operation.
Control machine speed. On/Off switch should be readily accessible, it should be
positioned in such away that operator can reach without any obstruction.
Worker should not get fatigue physically and mentally while working on the
machine. He should utilize minimum efforts to carry out the operations.

21.4

Fencing of Machinery : In work places following be provided.

Every moving part of the machinery in the factory be fenced or covered, or guarded
Any part of a stock bar which projects beyond the head stock of a lathe and, every
dangerous part of any other machinery shall be securely fenced by safeguards of
substantial construction which (shall be constantly maintained and kept in position)
while the parts of machinery they are fencing are in motion or in use ;

CHAPTER 22
WORK PERMIT SYSTEM
22.1

Permit-to-work system

The permit-to-work system was implemented with the view of preventing

incompatible work processes from being carried out in the same locations as well as to
ensure that necessary precautions are taken during hazardous work processes. These
permits are issued by concerned authorities.
The following work permit systems can be used in the yard and maintained :
a)

Hot work

b)

Painting in confined spaces

c)

Chemical cleaning of boiler and coolers

d)
Dismantling of valves and pipelines in Cargo tanks, double bottom tanks
and other enclosed spaces and heating coils
e)

Chemical cleaning of generators and motors

f)

Work activities in the Carbon dioxide room

g)

Work on asbestos materials

h)

Entry into confined spaces

j)

Repair/maintenance work on hydraulic machinery

k)

Radiography work

l)

Bunkering, transferring of oil

m)

Ballasting/deballasting of tanks

n)

Switchboard repair

o)

Oil/sludge/scale cleaning at confined spaces

These permit-to-work systems are to be reviewed constantly and upgraded when

necessary.

22.2

Checklists

Checklists are used in the yard to ensure that the processes are carried out in a
safe manner and the facilities provided meet with the safety requirements. Production
supervisors are responsible for the compliance of the safety requirements and signing of
the checklists.
Following checklists are used in yard
I)

for completed staging

ii)

For supervisors on the use of mobile cranes

iii)

For mobile crane operators

iv)

For hot work

v)

For tank cleaning

vi)

For blasting/painting

vii)

For engine work

CHAPTER 23

ENGINE FITTING/MACHINE/
COPPERSMITH SHOP
23.1

DOES AND DONTS:

MACHINERY GUARDS:

Do not remove any guard ,unless for repairing ,oiling or adjusting the machine.
Always stop the machine first and replace the guard when the work is done.
Before starting work on any machine make sure that all guards are securely in place.
If you find that any guard has been carelessly removed from any machine, notify the
supervisor.
If you find that any guard is broken or having inadequate protection, notify the
supervisor.
Your suggestions for additional guards in hazardous areas are welcome and will
receive careful consideration.

23.2

MACHINE SHOP

Keep tools off the floors; keep aisles and passage ways clear.
Put oily waste and flammable materials in metal cans.
Lift with muscles, not with the back.
Dont hitch-hike on trucks, conveyors and cranes
Keep off from suspended loads.
Don't climb over piles of material.
Don't wash in cutting oils or compounds.
Wear hand and foot protection. (safety shoes)
Get first aid for every injury.
All wire slings are to be tested and are assigned the safe working load. Check the
load on the attached tag before use.
Use goggles, eye shields or face shields, while chipping scale from electric welding,
while grinding and whenever required.
Do not overload rope slings, wire slings, chain slings, pulley lifts etc.
Maintain cleanliness of the shop at all time.
Report unsafe conditions immediately. Your safety is in your hand
Watch and check your fellow workers for unsafe practices
Do not use faulty wire slings for lifting load.
Do not use chisels or wedges made out of old files
Do not grip the job at the end of the vice jaws

Do not use worn out spanners or improper tools which are unsuitable to the type of
work.
Do not check the dimensions of jobs with machine running.
Do not use bare hands or jute for clearing metal filings or swarf from the machine
(use brush and pan to collect metal chips and maintain the floor clean)
Do not use extension of electric hand lamp without proper plugs.
Do not use hands or body as a brake to stop a moving machine part, even when the
power has been cut off.
When changing machine parts such as face plates or chucks, on lathes, do not use
any power.
Before starting adjustments on a machine, be sure that the power is off and the
machine is secured against accidental starting.

24.3

Use only spanners of good quality and the right spanner for the right job. Never use
substitutes.
While working in a confined space, take care that the grip you use will not endanger
you, make sure that there is plenty of clearance.
Always face an adjustable spanner forward in the way the handle is to turn.
See that the bite of an adjustable spanner is taken near the middle of the jaws, so that
there will be teeth in front ,if the spanner slips. Keep the teeth sharp.
Do not overstrain a small spanner or use a spanner as a hammer.
A bent spanner, if straightened, becomes weak. Get a new spanner.
Do not attempt to use a spanner on material that is on a machine in motion. Stop the
machine while working on the material.
Use spanners, that are the right type and size for the job; never use a piece of pipe on
the handle to get more leverage.
Use only spanners having jaws in good condition. Keep pipe wrench, jaws sharp and
clean.
Never use a shim to make an oversize spanner fit the nut.
Do not use a spanner as a hammer.
Always place the spanner on the nut so that the pull on the handle tends to force the
jaws further into the nut.
Pulling on a spanner is safer than pushing; if you must push, make sure your footing
is good before you push.

23.4

SPANNERS

FILES

See that there is a securely fitted good handle on each file, you use.
If files have particularly sharp pointed tips ,round then off to avoid snagging your
hand when reaching into the kit box.

When filing work close to the chuck in a lathe, file left-handed so your arm will not be
snagged.
Never hit a file with a hammer; pieces of the hardened steel are likely to fly.
Do not make a centre punch or a chisel out of an old file; the metal is too brittle for
this purpose.
A file breaks easily if you try to use it as pry and the splinters may fly.

23.5

Select a hammer suitable for the job, make sure the head is wedged securely on the
handle and that the head and handle are not chipped or broken.
Keep the hammer clean and free from all oil and grease, which might cause the handle
to slip ,out of your grasp.
Always strike with the hammer face, which is hardened for this purpose, do not
damage the hammer face by striking a material harder than the face itself.
Never leave the hammer lying overhead, it might fall and injure some one.
Hammer handle should be of good quality wood, and also free from knots.

23.6

HAMMER

MACHINE TOOLS.

All workers working on machine tools must wear safety shoes.

Wear eye shields while working with portable grinding machines.
All machine tools are to be operated only by authorized personnel.
Annealing furnace front must be kept clean and oil leakage must be wiped
Report worn out grinding stones of the pedestal grinding machine and keep the work
table clearance to the minimum.
There are no safety rules greater than your own personal care.
Report all unsafe conditions to the Departmental Head and advise your fellow
workers against unsafe practices.
Store material in an orderly and safe manner.
Keep all tools, fasteners and other equipment in an orderly manner for repetitive use.

CHAPTER 24

ICE SHOP
24.1

DO'S AND DON'TS

Never depend on jacks or chain hoists alone to support a engine you have to work
under. Support it on blocks.
Use only electric extension lamps and portable electric tools with cords and fittings
that are in good condition.
Guard against carbon monoxide gas from the exhausts of running engine. See that
there is proper ventilation.
Do not have gasoline stacked around in open containers. Use kerosene or other
relatively safe liquids/substances to clean machinery parts whenever possible.
Use safety grip when necessary to crank engines by hand.
Dont attempt to lift anything, which is too heavy for you. Get help or use a hoist.
Inspect the spanners and other tools you use. Keep them in safe working condition.
Keep a pair of safety goggles handy and wear them when doing work in which eye
protection is needed.
Keep aisles and open spaces on floor, free of tools and parts.
Be on your guard against flashes or explosions of gasoline vapors, anti-freeze solution
vapor and hydrogen from storage batteries. Keep flames and sparks away.
If your clothes become soaked with oil or gasoline, change them.
Never consider a job completed until you have checked to make sure all the lock
washers and cotter pins are in place.
Never allow grease and oil to remain on floor where you and others might slip on it
and fall.
Always keep a suitable fire extinguisher near and ready for use.

24.2
CRANKING GAS ENGINES
Stand clear of swing of the crank, in case engine back fires.

Make sure, in swinging the crank, that your fingers will not strike some object nearby.

Set a firm footing, bracing yourself with the free hand, if possible.

Grasp crank in palm of hand, with thumb at the back of (not over) crank handle.

Turn engine over once or twice, to prime motor before turning on switch.

Bend knees and pull up, with your leg muscles taking most of the strain-speed to a
quick jerk at top.

CHAPTER 25

FOUNDRY SHOP
25.1

Use gloves and goggles while charging the furnace.

Proper ventilation of furnace should be to avoid blow out of accumulated gas during
ignition.
While cleaning air passage use goggles and face shields.
Use gloves and goggles while removing slag from the spout.
All workers, working on or near furnace, must wear shoes, dark goggles and gloves as
provided.
Use asbestos or leather gloves while handling slag .
There are no safety rules better than your own personal care.
The nozzle of the furnace atomizer must be checked for any clog and be clear of all
dirt particles.

25.2

While pouring metal

Use safety shoes only. Rubber slipper and wooden sandals are not permitted.
Face shields must be worn.
Be aware of wet mould and its consequent blowing up.
Passages in way of the operation must be clear.
Report all unsafe conditions to Department Head and advise your fellow workers
against unsafe practices.

25.3.

Furnace operation

Knocking, chipping and dressing of castings

Use gloves, safety shoes and face shields.

Prevent injuries due to nails used for reinforcing the moulds, sharp metal fins and hot
slag etc.
No rules are better than self care.
Don't use chisels made out of broken files for chipping.

25.4
Moulding sand mixtures
Door to remove the sand mixture is not to be opened while the machine is running if
the safety interlocking device is not provided on the machine.
To scoop the remaining sand, a wooden stick shall be used and hand is not to be
introduced.
25.5

Laddles

Laddles for pouring hot metal shall be inspected by the competent authority at least
once a week to check on rotating shaft pins, keys and gear wheels

25.6

When the drying furnace for the moulds are shut down for renovation of brick lining
etc. a sign board shall be displayed on the burners at the firing end to prevent
accidental firing of the wrong chamber.
Oil burners fitting and the drip tray underneath shall be kept clean to prevent fire
hazard.
The heating furnaces shall be purged properly before lighting.
Dripping of oil into the furnace or letting in oil too long before lighting the furnace
will cause back fire specially when the furnace is still hot due to residual heat from
previous firing. This can be prevented by properly instructing the operator deputed
to light a furnace.

25.7

Dry and Heating Furnaces

E.O.T. Cranes

The cranes for handling hot metal( where safety is of paramount importance) shall be
inspected twice a month, or as and when required or once a month.
Any accumulation of combustible dirt is not to be permitted as it is a potential fire
hazard.

25.8

DOS AND DONTS FOR MOULDER

DOS

Ensure correct quality and mixture of sands including core-sand.

Use appropriate PPE's so that sand particles are not inhaled.
Use correct method of handling mould boxes etc.
If accessories to be used are heavy, use mechanical handling devices.
Ensure correct way of repairing moulds.
Ensure ventilation of gases formed during pouring.
Consult your superior after making a mould to ensure its strength to withstand
liquid metal pressure.
Keep area sufficiently clean.
If you are using reclaimed material, ensure that you do not compromise in quality.
Ensure that the material used is duly tested.
If you are using any chemicals for moulding know their properties especially their
effect while handling.
Store the accessories safely.
Ensure that moulding machines/ equipment are properly guarded.
Ensure that you have removed the pattern from the mould.

Keep safe distance from the mould when the metal is being poured.

DON'T :

Don't assume if drawing is not clear. Get it cleared from your superior.
Don't ram sand excessively.
Don't throw sand from a distance.
Don't keep sand in the middle of the area/aisles; store properly.
Don't use worn out tools.
Don't patch up moulds if it cannot withstand the pressure.
Don't allow any other person to work on your mould.
Don't use substitute material unless you have ensured that it is a correct substitute.

CHAPTER 26

RUBBER MOULDING
26.1
The rubber moulding department has the following health hazards
Contact of chemicals.
Inhalation of fumes, dust of carbon and other chemical in use.
Trapping in between rollers of moulding machines.
Contact of heat to body parts.
Fire due to presence of carbon dust and other flammable chemicals
Burns from heated rolls and associated heated parts.
Development of static electricity on rolling machine and its parts by metal contact.
In view of above, under mentioned precautions have to be taken while working in
rubber moulding section.
26.2

Raw rubber finished products and chemicals should be stored in areas which are not
prone to fire and as far as possible in an isolated area.
Chemicals should be stored in areas away from dining halls, water cooler etc.

26.3

HANDLING :

While mixing of chemicals, personnel involved should apply barrier cream on both
hands, especially on the palms.
While mixing of chemicals; personnel involved should wear proper PPE at least
cloth masks so that they do not inhale fumes, chemicals and dust particles of carbon
etc.
In case personnel have deep cuts or wounds, they should wear protective gloves.
Personnel should put on heat proof gloves made of asbestos or glass wool while
undertaking vulcanizing and pressing.
They should put on boiler suits and non skid safety shoes while mixing and moulding.
Care should be taken to prevent crushing of fingers in rolling mills, presses and
extruders.
Normal precautions of handling electrically operated machines should be observed
when such machines are in use.
If boilers are in use, normal precautions for pressure vessels should be observed.

26.4

STORAGE :

GENERAL :

A rubber moulding section has only the normal risks of any other production unit.
Usual safety measures are to be followed like other centres.

Enough fume extraction arrangements such as local exhaust ventilation should be

made available for the mixing mill.
The area in the workshop and stores should be cleaned on regular basis and kept free
of carbon and other particles as far as possible.
Sufficient ventilation should be available in the workshop and stores.
Sufficient lighting should be available in the workshop and stores.
Standard fire protection and fire fighting arrangements should be available in the
workshop and stores.
In case of ingress of chemicals in the eyes of personnel, eyes should be washed
thoroughly in running water and medical care
should be sought. Sample of the
chemical that fell in the eye should be shown to the doctor.
Personnel handling chemicals should wash their hands thoroughly in fresh water with
soap, after work.
In case of accidental inhalation/consumption of chemicals, medical help should be
sought immediately. Sample of the inhaled/consumed chemical should be shown to the
doctor.
Every employee working in the shop should know the hazard arising due to chemical
and raw material. Therefore they should know the appropriate precautions to be
taken during working.
The material safety data sheet of chemical used in the department shall be made
available and same shall be known to the persons concerned and shall be maintained.
This may be required by the Factory Inspector during his inspection.
Adequate fixed/portable guarding shall be provided to milling and rubber moulding
machine to avoid approach of worker near to nip zone during operation.
Rubber is a good electrical insulator and because of this property static charges can
be built up on machines on which a sheet or film is traveling. These charges can have
enough potential to become a source of ignition or shock those coming in contact with
these machines. Therefore static eliminators in the form of wire comb or ionizing air
should be used to reduce these charges and by properly earthing metal parts.

CHAPTER 27

REFRIGERATION AND AIR CONDITIONING

27.1

Working on air conditioning and refrigeration plants has following hazards

Inhalation of gases
Contact of cold with body parts
Working in confined spaces
Working with high pressure gases
Handling of compressed gas cylinders.

a.
It is very important to take proper care while working on these plants to avoid
accidents. Certain factors of safety aspects are mentioned
below .
b.
Check the gas which is being used in the system before charging or
while
pressurising the system .
c.
Fit proper pressure gauges at critical points , as the system is
divided
into high and low pressure side.
d.
Keep the compartment properly ventilated while releasing Freon /
Nitrogen /
Carbon- di -oxide gas.
e.
Never use mixture of gases for pressure testing .
f.
While working on a running refrigeration system ,be careful of l
eakage of
refrigerant gas in cool /cold room as liquid gas( freon) can
cause severe cold burns.
g.
While dismantling a compressor make sure there is no gas pressure
in it,
and the motor fuzes are removed and the compressor is decoupled.
h.
Chemical cleaning in poorly ventilated areas is not recommended.
j.
Never do hot work on a system which is under pressure.
k.
Gas cylinders are to be presue tested in shop before lowering on
board
for charging .

CHAPTER 28

BOILER SHOP
SAFETY IN THE USE OF ASBESTOS
28.1

GENERAL

Objects, Application and definitions :

The objectives of this code are :

To prevent the risk of exposure to asbestos dust at work.
To prevent harmful effects on the health of workers arising from exposure to asbestos
dust.
To provide reasonably practicable control procedures
and
practices
for
minimizing occupational exposure to asbestos dust.
Possible health consequences on exposure to asbestos dust

There are three main health consequences associated with exposure to airborne
asbestos :

asbestosis , fibrosis (thickening and scarring) of the lung tissue ;

lung cancer : cancer of the bronchial tubes;
meosthelioma : cancer of the pleura or peritoneum.

Other consequences of asbestos exposure can be the development of diffuse pleural

thickening and circumscribed pleural plaques which may become calcified. These are
regarded as no more than evidence of exposure to asbestos dust. Other types of cancer
(e.g. of the gastro-intestinal tract) have been attributed to asbestos exposure though the
evidence at present is inconclusive.
Application :
Use or application of asbestos-containing materials
Stripping, repair or maintenance of products containing asbestos;
Demolition of plant or structures containing asbestos materials;
Transportation, storage and handling of asbestos or asbestos containing materials.

Definitions :

Asbestos is defined as the fibrous form of mineral silicates belonging to the serpentine
and amphibole groups of rock-forming minerals, including : actinolite, amosite
(brown
asbestos, cummingtonite, grunnerite), anthophyllite, chrosotile (white
asbestos), crocidolite (blue asbestos), tremolite, or any mixture containing one or more
of these;

asbestos dust is defined as airborne particles of asbestos or settled particles of asbestos

which may become airborne in the working environment;
workplace covers all places where need to be or need to go by reason of their work
and which are under the direct or indirect control of the employer.
General duties :

nature and place of work;

type and quantity of asbestos or materials containing asbestos;
total number of workers exposed;
duration or anticipated duration of the work period;
protective and preventive measures to be taken.

Safety and health committees should endeavor to ensure the application of the
regulations on the prevention of airborne asbestos and should acquaint themselves
regularly with the results of the monitoring of the working environment.
METHODS OF CONTROL :
All appropriate and practicable measures of engineering, work practices and
administrative control should be taken to eliminate or to reduce the exposure of workers
to asbestos dust in the working environment to the lowest possible level.
Engineering controls should include mechanical handling, ventilation and redesign
of the process to eliminate, contain or collect asbestos dust emissions by such means as :
process separation, automation or enclosure ;
bonding asbestos fibers with other materials to prevent dust generation;
general ventilation of the working areas with clean air;
local ventilation of process, operations, equipment and tools for the prevention of dust
dissemination;
use of wet methods where appropriate;
separate workplaces for certain processes.
Appropriate work practices :
(a)
damping where appropriate of asbestos products and materials at workplaces
before processing, handling using, machining, cleaning stripping or removing;
(b)
regular cleaning of machinery and work areas by appropriate methods;
(c)
proper use of personal protective equipment.

(a)
(b)
(c)

Workrooms should be designed, built and maintained in such a manner as to :

separate the hazardous operations from the remainder of the premises;
reduce as far as possible surfaces on which asbestos dust and waste may
accumulate;
facilitate the cleaning of floors, walls, ceilings and machinery and

(d)
facilitate the collection of asbestos dust which may escape in the event of an
incident.
PERSONAL PROTECTION
Boiler suits and head gears
Respiratory equipment for protection dust of asbestos
Safety shoes.
Hand gloves where necessary
Eye protection like goggles.
Protective clothing :
Provision and use :
Where personal clothing may become contaminated with asbestos dust, the
employer, in accordance with national regulations and in consultation with workers
representatives, should provide appropriate works clothing.
Such special protective clothing should cover completely all works clothing so that
no asbestos dust is retained when the protective clothing is removed. Suitable head
covering should also be provided. Shower or washroom facilities should be provided and
should be sighted between the contaminated and clean locker rooms.
Only those types of respiratory equipment which have been tested and approved by the
competent authorities should be worn.
Training :
All workers required to use respiratory equipment should be instructed in its use.
28.4

Instruction should be given on the following points :

(a)
The reasons for the use of the equipment and the important of
using it conscientiously;
(b)
The circumstances in which it should be used and how these
circumstances should be recognized;
(c)
The manner in which the equipment operates;
(d)
The correct method of use and of checking the fit;
(e)
The method of checking for correct operation;
(f)
The need for regular servicing.
Such facilities should be cleaned regularly.

28.5

Cleaning of premises and plant :

Every employer should ensure, as far as is practicable, that the work premises
are maintained in a clean state and are free of asbestos waste.
Care should be taken that waste water containing asbestos fibres does not dry out
on the floor below.

28.6

Packaging, transport and storage :

Asbestos fibre should always be packed in impermeable bags.

The disposal of asbestos waste :
Where fixing or stripping operations are being carried out, floor surfaces should
be covered with plastic sheeting which can be folded to form sealed containers.
Hard waste, such as bonded asbestos, asbestos cement jointing and bitumastic
rubber residues, should be stored in such a manner as to ensure that it will not be
abraded or crushed while awaiting disposal.
Asbestos waste should not be mixed with other waste for which there are no special
disposal requirements. Where practicable. a special area should be set seperately.
28.7

Transportation of asbestos.

Asbestos waste, whether loose or in sealed containers, should be transported to the

disposal point in such a way that no asbestos dust is emitted into the air during
transportation.
If the spillage is substantial and the material dusty, it should be wetted if
practicable and covered immediately. The material should then be removed and during
this process appropriate safety precautions, which may include the use of protective
clothing and respiratory equipment, should be taken.
The waste should wherever practicable be deposited at the foot of the working face
of the landfill site or at the bottom of an excavation, dug for it.
28.8

Supervision of the health of workers :

A medical examination of the worker potentially exposed to asbestos dust should
take place upon recruitment or prior to assignment to a place of work involving exposure
to asbestos dust.
28.9.

INFORMATION, LABELING, EDUCATION AND TRAINING

Labeling of products and of risk areas :

All asbestos containing products should have an internationally recognized
warning symbol designating the product as asbestos containing and warning the user
that inhalation of asbestos dust may cause serious damage to health.
All work places where asbestos dust may cause a hazard should be clearly
indicated as an asbestos dust exposure area through the use of a well displayed sign
which identifies the hazards and the associated health effects.
28.10

ASBESTOS CEMENT :

Work on site :--Asbestos-cement products should where practicable be delivered to the

site ready for use and should not need further processing which may generate dust. Hand
tools or slow running tools producing coarse dust or chips should be used where
practicable rather than high speed machines or those which cut by abrading the material.
When high speed power tools are used, they should be fitted with efficient dust
extraction equipment designed for the purpose.
28.11

TEXTILES :

*
Woven materials should be cut not torn.
Packing :
*
Yarns, rope and roving may be packed in cartons. These should be mode dustproof with tape seals.
*
Asbestos cloth should be cut with shears, a guillotine, or a mechanical cutter. It
should not be torn or frayed.
*
When cutting and pipe wrapping, the laggers should wear protective clothing and
respiratory equipment.
*
When extensive rope lagging is being carried out, the work area should be
separated from other areas, or the work should be carried out at times when workers
without respiratory protection are absent.
Controlled wetting of waste should also be employed where practicable to reduce
asbestos dust emission during bag sealing or in the case of bag rupture.
28.12.
ENCAPSULATION OR REMOVAL OF FIREABLE THERMAL AND
ACOUSTIC INSULATION :
All entry points should carry prominently displayed warning notices which forbid entry
to anyone not wearing suitable protective equipment.
Hygiene :
Provision should be made for decontamination which should include:
(a)
protective clothing are provided for
(b)
shower facilities
(c)
storage for clean and contaminated clothing
(d)
provision for the collection and cleaning or disposal of
contaminated clothing.
Supervision :
All workers should receive careful instructions in the maintenance of workplace
cleanliness and personal hygiene and in the importance of adherence to decontamination
procedures.
Dry Stripping :
Dry stripping is associated with very high levels of asbestos dust. It should
therefore be used only :
(a)
where wet methods cannot be used;
(b)
where live electrical apparatus might become dangerous by
contact with water;

(c)
where hot metal is to be stripped and the use of water may be
damaging.
Where dry stripping is employed, as effective a standard of separation as possible
should be preserved between the work site and the adjacent areas to prevent the escape of
asbestos dust.
Surfaces from which the insulation has been removed should be sealed to prevent
the release of remaining fibres into the air.
Waste containers should be sealed and should be identifiable.
Wet stripping :
Electrical equipment in the area should be isolated from the entry of water.
Where cladding has to be removed, it should first where practicable be punctured
and the asbestos containing material within the cladding should be thoroughly wetted.
The cladding should then be removed carefully within the enclosure and all
surfaces should be vacuumed or sprayed with water.
28.13

HANDLING OF ASBESTOS FIBRE IN PORTS :

All asbestos fibre to be handled by waterside or terminal workers should be

packed in airtight bags.
The packages should be made up into unit loads securely fastened by binding.
Hooks or other sharp equipment should not be used on bags or unit loads.
28.14

CONSTRUCTION, DEMOLITION AND ALTERATION

WORK

It should be the responsibilities of authorized persons or bodies to identify

asbestos containing insulation or lagging before demolition commences and to ensure the
safe removal and disposal of the material in accordance with the provisions of the
national regulations.
All workers engaged in the work of demolition or alteration should be made aware
of the health hazards and should be made aware that the work should be performed in
accordance with the prescribed safety and health regulations.

CHAPTER 29

TEST HOUSES
29.1

STEAM TEST HOUSE, DIESEL ENGINE TEST HOUSE,

MOTOR AND GENERATOR TEST HOUSE

HAZARDS IN THE TEST HOUSES:

*
Noise, vibration
*
Heat
*
Exhaust fumes from engine under test.
*
Gases of fuels.
*
Leakage of steam ,oil ,grease from various machinerys and
systems.
*
Work in confined spaces, such as tunnel space, bilges etc.
*
Electrical shock due to leakage, improper connection.
*
Sparking from running machinery due to inadequate
clearance between idle and running parts.
*
Fire and explosion .
*
Material handling of heavy parts of machinery
*
Working at heights during fitment of machinery, valves
pipes, cables etc.
*
Corrosion and its effects in use of salt water .
*
Use of chemicals for testing, cleaning of plant
*
Use of CO2 as fire extinguishers.
29.2
Precautions to be taken against hazards, in the steam test houses, diesel test
houses, electronic test houses, pressure test houses, hydraulic test houses are listed below
for compliance of safe working conditions in the areas like noise/vibration/ high voltage/
material handling / fire/ power operated and hand tools.
a.
High noise level can be avoided by using correct reduction
methods and spares .
b.
Reduction in vibration levels by using shock mounts.
c.
Isolate
the
process,
equipment
causing
excessive
/vibration and enclose it.
d.
Use of vibration damper mountings is recommended
e.
Material handling of all heavy parts should be done by trained
persons. (For details refer Chapter no. 21).
f.
All fire prevention systems like fire main, CO2 gas and first aid
fire extinguishe to be tested at regular intervals for normal
working condition and with proper precautions.

noise

G.
The lifting appliances be inspected at adequate regular intervals
and repaired, tested and certified by a competent person and
record maintained.
g.
Proper work procedures to be carried out to avoid accidents.
j.
Proper tools and systems to be used to maintain / test
equipment.
k.
Use of proper PPE which will reduce accidents.
l.
Necessary machine guards should be installed on all rotating
part of the machine
m.
Enclosure or isolation of equipment and process which produce
noise, heat pollution
n.
Adequate and proper use of personnel protective equipment.
p.
Use of expansion bellows at places where the expansion/
contraction takes place
q.
Proper ventilation shall be provided to reduce the effect of heat
and radiation.
r.
Access near equipment under testing with proper safety aids
and to the specified time limit.
s.
Corrosion prevention programs at all stages to avoid break
downs .
t.
Use of less harmful chemicals instead of dangerous ones.
u.
Medical examinations at intervals to assess the hearing
impairment due to noise hazard and inhalation of fumes.
v.
Predictive maintenance to reduce accidents and down time.
w.
Good house keeping to avoid slippage due to oil, water, steam,
grease, acid etc.
x
Air monitoring at intervals to asses the quantum of polluted
air .

CHAPTER 30

SAFE USE OF ELECTRICITY

30.1
Electricity is the most convenient form of energy and is used extensively.
However, it is also a source of potential danger. Electrical hazards, unlike many
mechanical hazards, are not usually obvious; a live conductor does not differ in
appearance from a dead conductor and the lack of earthing of a metal enclosure may pass
unnoticed until too late, when the metal-work is touched and found to be dangerously live.
Electric shock can cause death instantaneously or within a short time. To avoid such
incidence the following Do's and Don'ts will be helpful .
30. 2

Dos

*
Obtain work permit before starting the work on an electrical equipment or
installation.
*
Ensure that all the control switches are opened and locked in off position and/or
fuses withdrawn before commencing work on any electrical equipment or installation.
*
When carrying out repairs on any equipment, follow scrupulously the
maintenance instructions of the manufacturer as given in the manual.
*
Know the voltage and frequency of the circuit.
*
Confirm colour coding used for the wiring in making correct connection
*
Confirm the abbreviations and symbols used in the circuit diagram are as per the
manual.
*
Use appropriate personal protective equipment.
*
Confirm from manuals supplied by the manufacturer of equipment that provisions
are catered for : Personal safety against electric shock
Personal safety against effect of excessive temperature
Safety against fire and
Appliances designed to contain liquid or provided with steam producing devices shall
have adequate safeguards against the risk of explosion.
*
Treat circuits as live until they are proved to be dead.
*
Where a fuse or cut out is incorporated in any appliance, its location should
be
clearly indicated by suitable visible marking.
*
Ensure that the internal wiring and connections are adequately
protected
or enclosed so that they are not exposed to steam, vapour
or spillage during
normal operation.
*
Internal wiring should be fixed in such a way that the functional
insulation
does not come into contact with external parts.
*
Insulation shall be such that it is not damaged in normal use.
*
Before energizing any equipment ensure that the permanent grounding
arrangements are properly connected.
30.3.

Donts

*
Don't touch electrical equipment with bare, wet hand.
*
Don't put off any switch unless you are familiar with the circuit
which
it controls and know the reason for it being left on.
*
Don't touch or tamper with any electrical switchgear or conductor, unless you
have made sure it is dead and properly earthed.
*
Don't test circuit with bare finger or hand.
*
Don't use metal scales or tapes near electrical circuits.
*
Don't use wires with poor and deteriorated insulation.
*
Don't allow visitors and unauthorized persons to touch or handle
electrical
apparatus or come near the danger zone of high voltage
apparatus.
*
Don't use wood, cotton, silk, paper and similar hydroscopic material for
insulation unless otherwise specified.

DANGERS OF ELECTROCUTION.
a.
b.
c.
d.

SHOCK
BURNS
EYE FLASH
FIRE AND EXPLOSION

30.5
ELECTRICAL QUANTITIES ASSOCIATED WITH HUMAN INJURY
a.AC Current15-20 MA
Above 20 MA
Above 50 MA
prevents
Breathing
The
victim from
difficult or
shock is likely
releasing the impossible, artito be fatal
grasp
ficial respiration
required to save life.
b. Voltage
General average
24 Volts for
60 volts for
limit may be children
adult
taken as
(Wet situations are exceptions)
c. Body
Dry Condition
Wet Condition
resistance 500 ohms
200 ohms
30.6

PROTECTIVE DEVICES
Means of cutting off power:-

*
Every part of a system should be capable of being cut off from supply by efficient
and suitably located means.
*
Transformers, converters, motors and such apparatus should have
separate
switches suitably placed and distinctly marked.
*
Machines driven by motors should have individual stopping and
starting
arrangement which should be easily accessible.

OVER-LOAD AND SHORT CIRCUIT PROTECTION

a)
b)
c)

Fuses
Circuit Breakers
Thermal Protection

These should effectively interrupt the current when it exceeds the working
rate and should have sufficient protection capacity to operate safely at short circuit.

EARTH LEAKAGE PROTECTION

*
All non current carrying metal parts of electrical equipment should be earthed.
*
For medium and high voltage equipment ,two separate and distinct earth
connections must be provided
*
Cross sectional area of earth conductors should not be less than half the size of
current carrying conductors
*
Minimum size of conductors :
Copper : 3 mm square
GI
: 6 mm square
*
Earth provides protection by:
Ensuring immediate discharge of electrical energy without
danger
Allowing sufficient current to flow to blow fuses or operate
protective
devices.

EARTH LEAKAGE PROTECTION

This can be achieved:
*
by increasing the size of the electrode
*
by connecting electrodes in parallel
*
by reducing the resistivity of the soil
*
where it is not practicable to obtain low earth resistance, earth leakage relays
should be used.
31.7

INJURIES FROM ELECTRIC SHOCK

*
The severity of injury by electric shock will be determined by the following
conditions :
*
Amount of current that flows through the body
*
Path of current taken through the body
*
Length of time the victim is in the circuit
*
Type of electric energy in question
*
Physical condition of the victim
*
The amount of current that flows through the victim's body will depend upon:
*
The voltage of the current with which he is in contact
*
The insulating qualities of the place in which he is located at the
instant.
*
The resistance of his skin or clothing or both
*
The area of contact with the live conductor
*
The pressure of contact with the live conductor

The current will take the path of least resistance through the body or over its
surface or will be a combination of the two Wet clothing may furnish a lower resistance
path that parts of the current may flow through the body and part over its surface.
EQUIPMENT AND HAZARD

CORRECT CONDITION

a.
Sockets on extension cords or
Use only insulated
drop cords ,brass shells become live
combination socket and
readily through moisture or conduc
handle with no live
-ting dust and dirt or through wear
parts exposed.
or hard usage. The mechanism of key
sockets may fail. Sufficient
moisture or conducting dust may
allow a shock to be received from
over a key type weather proof socket.
----------------------------------------------------------------------------------------b.
Cords(extension)insulation fails,
Use heavy live rubber
metal lamp guards and metal cases
cord plug of the
become live through lack of insulation,
moulded non- breakable
moisture or dirt ,key sockets fail, plugs
type. Good practice
break or the parts loosen. Those used on
requires that wall
portable power tools are subject to
receptacles be
harder use and are more often exposed
provided for all
to oil and grease.
extension cord use.
Avoid unnecessary wear
and abuse..
----------------------------------------------------------------------------------------c.
Electric wiring loose
Install all wiring in
or improperly insulated or
substantial and perma
inadequately spaced wire may
nent manner.Do not
cause fires. Contact even
run wiring where it
with covered wires may result
may receive mechain shocks. Improperly placed
nical injury. Allow no
wiring may be damaged.
cords, pendants or
other conductors to be wrapped
around pipes steal
columns or other metal
parts. Use only rigid
conductors in damp
basement or similarly
wet locations.Wiring
for such incidental
services as electric
irons, clocks etc should
not be substandard.
----------------------------------------------------------------------------------------d.
Fuses often bridged to
Bridging not permissible.

permit overload. Refillable

fuses with extra links to
carry starting overload.

Mounting in boxes under

lock and key sometimes
advisable.Bbridging
usually evidence of
overloaded circuit Fuses
should be on the load side
of switch and of correct
rating for load. Limit
extra links refillable
fuses to authorized
personnel only.
-----------------------------------------------------------------------------------------e.
Electric welding receptacles.
Special standard
Men attach welding leads to
welders receptacles
switch box with clips.
should be provided
for electric welders.
The practice of clipping
the loads to switch
boxes is dangerous. In
some cases clips have
been found on the power
side of the line which
increases the hazard.
-----------------------------------------------------------------------------------------f.
Switchboards shocks from
Guard live parts. Fence
exposed live parts, flashes
off spaces behind of all
from the operation of air
boards. Provide insulatbreak switches or circuit
ing mats dead frond
breakers.
boards preferable.
-----------------------------------------------------------------------------------------g.
Switches shock from
Use only safety type
accidental contact or burns
of switches. Mount them
and shocks from operation
so that blades are dead
under load.
when switch is open.
-----------------------------------------------------------------------------------------h.
Resistance controller etc
Enclose all live parts
burns from resistance grids
with operating handle
shock from live parts.
kept accessible from outside.
-----------------------------------------------------------------------------------------j.
Treatment of victim for
At least key men in
shock .Failure to do the right
every group should be
thing may mean death to the
trained to apply suitvictim.
able resuscitation. All
safety inspectors should
also be trained and be
competent to train
others.

-----------------------------------------------------------------------------------------30.8
GENERAL RULES FOR SAFE USE OF ELECTRICITY IN
DOCKYARD AND ON BOARD SHIPS

Because of the special nature of electrical work, employees working on electrical

equipment must be cautious and alert at all times ,recognizing the seriousness of
consequences which might result from a mishap. There are many unanticipated and
unusual happenings that can lead to trouble in electrical work. Regard all electrical
equipment as potentially dangerous.

All voltages should be handled properly and safely. It must be realized that relatively
low voltages such as 240v and 120v can cause injury. Very special care should be
exercised when working at elevations. A moment of neglect can result in a lifetime of
regret.
Avoid working on live equipment as far as practicable. Trouble shooting and making
connections to energized 440 volt circuits or higher, must be approved by electrical
department supervisiors and carried out under supervision.
When it is necessary to work on or near live circuits, it is important to work on only
one wire at a time and to insulate all conductors which may come in contact with the
body.
Adequate protective equipment must be used when working on live circuits. Special
attention should be given to checking rubber gloves and ensuring that they are in
good condition,
Only non-conductive ladders should be used by electrical workers.
Insulation to electrical wires cannot always be depended upon to give protection from
shock. Familiarize yourself with the conditions at hand.
Treat all electrical equipment designed for 440 volts and above as though it were live,
even though it is known or believed to be dead or de-energized.
Keep the area around electrical equipment as dry as possible to minimize possibility of
shock. Obtain dry wooden boards to stand on if necessary,
Insofar as practicable work shall not be performed on electrical equipment having
moving parts while in operation.
Shut off power before removing guards from motor driven equipment.
When it is necessary to work on an electrical circuit or other electrical equipment or
to dismantle or remove machinery driven by electrical motors, the proper switches
must be opened and tagged.
As an additional precaution, fuses must also be pulled out where provided.
Never bridge a fuse or use a fuse which is heavier than the capacity of the circuits.
Replaced fuses should be of the same capacity as those removed.
Finger rings, bracelets and metal wrist watches should not be worn by persons
working with electrical equipment.
Tags are to be used on switches when these are opened to permit work on electrical
equipment.

Electrical switches must be tagged properly by authorized persons when working on

electrical motor driven equipment .
Never close a switch without having full knowledge concerning the circuit and the
reason why the switch was tagged open previously.
Do not operate any oil immersed switch with the oil pan in the lowered position.
On 2,400 volts and above make sure that the switch is disconnected on the line and
tagged before opening the enclosure or the oil tank of a circuit breaker, starter or any
other electrical device.
While opening , shield the eyes from a possible flash.
Be sure the circuit breaker is open before attempting to remove draw out type circuit
breakers from their enclosures.
Replace cover plates on lighting and power cabinets or other electrical enclosures
after repairs.
Safety belts is to be part of a linemans equipment and is to be used whenever the
lineman is supported by climbing hooks at an elevation. Lineman should check safety
belts before each use.
Climbing hook should not be worn unnecessarily while working or walking on the
ground.
When serving a lineman the groundman should not stand at the foot of pole .
Consider a line hot unless it is grounded.(ground all phases of the line)
Handle telephone or signal wires with care since these may come in contact with high
voltage wires thus becoming dangerously charged.
Support shaky poles with pike or by other means before removing all wires.
It is best not to use arm guys, braces or fixtures as handhold while climbing pole.
These might pull loose.
In working on hot lines 440 volts or over, two men should always work at the pole
together except when changing fuses. One man must keep himself in the clear and in a
position to aid his pole mate if necessary.
Personnel working on elevated hot circuits from insulated baskets of the aerial
platform truck should make certain that loose materials being handled do not ground
them to the machine.
Temporary installation shall conform to generally accepted safety practices. It is
particularly important that all electrical installation be properly grounded, sufficient
clearances be provided over railroads and roadways, and proper type equipment be
installed in a gaseous areas.
Suitable barricades must be installed around exposed temporary high voltage
electrical equipment such as field transformers.
Barricades or markers must be provided for unattended open under ground conduit
manways. Watch carefully for flammable materials seeping into manholes and taken
necessary precautions to prevent being overcome by vapour or igniting the material.
Inspect all electrical extensions before placing in services. Avoid wrapping cords
around any part of the body.
Temporary lighting circuits of 120 volts and approved fixtures may be installed in
tanks or other large vessels provided the lines are in conduit or are suspended beyond
the reach of workman.

Ground all electrical power tools. Examine electrical extension light tool cable for
defects before using.
PORTABLE ELECTRIC TOOLS

Common cause of accident

Not providing earth
Improper neutral connections
Loose connection
Make shift methods
Improper accessories

Precautions
Earth the body by means of
3 core cable with 3 pin plug
Neutral connections should
be taken only from neutral
load.
Inspect frequently and
maintain proper connection
Never adopt make shift
methods.
Use only proper accessories

Protection through reduced voltage

*
The safest method is to use portable tools working on low voltages with step down
transformer 230/20v
*
By earthing the centre tap of transformer secondary, the voltage to earth(shock
voltage) is reduced to half the supply voltage from secondary.
*
From medium size tool rated 110v, use of 230/110v transformer with earthed
center tap on secondary is recommended. Shock voltage in this case will be limited to 55v.
*
For voltage reduction, double wound transformer only should be used.
Protection through isolating transformer
The principle of safety in this system is to isolate the secondary circuit from both the
supply and the earth system.
*
Metal frame of tools need not be earthen.
*
Tool circuit should be as short as possible and well maintained to keep it earth free
always
*
There should be a separate transformer for every appliance.

CHAPTER 31
CARDIO -PULMONARY - RESUSCITATION
31.1
Cardiopulmonary Resuscitation (CPR) plays vital roll in prevention of
death in cases of accidental contact of electric shock and unconsciousness due to toxic
gases inhalation. If breathing has stopped, artificial/manual respiration can be
performed but correct method is to be carried out by experienced persons. The
procedure of CPR is as follows : Basic Life supports:- Airways, Breathing, Circulation.
*

AIRWAYS
Lay victim on his back. If any foreign matter is in mouth, turn the head to one
side, force mouth open and wipe it out with fingers. Tilt head as far back as possible by
holding the crown of the head with one hand and pull the chin. This makes air passage
clear to his lungs.
*

BREATHING :
Keep his head tilted backward and separate lips with thumb. Open your mouth
widely and place it tightly over his mouth. Press your cheek against his nostrils to
prevent air leakage . Watch the victims chest as you blow, when it rises take your mouth
away and let him breath out naturally. Listen to the air being exhaled. Make the first ten
breath deep and at a rapid rate to give a good, quick supply of life giving oxygen.
*

CIRCULATION :

If victim doesnt respond to the above method start the circulation method. Stop
blowing for a moment and press your hand (by keeping hand on hand) between navel
and breast bone. Release hand pressure and blow air again. Repeat the procedure.
Never interrupt circulation for more than 5 seconds.

Because electrical shock can stop the heart and lungs, be sure that worker involved in
hazardous electrical energy level know cardiopulmonary resuscitation (CPR) and
rescue procedure. CPR training is provided by National Safety Council, First Aid
Association,

Immediately apply CPR to a victim of electric shock . Continue CPR until they
revive , or until a physician diagnoses death. The sooner that CPR is started , the
better the chance of revival.

Be sure that employees engaged in tank cleaning know appropriate first aid and CPR.
Have them periodically trained in these skills. A tank cleaner who is overcome by
vapour or toxic gases should be removed to fresh air immediately and, if necessary,

given CPR until breathing resumes. Summon medical assistance, and keep the rescued
worker and warm until breathing and circulation are normal.

CHAPTER 32

ELECTROPLATING
32.1
equipment.

Following safety measures to be taken during working on electroplating

Always wear gumboots, rubber hand gloves and rubber

and working with chemicals.

Wear gas masks while working with toxic and hazardous chemicals.

Wear face mask /face shield and cotton apron while buffing and polishing
operations are being carried out.

When handling different types of chemicals, ensure that the gloves are washed
thoroughly before handling other chemicals, to avoid mixing up of chemical
which may produce poisonous gases and also chemical reactions may produce
heat which will damage hand gloves.

Do not forget to wash hands and face before taking food and water.

32.2

apron while handling

In case of accidental contact with chemical :-

Wash body with copious amount of running water for at least 15 minutes and
get medical aid quickly.

In case of eyes-thoroughly clean it in water fountain atleast for 15 minutes and

go for medical aid quickly.

All poisonous and dangerous chemical should be kept in a locked room and
accesses to the room should be allowed only with the knowledge of superiors.

Never store strong acid and alkalis together, An accidental spill may produce
poisonous gases as also a fire hazard.

Keep the lids of storage vessels in which chemicals are stored , tightly closed . This
will prevent contamination with air.

While diluting sulphuric acid always add sulphuric acid in water.

water to sulphuric acid .

A lways start exhaust system before any plating job is done.

Never add

Ensure that the temperature of different solution are correctly maintained

within specified limit.

Always wash the job after treating in acid or alkali before dipping in other solution to
avoid formation of obnoxious gas.

While preparing solution for plating operation the density of the mix should be in
ascending order .

During pickling of metal in hot acid desired temperature should not be exceeded
.

Avoid strong acid (nitric and sulphuric) to fall on wooden shell, saw dust , waste
cloth, or any other organic material.

For taking out fallen parts from the bath, special devices should be used like
strong magnet for steel and perforated scoop for other parts having large handle .

While changing and refitting wheels of polishing machinery ensure isolation of

electric current to avoid accidental running of machine .

Before starting the polishing machine operation, ensure that the direction of
rotation of machine is correct.

All persons working with chemical and electroplating operation should be well
trained and conversant of safety precautions to be observed during operations.

Warning board must be displayed in the shop at conspicuous places as also

correct handling procedure and instruction.

All employees should be made aware about the danger and precaution to be
taken in case of emergency.

Emergency handling kit must be located at conspicuous place and should be

known to concerned people..

CHAPTER 33
HIGH PRESSURE AIR, HYDRAULIC SYSTEM
GENERAL GUIDE LINES WHILE WORKING ON / WITH
PNEUMATIC AND HYDRAULIC SYSTEMS :

HIGH PRESSURE

All personnel who maintain, repair, or operate pressure equipment/s should be

familiar with their hazards and the precautionary measures which must be observed.

Only qualified and authorized personnel should install, maintain, repair, adjust, or
operate pressure system equipment, specially the safety devices
Personnel assigned to work on pressure systems should be familiar with the locations
and purposes of the control valves and with procedure for emergency
depressurization.
Pressurized equipment and lines should be depressurized before any repair is
attempted or any effort made to loosen or open any parts. Pressure vessels and lines
should be considered hazardous until it has been absolutely established that all pressure has been released. Personnel should themselves ensure that a system
depressurised either by checking a gauge connected to the immediate line or
equipment, by opening a test cock, or by noting that a disconnection in a line already
exists.
All pressure system components should be marked to indicate their rated pressures
and direction of flow.
Face shields or goggles should be worn by all persons working on or with pressure
systems.
Compressed air at pressure greater than 2 kg/cmsq should not be used to clean metal
chips or other solid particles from work areas or from equipment unless protective
equipment is worn. Compressed air should not be used to clean clothing or parts of
the body.
Compressed air should never be directed at another person .
The pressure system being installed or repaired should be kept clean and free of dirt
or debris, which might be accelerated to high speeds in the lines and cause internal
damage to piping or equipment.
Rigid lines should be used where possible, instead of flexible hose. Lines should be
secured on both sides of a bend at suitable intervals along straight runs and near
connection fittings.
Where a flexible hose is necessary it should be as short as possible and clamped
(preferably) or chained to a fixture of strength. A long hose should be weighed down
with lead weight (preferably)or sandbags, or otherwise secured along its length at 1.8
mtr intervals. The entire length of the hose should be contained by a structure system
separate from the hose, but in no way interfering with its normal flexibility.
A hose should not be used at a pressure greater than its manufactured rating. The
hose should be checked to determine whether it is intended for use at the desired
pressure . The hose and fittings should meet appropriate standards. When not in use
the hose should be plugged or capped and stored in a designated location where it will
not be subject to deterioration.
No pressure line should be used as a step for climbing.
Pressure vessels, hose lines and other equipment should be tested periodically and at
the pressures indicated in prescribed regulations ,codes or standards as per the
Factory Act 1948. The records of inspection ,test, examination and repairs carried
are to be maintained in a register. Same shall be produced to the Factory Inspector
on demand.
No system requiring a pressure regulator, pressure reducing valve, safety valve or
other relieving device should be activated unless it is in place and in operable
condition. Only qualified and authorized personnel should change the settings on these

valves and regulators. Where changes are made, the valves should then be retested
for the desired settings.
Each high pressure vessel and any line which can be closed off should be equipped
with a suitable relieving device. There should be no shutoff valve between the vessel
or line and the relieving device. The relieving device must be sized to permit flow
which will keep the pressure to a safe level.
Safety and relief valves should be tested at prescribed intervals. Leaking valves
should be replaced. The discharge from a pressure relieving device should be
conducted to a safe area.
Valves should be checked periodically to ensure that they will work adequately and
safely under the pressures which will exist in the systems in which they are installed.
Valves should not be installed in an inverted position since they might get filled with
debris and be difficult to close.
Valves should be used only in the manner for which they are designed. Gate valves
should be used only in the fully opened or fully closed positions.
Where possible, valves should be installed in fail-safe configurations so that any valve
failure will result in the safest possible condition for the system.

CHAPTER 34

RADIATION
34.1
Radiation cannot be seen , cannot be felt, cannot be smelt, cannot be heard
and cannot be touched, yet it exists. It is abuse or improper use presents great hazards.
These are two types of Radiation
1)
2)

Ionizing Radiation
Non-ionizing Radiation

34.2
IONIZING RADIATIONS : Alpha, beta, neutron particles , X-ray and
gamma rays are ionizing radiation.
EFFECTS OF IONIZING RADIATIONS

Blood : White cells are most sensitive to the radiation ,which will reduce their
number and, blood clotting capability . Number of red cells decreases to a point that
results in anemia.

Bone marrow : Radiation can cause injury to bone marrow which resulting
replacement of new blood cells not taking place.

Eye :

Skin : Easily damages the cells.

Reproductive Organs : It produces sterility in a person at a high dose. Damages,

reproductive cell after exposure.

Digestive System : Damages the cells of small intestine causing nausea and vomiting.
Further exposure may lead to ulcers and inability to absorb food.

Can create cataract since the cell are not being replaced.

Symptoms and effects from acute body exposure to Radiation

Exposure Range

Symptom/effect

(Roentgen)
a.) 0 - 25

Delayed effect may occur.

b.) 25-100

Delayed effect possible, but

serious effect on an average
individual unlikely.

c.) 100-200

Produces nausea and fatigue

with possible vomiting.

d). 200-300

e.) 300-600

f)Above 600

34.3.

As above. Further loss of

appetite general illness or
discomfort, sore
throat
,diarrhea and moderate
emancipation.
As above for the first few
hours and thereafter
followed by hemorrhages,
inflammation of
mouth and
throat. In some
cases death
in 3 weeks. Possibility of
death 50%.
Produces above symptoms
within a few hours,following
exposure may cause fever
and an early rapid
death as second week
(possible death 100%)
NON IONIZING RADIATIONS

Non-ionizing means radiation caused by electromagnetic region for ultra violet to

radio waves . Three major types which can cause injury are ultra violet, infrared and
microwaves.

ULTRAVIOLET :-- Injurious, either by thermal or photochemical . These waves

cannot penetrate through intact skin but under certain conditions and wave length
can cause rapid increase in cell of lower layer of epidermis, which tends to thicken.
When an acute dose of 8 milliwatt - sec/per sq. EMS is received it will cause second
degree of burn . In certain cases it may cause skin cancer.
(a))

Effect on eyes :

High energy X-rays and gamma rays pass completely through eyes .

Short ultra violet, absorption occurs principally at cornea.

Long ultra violet and visible light are refracted at cornea and rays are absorbed at
retina.

Near infrared energy is absorbed in ocular media and at the retina. Near infrared
are refracted.

Microwave radiation is transmitted through eyes although a large percentage may be

absorbed.

INFRARED RADIATION :-- Infrared radiation is electromagnetic in nature . This

can be easily converted into heat energy. That is why this give thermal effect on the
body and its parts.
Bad effects of infrared radiation :

Skin burns

Long and continued exposure to high intensity may result in permanent capillary
dilation so that skin always appears red.

Heat exhalation

Heat cramps

Causes cataract of eyes

Damages intestines
Shielding Recommended for Ionizing Radiation

Radiation type

Range of Rays
Shield material
in Air
Type
Thickness
---------------------------------------------------------------------------------------

Alpha Particles
(4 million electron
volts)
Beta Particles

2.8 cm

Al. sheet ........

Paper ........
Ord. clothing ..

13.00 mtr

Lead..........

1mm
1mm
.1mm

1.4 mm

(3 million electron

Al.

.........
5.3 mm
volts)
........... 6.6 mm
Lucite .......... 12.4 mm
Water ......... 14.8 mm
Shielding is accomplished by
reducing intensity of incident
gamma rays by scattering
intersection with a shield. The
thickness of material required
to reduce radiation by 1/2 is
called half value layer The half
value layers for typical materials are :
Lead..............
7.5mm
Iron .............
12.5 mm
Al. .............
68.5 mm
Concrete ........
68.5 mm
Water ................ 210 mm
Pyrex

Gamma rays

Microwave Radiations :-The absorption of the waves by the body may increase the kinetic energy which
manifests itself as heat- some times with an increase in temperature. The main hazard is
incapability of organ to dissipate the heat of microwave energy, with possible burn
injury.
Sources of this radiation :
a)
Oven
b)
Dryers
c)
Heater
d)
High Power Radar system
e)
Air craft and aircraft control radar
f)
Navigational radar
g)
Microwave communication system
h)
Alarm system
i)
Signal generators
Power density of 100 MW/cm3 for 1 hour
frequency 1.2 to 24.5 x 10 hertz -can be increase thermal body temperature and can
cause cataract.
Safe permissible level is 10 mw/cm3 (American standard)
Protection for microwave radiations :

No microwave antenna or other emitter should be inspected nor work be done on it

by a person in the radiation path during periods when it is energized.

Dummy loads or water load should be used whenever possible to absorb the energy
output of transmitting microwave equipment while it is being operated or tested. If

this cannot be done, absorbent screening should be used to isolate the radiating
equipment.

Operating microwave equipment should not be pointed towards inhabited area.

Rings ,watches, keys or other metallic objects should not be worn or carried by a
person working in areas where there might be microwave radiation, including
radiation of low intensity.

Tools or other metallic object that were in a microwave field should be grasped
carefully because they may be hot.

Flammable or explosive material, in or in contact with a metallic container, should not

be left in an electromagnetic field generated by microwave equipment.

A warning device should be provided on each piece of microwave equipment to

indicate when working.

34.4

PRECAUTIONARY MEASURE

AGAINST IONIZING RADIATION

Only personnel familiar with the hazard involved should be permitted to use, operate,
handle, transport, or store equipment or material which produces ionizing radiations.
Ensure that operators of ionizing radiation equipment are currently certified where
certification is required.
Prior to activation or use of a facility where ionizing radiation may be produced, a
survey should be made by a qualified expert to determine the adequacy of the facility,
its equipment protective devices, and safety precautions.
Safety engineers should be aware of any equipment or material in their plant which
could produce ionizing radiations, and ensure that suitable precautionary measures
are stipulated and in use. Ensure that a license is obtained for each ionizing radiation
source prior to initiation of operation.
Operating and emergency procedures for radiation safety should be prepared and
posted at the accesses to any facility where there may be ionizing radiation. Personnel
working in such facilities should be familiar with these procedures.
Access to areas in which equipment or materials producing ionizing radiation are
present should be restricted to personnel directly concerned with operation,
maintenance or other required activity.
All accesses to areas in which ionizing radiation may be present, either intentionally or
accidentally, should be posted with suitable warnings. Accesses to locations where
equipment generating ionizing radiations are in use should be provided with flashing
or rotating purple warning lights which operate automatically when radiation is being
produced.
All electronic devices capable of producing radiation should be operated only in
shielded enclosures which attenuate the radiation to a permissible level on the outer
surfaces.

Radiation levels outside shielding, around equipment or material emitting ionizing

radiation should be monitored periodically to ensure that the effect of the shielding is
maintained.
Records should be maintained for individual exposure to ionizing radiation to ensure
that permissible levels are not exceeded.
Periods during which personnel remain in areas where ionizing radiation may be
present should be kept to a minimum.
Any person who believes that he has been subjected to ionizing radiation should
report to the medical facility for examination.
Personnel who enter areas where ionizing radiation may be present should be
provided with personnel dosimeter to measure excessive doses.
Protective clothing and equipment worn in such areas will depend on the level of
radio activity that might be present.. Wearing of overalls , hoods, masks, gloves, shoe
covering, and other equipment will depend on the risk and level of possible
contamination.
No edible material of any kind, cosmetics or cigarettes should be brought into an area
where there might be the possibility of radioactive contamination. Hands should be
washed and outer protective clothing discarded after leaving hazardous area and
prior to eating, applying cosmetics or smoking.
Cleanup techniques, equipment, and procedures should be developed and ready
before any radioactive material is permitted in the plant. Procedures should include :
Any person who notices a spill of radioactive material to notify the proper office or
person responsible for containing and cleaning up the spill.
Rapid action is to taken to minimize spread of spilled radioactive material. Fans and
blowers to and from the affected area should be turned off, and windows and doors
closed and sealed. Spills of radioactive material should be covered with wet absorbent
paper or cleaned up with vacuum cleaner specifically designed for the purpose if one
is immediately available. A wet spill should be covered immediately with absorbent
paper.
Accesses to affected areas should be marked with warning signs.
Anyone who may have been in the area where the spill occurred should be checked for
contamination. If affirmative, he should be directed to obtain medical assistance.
Cleanup and decontamination should be undertaken only by personnel designated
and trained for the purpose. Personnel decontaminating affected areas or equipment
should do so only while wearing appropriate protective clothing and respiratory
equipment.
No other person should be permitted to enter the area until it has been monitored and
confirmed that no contamination exists.

PART : 6
CONSTRUCTION PRODUCTION
SYSTEM

CHAPTER 35
WELDING AND CUTTING
35.1

a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
m)
n)
o)
p)
q)

REGULATION AND INSTRUCTIONS FOR THE USE OF WELDING

GEAR

Welding connections between transformer and regulator must be of a firm fit.

All cable junctions must be kept firm with no bare metal .
All cables in service must be kept to full insulation standards at all times
No electrical kinks in any power cable are permitted
Regulators must be checked frequently for oil leaks .If oil leak is observed the
regulator must be withdrawn from service.
All earthing must be of a positive nature and temporary earthing must be kept as
short as possible. Improper or loose earthing is dangerous due to possibility of leakage
of current.
Electrode holder must be capable of gripping the electrode firmly as any slackness will
generate heat through the holder.
All holders must be kept in a safe position as any connection to the work piece for any
length of time ,will result in an electrical fire.
All regulators should be put in the "off" position if out of use for any length of time.
No "live" equipment should be touched without gloves
The presence of dampness or water increases the possibility of electrical shock
No wire slings or shackles should be used as an earth lead. This practice can seriously
affect the life of the equipment
No regulator should be interfered with, whilst the arc is established, since severe
damage will result.
Do use the correct goggles ,hand gloves face shields.
All welding helmets should be maintained in such a condition that no rays can
penetrate though the face shield.
The welding filter glass must be kept solinter and crack free to prevent eye strain.
Stray arc should be avoided, as this can lead to hair line cracking and plate failure.

35.2

REGULATIONS AND INSTRUCTIONS FOR THE USE OF BURNING

EQUIPMENT

a) Burning equipment is to be tested every fortnight and a record kept.

b) Any defective equipment found by test or at any time must be withdrawn and
replaced.
c) New employees are to be issued with new or tested protective gear, like gloves,
goggles and a copy of safety rules.
d) Cylinders must be handled with care .They should never be dropped. Use of rollers or
supports is recommended. Cylinders should be kept upright.
e) Cylinders should not be exposed to heat from flame, boiler, etc. In case, they get
heated they must be safely cooled with water.

f) Do not allow oil grease or any combustible material to come into contact with
cylinders ,valves ,regulators or fitting as they could be dangerous.
g) The valves of cylinders or pipelines, must be closed immediately, when any defect
develop in the gear ,when stopping work, when supplies are finished or during
shifting to another job.
h) Cylinder and pipeline valves must be cleaned and free from grit. After fitting of any
regulator, ensure that valves are opened slowly, confirming that no naked flame or
fire is nearby.
i) Do not test for leaks with flame, but only by using soap water.
j) Cylinder must not be taken below decks or into confined spaces. Care must be taken
that the hoses and blowpipes are also taken above deck , after completion of work.
.
k) Non-return valve should be fitted at blowpipe and hoses to prevent flashbacks.
l) It is the responsibility of all operators to ensure that on all occasions when using
burning equipment that the proper gear is used and properly assembled.
m) All work to be done on ships fitting should be carefully assessed for fire risk, and
necessary precautions taken.
35.3

WELDING, GAS CUTTING AND HEATING OPERATIONS

Any tank or drum container shall not be subjected to hot work unless the greasy
contents of the container are thoroughly cleaned. The tank or drum shall be filled with
water to drive out all gas before hot work is commenced.
Use of preservative to remove chemical in the form of gas may be recommended for
cleaning.
No naked lights should be taken near a drum or a tank known to have contained paint
or freshly coated with paint. This also applies to a tank or very small enclosed
compartment freshly coated with zinc primer. This is an explosion risk
If a welder has to enter a tank or drum which had contained petroleum products for
welding the same is to be tested for gas free conditions before starting work and
adequate ventilation is ensured.
Hollow ,one piece cast brass buckets or jacketed vessels shall be vented either by
opening a plug or drilling a hole before heating or gas welding in order to prevent
building up of pressure and subsequent explosion.
All structural voids like the inside of a rudder, bilge keels etc are to be vented by
opening out the plugs at the top most part and at the bottom and if possible shall be
filled with water and drained before applying gas cutting or heating or welding.
While carrying out heating or gas cutting work water is to be sprayed on the metal
surface having metallic continuity with the surface area worked on to prevent the heat
being conducted to the area covered with toxic coating or having some combustible
material.
When resin is filled in a cupro-nickel and iron pipes to facilitate flawless bending
this resin shall be removed after the bending operation by gradually heating at one
end and keeping the pipe inclined for draining the melted resin to avoid building up
of locked vapor pressure within the resin column in the pipe.
Gas bottles shall be handled by using rope, not slings.

If a dent is observed on a gas bottle without the marking on it indicating meaning

tested or examined, that bottle is not to be used, the bottle is to be sent to the shop with
a tally and a report to the superintendent welding for action.
When an officer in site happens to see that a gas bottle received a severe bump while
handling shall give a visual check up if it is badly damaged in which case the use of
such damaged bottle will be disallowed and sent back to the shop with a tally
"damaged while handling".
All gas bottles outlet valve fittings shall be protected with a metallic screwed cap while
in transit.
turn off the gas cylinder valve when not in use and release the regulator screw before
turning on the cylinder valve.
open the cylinder valve slowly.
Grease, oil is not to be applied to the gas bottle valve fitting or to lubricate the
protection cap threads.
Gas cylinder bottles shall not be taken into confined spaces
While transporting gas bottles they are to be well secured.
While shifting gas bottles in the shop or place of work ,they are to be tilted and rolled
on the bottom edges but must not be rolled in the horizontal position.
Welding electrodes must not be struck on gas cylinders. This is a serious offense.
Rubber hoses that have suffered a flash black are found in bad condition must not be
used unless tested and certified by the head of the welding department.
While opening a box containing gas rubber hoses the worker shall be instructed not
to smoke.
Gas cylinders shall be kept at a good distance from the place where electric welding is
in progress so that any spark from welding does not reach the gas cylinder.
Workers in the vicinity of electric welding work area to protect their eyes against arc
inside the shop and on the ship under repairs
Portable screens shall be supplied to all welding shops. Structures, pipe lines carrying
oil, yard crane tracks are not to be used as part of the return current circuit.
At the end of each shift or during lunch break if the work is suspended for a
considerable length of time, the welding current is to be "switched off".

35.4

NON DESTRUCTIVE TESTING

a. Use of oxygen as compressed air is prohibited.

b. Do not weld galvanized or other treated material without taking the correct
precautions.
c. Do not try to trace a gas leak with a match or flame.
d. Do respect the warning notices posted during radiographic inspection work.
e. Do not get too close to x-ray or gamma-ray equipment when in use,
35.5 PRECAUTIONS TO BE OBSERVED PRIOR TO UNDERTAKING HOT WORK
ON BOARD IN SHIPS/YARD CRAFTS ETC.
HOT WORK

All items of work involving riveting, gas welding & cutting electric arc welding,
TIG and MIG welding is termed as "Hot work. Even caulking or chipping in way of
magazines is termed as Hot work.
"When a compartment is safe for entry it is not necessary that it is safe for hot
work".

The following spaces are not safe for hot work.

Area within 2 watertight decks or watertight bulk heads adjacent to a magazine
containing ammunition.
Areas within 6 mtrs from any loaded ammunition locker, live depth charge storage,
torpedoes, pyrotechnic storage, life raft storage or live magazine.
Area in the near vicinity (within 18 cms) of any live paint/sprig/wine/ghee store, lub
oil, fuel tank air escape pipes of fuel tanks of the ship in question .
Whenever a loaded tanker or an oil tanker is berthed alongside or fueling or refueling
operations are in progress.
Any pipe, truck or fitting's portion of which passes through a live magazine.
Areas within 6 mtrs of a live fuel pipe line or oil storage on board or ashore, oil in the
water.
Areas within 10 mtrs of a battery ventilated system in use but not vented.
Spaces containing oil, sludge or rags/wood sawdust soaked with oil.

35.6

PRECAUTIONS

Remove all flammable material such as wooden frame work, furniture, stores, canvas
etc well clear of the hot work limits.

Cover deck coverings such as linoleum, PVC tiles etc with wet asbestos.

Cover all electric cables in near vicinity with wet asbestos

Ensure where staging is rigged that only wire lanyards are used.

Make the boundary limits of the hot work on both sides of the steel surface in blue
paint and ensure no work is carried out beyond these limits.

Inform ship staff about the areas where hot work is to be carried out as early as 16
hours prior to the commencement of actual work and obtain a certificate in duplicate
listing all the compartments declared safe, from the Officer on duty of the ship

Ensure that adequate fire precautions are taken and fire sentry is always present
while hot work is being done.

CHAPTER 36

PLATER/BLACK SMITH/SHEET METAL

WORK
36.1
*

DO'S AND DON'T

Hydraulic Press

While bending awkward centered shapes of plates ,operators must stand behind the
cover to guard against flying wedges

Use wedges, preferably made of wood

Hydraulic Press Brake (300T)

Use gloves while handling plates for flanging and swaging

Guillotine Machine

a.

Do not operate the machine without the transparent guard

b.
Foot should be put on the peddle switch under the guard only when the machine is
to be operated. The foot should be withdrawn during the waiting period.
*

Plano Sheer Machine

While handling cut pieces ,use gloves and shoes.
The operator should ensure that all the workmen are clear of the hydraulic rams
when switched on for clamping the job
During shearing operations the workman handling and feeding the job must wear
gloves and safety shoes
The separated section falls freely and so the workman should keep clear of the back
side of the machine

COLD FRAME BENDING MACHINE

Handle carefully while feeding the length of the frame and watch your fingers

36.2
*

GENERAL RULES
Safety shoes are the important gear of your protective dress, wear them

*
While working on unit assembly, be aware of the surroundings, keep your tools
well within your comfortable reach
*
Report unsafe conditions to the head of your department
*
Warn your co-workers against unsafe practices . One man's fault may endanger
many persons lives
*
While cutting plates on machine or punching on machine see that the machine is
well guarded
*
While using an oxy-acetylene cylinder, do not dash or throw it on the ground ,from
a height while working. Keep the acetylene cylinder vertical and well secured and oxygen
cylinder horizontal to the ground. Do not expose it to heat or let it come in contact with oil
.After completion of work, cylinder is to be shut off and checked for any leak
*
While working on grinding machines see that the gap between the wheel and
holder is not more than 1/16 inches. Portable grinding machine should have a guard
fitted.
*
Do not use compressed air for ventilation purpose .Flying dust particles are
injurious to health
*
Wear proper clothing and use personal protective equipment as necessary for the
type of job
*
Maintain the shop's cleanliness and keep aisles clear to promote safety.

CHAPTER 37

PAINTING
37.1

SPRAY PAINTING AND BRUSH PAINTING

For Zinc rich , primers and other similar paints mixed with toxic solvents
like xylene, Toluene or Benzene, the following precautions are to be observed.
*.
Zinc rich primer is usually sprayed in an open shop like platter and assembly
shop, where steady flow of fresh air current is to be maintained to clear the space filled
by explosive vapour.
*
For maintaining the current of air, blowers at one end shall be used with induced
draft exhaust blowers at the other end.
*

Smoking or use of naked lights is to be prohibited.

*
Use of any electric fitting or equipment like blower or exhaust fan motors shall be
used with flame proof and shock proof arrangement only.
*
All metallic parts of the equipment in use like spray nozzle body and blower or
exhaust fan frames shall be of non ferrous materials. In case the frames are of ferrous
material they should be properly earthed.
*
If the ventilation of the space fails, the spraying work is to be stopped or a
continuous check of the atmosphere is to be made to keep air gas mixture, below 10% of
the lower explosive limit. Maintaining a frequent check on the atmosphere will be
considered prudent.
*
It shall be considered hazardous to carry out gas cutting or welding work within 4
to 6 mtrs from the place where the shopcoat primer is being sprayed. Even if the gas
cutting or welding work is needed to be at a distance of 4 to 6 mtrs, a water screen shall
be provided. Any other barrier screen is also to be permitted, provided the ventilation
and clearing off the solvent vapor is in an efficient manner and the barrier is high enough
to prevent any accumulation of vapor to rise up and cross over the barrier to settle down
on the other side.
NOTE: Remember that hydrocarbon vapours are 1.4 to 1.8 times heavier than air.
*
The workmen spraying the paint in the pit shall wear a filter mask, similarly a
workman entering the pit for a short period shall also wear a filter mask to prevent
inhalation of toxic dust.
37.2

PAINTING IN ENCLOSED/ CONFINED SPACES

*
Workers are to be protected with air line respirators with tight fitting rubber
mask in confined spaces. These should be able to regulate the air pressure as per
requirement.

*
Worker working in the confined space are to be aided by another helper who can
be contacted in case of an emergency for assistance. The communication may be by a
string passed between them .
*
The compartment being sprayed or painted is to be ventilated by means of an
extraction fan with a suction hose as low as possible in the confined space.
*
Fresh air intake is to be either through a natural current from outside atmosphere
into the tank or by means of an air hose little above atmospheric pressure, with its outlet
a few feet below the tank opening.
*
No attempt shall be made to freshen up the enclosed compartment by injection of
air at a pressure of 7 kg/ sqcm. This is likely to stir up the tank atmosphere giving a fine
mist of air and vapour, thus increasing the chances for an explosion hazard.
*
All paint drums and thinner drums are to be kept away from the compartment to
be sprayed. If they are required to be brought to the place for mixing of paints, they shall
be kept on wooden planks and not on the steel deck of the ship.
*
Temporary flood lights introduced inside the compartments are to have non
ferrous reflectors and are to be of flame proof construction and of approved and certified
quality by a competent authority, and power cables are to be with good insulation.
*
Spiral steel springs embedded inside walls of the extraction hoses and the
body
of extraction fan blower kept outside on the main deck on the ship, to be properly
earthen.
*
Exhaust ducts are to be discharged clear of working area and away from the
places where hot work is done or any other possible source of ignition, like sparking
electric motors or boiler funnel sparks.
*
If the ventilation stops on the confined space being sprayed , the spraying work is
also be stopped. Ventilation of the space to be continued for at least for an hour after the
spraying is stopped or until the compartment is gas free, if the gas freeing time needed is
to be more than an hour.
*
Under no circumstances, any exhaust ducts (or hoses) are to be removed from the
compartment unless the sprayed/painted compartment is completely gas free.
NOTE: While attempting to remove an exhaust duct from a sprayed
tank/compartment which is not made gas free, the vapour column inside the duct breaks
off from the connection to the tank, and if at that time ,there is a charge of static
electricity, and if the mixture is at flash point, an explosion will occur .

*
While pouring paint thinner or solvent from the drum into a container, metallic
contact is not to be maintained between the drum and the container so as to keep them at
the same static electric potential.
*.
The shopcoat primer is not to be used in an enclosed compartment. If at all it is to
be used for touching up on few exposed spots, not more than one man is to be allowed
inside the compartment at a time. He is not to carry more than the necessary quantity of
paint and he should work for a limited time. He is also to be given assistance of a helper
who will remain outside the compartment to enlist help, if necessary.
*
Adequate ventilation of such a compartment is to be maintained by using
extraction hoses. If the compartment has only one opening the extraction hoses is not to
cover more than one third area of the opening and shall permit easy exit of the workmen.
*.
If touching up with paints, is likely to take a longer time, then two operators are to
be deputed to enter the compartment to work in turns and each is to be given a helper for
assistance. These operators are to be protected with filter masks while at work.
*
Solvents used for quick drying paints are aromatic compounds of Benzene group.
Workers known to be addicts to these compounds are not be entrusted with work in an
enclosed compartment or otherwise their movements shall be timed and controlled by a
supervisor. Similar precaution is necessary when a workman is put in a small
compartment like a stern gland compartment(pump and filter space) to clean stern gland
seal components with any cleanser. This compartment should be well ventilated while
such work is in progress.
37.3

IMPORTANT NOTES ON SPECIFIC WORK

Rubber based metallic paints with aluminum powder in suspension is highly explosive.
If static electrical charges are set up and discharged in this atmosphere the
consequences are disastrous.

Epoxy resin have been in use for more than twenty years and the resins technology is
being continuously improved upon. These plastic coating could be sprayed as well as
applied by a brush. Different blendings of various varieties of resins manufactured are
supplied to the customers depending upon the physical properties called for, while in
service ,as protective coating of the steel structure. Pure resins themselves do not
present a potential danger so far as health is concerned. But the hardeners used with
epoxy resins are skin irritants, having some potential to cause dermatitis or eczema in
which case use of various
barrier creams, sold under commercial names KERODEX (for protection) and KEROCLEANS are suggested. Our experience is confined
to the type ARALDITE liquid epoxy resins, which is solvent free, gives out negligible
vapour, with mixture HY 850 as hardeners, which present low potentiality towards
dermatitis or eczema.

CHAPTER 38

DOCKING AND UNDOCKING OF SHIPS

38.1

GENERAL INSTRUCTIONS

During docking and undocking time, the area on either side of the dry dock is to be
clear of all obstacles ,so as to give full freedom of movements to the ship's hauling
ropes, persons etc.
The ground surface on either side of the dry dock is to be maintained at even level all
the time. Any pit left in the ground while handling heavy material, such as steel plates
etc. are to be filled in.
If the ground in the vicinity of the dry dock is dug up for repairing any underground
installation like water pipe line, electric cable etc. it shall be made good immediately
after the repair is completed. Until then, a danger warning sign and rope railing
surrounding the area shall be kept. At night to a red lamp is also to be used to indicate
this danger.
While towing a ship inside the dry dock by means of a winch or a capstan on the shore
or by means of ships windlass, workmen should not be permitted to go over,
or
under the towing line, under tension.
After the docking or undocking of the vessel , the barrier chains removed alongside
the dock walls are to be replaced in position.
While undocking the vessel, regardless of its size, the barrier chain posts are not to be
used as bollards to hold the vessel in position. Similarly, no lines likely to be in tension
are to be tied to pipe lines or any such other objects ,which are not to be used as
bollards.
After the vessel settles on the blocks and the water is pumped out, the dry dock is to be
properly cleaned and cleared of all the debris, shells, and barnacles etc. before the
work commences.
All stone steps and the dry dock floor are to be scraped and kept free from marine
growth every time a vessel is docked and settled on the blocks.
All workers working in the dry docks are to wear helmets, non- skid shoes and
overalls atleast.
Personal working on the ships side or at height are to wear safety belts in addition.
All tools, equipment, items are to be separately secured laving the hands free for
work or personal protection.
The dry dock is to be well illuminated, especially at the stair cases entrances and
around the sides.
If there is any spillage of oil while draining out fuel oil or lub. oil or oily water bilges
into drums, the dry dock is to be washed down and the water is to be pumped out of
the dry dock.
Oil filled drums are not to be stored on the dry dock floor, where gas cutting and
welding work are in progress.

Old double bottom plates or shipside plates ,removed for renewal are not to be left
either on dry dock floor or along side of the dry dock for more than twenty four
hours.
The barrier chains along the dry dock wall and the guard rails surrounding the
opening to stone steps are to kept in place at all times. In case they are removed to
facilitate work like handling of the repair items ,they are to immediately put back in
position.
Fire main valves along the dry dock wall are not to left leaking which will encourage
weed growth on the dry dock wall altars and on the dry dock floor. These valves are to
be maintained in good order all the time.

38.2

PRESSURE PUMP - U/W CLEANING

Use of pressure pump for cleaning of under water hull and dock floor is to be done
with precautions.
The operator employed is to be adequately trained in the use of its accessories and
adherence of proper precautions.
Use of adequate and proper protective equipment at all times is to be ensured.
Regular inspection of pressure parts like tubes, nozzles, hoses is to be ensured for
safe operation.
While working at heights, utmost precaution is to be taken to ensure safe working as
well as protecting oneself from an accidental fall.
Regular maintenance is to be carried out to check the pressure parts and examination,
test, certification by a competent authority are to be ensured for the safety of the
person and equipment.
Hoist is to be inspected before use with a pressure hose for clearance.
Pumps and compressors are to be inspected often for their rated output and pressure,
and for their safety devices like pressure regulating valves, etc.
High pressure water/ air jet are to be kept away from making direct contact with
body parts to prevent injury and damage to the body .
Blocking of nozzle is to be avoided to prevent any pressure build up in the hose nozzle
and pump compressor.
At all times, the hose is to be held by the operator before starting of pump.
Unattended operation of nozzle is prohibited.
The direction of the pressurized water/air jet is to be only on the floor/ships hull
where cleaning is necessary.
Earthing of motor is to be done properly to avoid possibility of electric shock.
Pressure jet is to be isolated from other persons, who work in the vicinity, to avoid
accidental striking by pressurised water etc.
The jet pipe is always to be held by the operator and should not be allowed to fall on
the floor or to be kept at any place when pump and compressor supply the water jet.
Access to the pump and motor is to be restricted only to trained personnel with
proper precautions.
No unauthorized persons are to be permitted to use the nozzle for cleaning of any
part of the ship.

Medical examination at regular intervals are to be conducted on the persons

employed ,to ascertain absence of any disease in the operator at any time
All noise levels greater than those allowed are to be reduced by prevention.
High pressure affects the human organ system and continuous work be avoided to
reduce the effect on health.

CHAPTER 39

STAGING AND WORKING AT HEIGHT

39.1

MATERIAL FOR STAGING

Sufficient supply of substantial material and appliance are to available in a

convenient place for the construction of staging.
All plank and other materials and appliances intended to be used or reused for staging
are to be carefully examined by a senior supervisor before being used, or reused in
any staging.
A staging plank should be of hardwood or any equivalent quality and should not be
less than 27.5cms. width and 6.5cms. thickness.
Trestles, planks and ladders are to be kept in good condition, and if found defective,
should be replaced immediately.
Staging planks must be laid evenly in the same horizontal plane, and the ends must be
securely lashed.
Due to the nature of work, if alterations to the staging become necessary, then great
care must be taken to check the condition of the staging to ensure that it is safe before
the work recommences.
The staging should not be less than the width of two planks (55 cms.) for simple jobs
like load-line marking and painting, drilling test holes burning of rivets, cutting of
plates or ring welding the rivet heads.
For difficult jobs like handling of the shipside plates (removal or renewal) caulking of
the seams and riveting etc. the staging width should not be less than
three planks
width (85 cms.) along the parallel portion of the ships hull.
For places where the ship's contours change rapidly near the bow and the stern of the
ship and for all difficult handling of job ,the staging should be of four planks width
(110 cms.). It may be more depending on the job in hand.
Whenever staging is required to be suspended from the ship's main railings, special
attention should be paid to the length of the suspended support shores for the staging
planks. These shores must firmly rest against the ship side plates and the planks
should be lashed up firmly with shores. The materials used for lashing of the staging is
of utmost importance, and the supervisor in charge / Asst. Manager should ensure
that standard lashing material is supplied to riggers which would take the strain with
the outer staging material. All supervisors / Asst. Managers must ensure that worn out
material is not used.
Particular care needs to be exercised while preparing the type of staging, popularly
known as "MARY PARANJA' used near the ship's bow. No adjustment in the "Mary
Paranja" should be carried out while the workmen are on the staging. If minor
adjustment is found necessary, the workman on the staging should be properly
cautioned before shifting the guy ropes and he must have his safety belt on. A ladder
giving access to this staging must be properly secured and must be in order.

Not more than two workmen should go on the Mary Paranja staging as described
above. Under no circumstances should the workmen on this staging be left
unattended especially when the vessel is in dry dock.
For any type of staging the gap between the work face and the staging should not be
more than 25 cms. Unless in cases where the configuration of the work place is such
that the gap should necessarily be more for the convenience of the work, then in such
cases greater vigilance and safety precautions all round, are necessary, such as life
lines etc. The staging should be lashed firmly to prevent it from swinging.
When the shipside plate is required to be dislodged from its position for its renewal, it
is essential that the plate be anchored with a nut and bolt not more than 15 cms. to 20
cms. long in order to prevent it from springing out suddenly and striking against any
part of the staging, thereby endangering the workmen on the staging.

LIGHTING Maximum visibility is essential both for good workmanship as well

as for safety. All supervisors/officers should ensure proper lighting on the staging. This is
particularly important when the staging is being used in dry docks.

Safety belts and life lines have been provided in sufficient number and it is
the
duty of all officers/supervisors to see that these safety belts are in good condition and
are being used, The requisite number whenever not essential should be maintained in
stock for use at all times.

While using a safety belt, the length of the cord should be adjusted to keep it shorter
than the height on which the operation is to be carried out.

Whenever ropes are used on suspension staging ,they should be reeved through pulley
blocks or roller guides to prevent the ropes being chaffed or damaged by coming in
contact with sharp edges. Under no circumstances, must the ropes suspending the
staging on ship's side pass over sharp edges.

In any case alteration in the staging work is necessary as the work progresses, it
should be done properly with safety considerations in view. Make shift arrangements
should be avoided.

During prolonged jobs, frequent checks must be made on the condition of the staging
to ensure that it is safe.

In ship repair work, it is not always possible to provide firm railings all around the
plank staging. However, all possible efforts must be made to tie rope railings or guard
ropes on the other edge of the shipside staging, to provide protection. Particularly
when work is being carried out on board submarines, proper railings or guard ropes
are to be rigged all around on the upper deck area to prevent anyone failing
overboard .

While working on air ventilators, for ships under repair, proper staging shall be
erected to reach the place of work, regardless of the size, nature and the extent of
work.

If the contingencies are such that either making or standing on plastic translucent
roofing shade becomes imperative, a wooden plank of at least 30 cms. width and 1.75
to 2.00 mtrs. in length is to be used to walk or to stand on such plastic sheets or of any
other brittle material.

Note:- This will distribute the load evenly over a wider area and chances of a
worker falling through, due to cracking of the sheets will be prevented.

If the wooden plank used is of a shorter length, care must be taken to see that it spans
adequately and well over at least two parallel members of the steel structure, supporting such roofing.
All the precautions as stated above shall also be observed while carrying out premonsoon cleaning of all types of roofs/terraces of the shops in Naval Dockyard
premises.
When shipside painting and repair work is going on, the worker working at heights
must not be required to hold the tools, paint tin etc. in his hands. This equipment and
accessories should be independently suspended so that the workers hands are free for
safe guarding and supporting himself in an emergency.
When work is required to be carried out on the mast of a vessel, electric supply to the
mast is to be switched off and when work is done at night, portable hand lamps must
be made available.
While working at heights the extent of hazards and the magnitude of its consequences
should not be judged from the minor nature of work or the short duration for which
the job is required to be done or the technical importance of the job. Any false notions
along these lines could lead to unsafe makeshift arrangements, lack of consideration of
safety and serious accidents.

CHAPTER 40

WOOD WORKING MACHINERY

40.1
below

General safety principles while using wood working machinery are as

Ensure that operators follow existing regulatory standard for selecting proper
equipment for the job. All electrical driven machines should be adequately guarded ,
have a cutoff switch, and have same means of rendering the control inoperative to
prevent injury. All belts, shafts, gears and other moving parts must be guarded.
Maintain ample work areas around each machine and keep floors and work places
clear and free from hazards. Adequate lighting and ventilation can prevent many
injuries and accidents. Machine should be so arranged to ensure a steady flow of
material. Operators should not have to stand in or near aisles. Machine operating
controls, safety controls, power drive and cutting edges should be inspected at each
stage, setup and at the start of each shift.
Wood working machine pose several health hazards for workers. The supervisors
should ensure that precaution are taken against hearing loss, air borne dust and
contamination, explosion and fire hazards and related problems. Workers should use
PPE ,such as eye protection, hair nets or caps, safety foot wear and other gears as
required.
The most common type of saw, used in industries include circular saw, overhead
swing saw and straight line pull cut off saw, under slung cutoff saw, radial saw,
powered rip saw. band saw, and jig saw. Supervisors can minimize the hazard posed
by the saws by :
Training the operator
Ensuring all machines are guarded
Making sure operator follow all safety procedure.

The common injuries involving a saw include blade cuts, abrasions and kickbacks.
Circular saws are difficult to guard because they are designed for a wide range of
cutting tasks. The most common injuries on these saw includes blade cuts or
abrasions and kickback. Hoods or Jigs will protect workers from most of the hazards,
if not all hazards. Operators should make sure the blades are sharp and at the
correct height ,run at the correct speed, cuts a straight line and is secured in place.
To operate a circular saw safely, workers should keep their hands out of the cut line
and use a holder to guide the stock. It is important to select the right blade for the job
and to maintain it properly.
Overhead swing saw and straight line pull cut off saw causes hand injuries when blade
coasts or idles, when operator tries to remove the stock, and when operator place
stock in position for cut. Hood guards are used for cutoff saw while counterweight
will return swing saw to the proper position. Worker should always hold the board

with the opposite hand, that they use to pull the saw, to prevent injuries. Start and
stop buttons are to be placed at easy access positions.
Under slung cutoff saw can be guarded by constructing a barrier on either side of the
line of the travel. The upper half of the radial saw should always be guarded, while
lower half should have an articulating guard for 90 degrees, cross cut operation. The
operator should always follow the proper direction when sawing to avoid injuries
from cuts and kickback .
Because, powered -rip- saws are often used to cut a long stock, the operator should
adjust feed rolls to the thickness of the stock being cut to prevent kickbacks. Band
saws are less hazardous than circular saws, but must still be adequately tightened and
more or less completely covered. They should have tension control devices and wheel
brakes.
Jigsaws are not normally considered hazardous, but proper operating procedures
require the blade to be secured ,attached, the threshold rest and slotted to be on the
stock, the guard to be in an effective position, operators to keep their hands at a safe
distance from the blade, and moving parts to be adequately guarded.
Other wood working equipment include jointers planers shapers, powered thick
planers, sanders, lathes and routers. Hand feed jointers and surface planers are
among the most dangerous wood working equipment. To protect the workers the
jointer should be equipped with a horizontal cutter head and the table opening
covered with a guard that adjusts to moving stock.
The main hazard in using wood shaper is that the operators hands and fingers might
strike the revolving knives or be cut by broken knives when they are thrown by the
machine. Workers should use push back or jigs to keep their hands away from knives
and solid cutters or safety collars should be fitted over the spindle to prevent injuries
from thrown knives blades. A braking device will stop the spindle after the power is
shut off.
Power fed planer should be secured to reduce vibration and isolated to help control
noise hazards . Metal guards should enclose the cutter heads to prevent injuries, and
proper guard will also prevent kickbacks. Workers must make sure that, all moving
parts are completely stopped before moving wood fragments and making adjustments.
To operate sanders safely, workers should make sure that drum, disk or belt sanding
machine are enclosed by dust exhaust hood. They should wear goggles and dust
respirator before the operation is started, make sure all belts are tight and in good
condition, and that hand feed sanders have proper distance between the sander and
work rest.
The rotating head of the lathe, whether running or not, should be covered as
completely as possible by hoods or shields. Guard should extend over the top of lathe
to prevent the work being thrown out. Lathe operators must be selected and trained
with care to use, inspect and maintain their equipment and to wear protective
equipment and gear.

SIS No 11/2000

SECURITY
The Security staff can assist the safety engineer and officers by reporting
hazards which they find during their normal rounds. General points for security
personnel are :-- Ensure that :-

Emergency accesses are not blocked.

Unauthorized persons do not use dockyard equipment and materials.
Entry to areas restricted for unauthorized person are prohibited .

All vehicles on dockyard premises are operated with due care and within safe
speed limit.
Doors or gates to enclosed hazardous areas such as electric transformer bunks
are locked.
Accesses are not blocked due to piles of material, store items which are to
normally remain clear for fire
fighting in case of emergency
Oily rags , or other flammable material are in side proper containers.
Steam, oil, water or chemical leakages are reported for prevention.
Improperly stored or inadequately secured gas containers are set right.
Broken electrical fittings ,outlets plugs and other devices are repaired.
Broken glasses or other sharp unprotected points or surfaces are replaced.
Unusual odors or fumes are investigated.
Cigarette butts, matches or other evidence of smoking in non-smoking areas.
Barriers, lights and other protective device missing at excavation, manholes,
ditches or other openings into which a person or vehicle could fall .
Wet ,oily or heavily waxed floors or roads on which person or vehicle can slip
or fall.
Boxes, crates, bales, drums, cartoons, or other packages piled on height that may
fall and injure in the premises of dockyard.