Documente Academic
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Documente Cultură
SAFETY ENGINEERING
B.Tech./ MECHANICAL/IV/VIII SEM
Mr.A.BHOJAN
1.8 LUBRICANTS 7
1.9 LUBRICATIONS 8
1.9.1 THICK FLIM LUBRICATIONS 8
1.9.2 THIN FLIM LUBRICATIONS 8
1.9.3 EXTERME PRESSURE 8
LUBRICATIONS
1.10 MAINTENANCE OF 9
MECHANICAL
TRANSMISSION SYSTEMS
AND PROCESS PLANTS
1.10.1 GOOD MAINTENANCE 9
PRACTICE OF GEARS
1.10.2 MAINTENANCE PRACTICE 9
OF GUIDE WAYS
1.10.3 MAINTENANCE PRACTICE 10
OF BEARINGS
UNIT -2
2.1 PREDECTIVE 12
MAINTENANCE
2.2 VIBRATION AND NOISE AS 12
MAINTENANCE TOOL
2.3 WEAR DEBRIS ANALYSIS 14
Even though maintenance engineering and maintenance have the same end objective
or goal (i.e., mission-ready equipment/item at minimum cost), the environments
under which they operate differ significantly. More specifically, maintenance
engineering is an analytical function as well as it is deliberate and methodical. In
contrast, maintenance is a function that must be performed under normally adverse
circumstances and stress, and its main objective is to rapidly restore the equipment to
its operational readiness state using available resources. Nonetheless, the contributing
objectives of maintenance engineering include: improve maintenance operations,
reduce the amount and frequency of maintenance, reduce the effect of complexity,
reduce the maintenance.
1.2.1MAINTENANCE TERMS
1.2.2MAINTENANCE FUNCTIONS
Maintain and carry out repair of buildings, utilities and allied equipment.
1.3Types of Maintenance:
1.3.4Zero Hours Maintenance (Overhaul): The set of tasks whose goal is to review
the equipment at scheduled intervals before appearing any failure, either when the
reliability of the equipment has decreased considerably so it is risky to make
forecasts of production capacity . This review is based on leaving the equipment to
zero hours of operation, that is, as if the equipment were new. These reviews will
replace or repair all items subject to wear. The aim is to ensure, with high
probability, a good working time fixed in advance.
This can involve maintaining a stock of replacement parts for every piece of
equipment onsite, or else paying for rush shipping on new components as the
old ones fail. There are typically also costs associated with downtime, so this
approach to maintenance is not well-suited to any business operation that
would suffer large monetary losses from the sudden failure of any given piece of
equipment.
Advantages
• Energy savings.
Disadvantages
1.8 Lubricants
Any materials used to reduce friction wearing surface with high coefficient of
friction by establishing low-viscous film are called lubricants. Lubricants are
available in solid and gaseous forms.
1.9 lubrications
When the moving/sliding surfaces are under very high pressure and speed,
a high local temperature is attained under such conditions, liquid lubricants
fail to stick and may decompose and even vaporize.
To meet these extreme pressure conditions, special additives are added to
minerals oils. These are called extreme pressure additives.
These additives form more durable films (capable of withstanding very high
loads and high temperatures) on metal surfaces. Important additives are
organic compounds having active radicals or groups such as chlorine (as in
chlorinated esters), sulphur (as in sulphurized oils) or phosphorus (as in
tricresyl phosphate). These compounds react with metallic surfaces, at
existing high temperatures, to form metallic chlorides, sulphides or
phosphides.
It is essential and desirable to have gears with lengthy and satisfactory life
period. in order to achieve this, it will be better to schedule an effective
maintenance programs. If oil leakage is sensed, the unit should be shut down. This
cause to traced and corrective action to be initiated and also the oil level to be
checked. It is necessary to shut down for a period of more than a week and the
unit should run at least 10 minutes each week when it is idle. This may help to
keep gears and bearings coated with and prevent rusting due to condensation of
moisture. It is the usual experience with a set of gears in a gear unit. Assuming
proper design, manufacture, application and operation that will be initial running
period during which if the gears are properly lubricated and not over loaded the
combined action of rolling and sliding of the teeth may smooth and high polish
under continued proper conditions of operation , gear teeth will the show little or
no sign of wear.
The guide ways are a part of machine tools which are used to offer
smooth sliding motion between the mating surface and to withstand heavy load
during machining operation. Proper design and manufacture of guide ways helps
to maintain/achieve very good geometric dimensioning and tolerancing of the job
being produced. To have better and satisfactory performance of slide ways bearing
Since the sliding surface moves and cover only a portion of total length of the guide
ways, it is natural that wear characteristic may no be same over the length. And also
wear occurs on the sliding surface and guide ways may be due to any of the following
reason
Vibration
Hand-arm vibration is vibration transmitted from work processes into workers’ hands
and arms. It can be caused by operating hand-held power tools, such as road
breakers, and hand-guided equipment, such as powered lawnmowers, or by holding
materials being processed by machines, such as pedestal grinders.
Clothing - Vibration
All employees shall be provided with protective clothing when necessary to keep
them warm and dry. This will encourage good blood circulation which should help
Wear debris analysis is a relatively simple procedure not requiring a high skills level to
perform. Even so the results give a direct indication as to the level of threat and
damage within industrial drives absent from some of the more sophisticated
techniques
By using a systems approach and a case study process, how condition based
maintenance can be implemented as a routine has been investigated. The result is an
implementation method in which four suggested phases are presented. The method
starts with a feasibility test. It then continues with an analysis phase, an
implementation phase, and an assessment phase. These steps are taken in order, for
example, to invest in the proper condition based maintenance
2.5.1Pillar 1 - 5s :
TPM starts with 5S. Problems cannot be clearly seen when the work place is
unorganized. Cleaning and organizing the workplace helps the team to uncover
problems. Making problems visible is the first step of improvement
This means sorting and organizing the items as critical, important, frequently used
items, useless, or items that are not need as of now. Unwanted items can be salvaged.
Critical items should be kept for use nearby and items that are not be used in near
future, should be stored in some place. For this step, the worth of the item should be
decided based on utility and not cost. As a result of this step, the search time is
reduced.
SEITON - Organize :
The concept here is that "Each items has a place, and only one place". The items
should be placed back after usage at the same place. To identify items easily, name
plates and colored tags has to be used. Vertical racks can be used for this purpose,
and heavy items occupy the bottom position in the racks.
This involves cleaning the work place free of burrs, grease, oil, waste, scrap etc. No
loosely hanging wires or oil leakage from machines.
SEIKETSU - Standardization :
Employees has to discuss together and decide on standards for keeping the work place
/ Machines / pathways neat and clean. This standards are implemented for whole
organization and are tested / Inspected randomly.
Considering 5S as a way of life and bring about self-discipline among the employees of
the organization. This includes wearing badges, following work procedures,
punctuality, dedication to the organization etc
This pillar is geared towards developing operators to be able to take care of small
maintenance tasks, thus freeing up the skilled maintenance people to spend time on
more value added activity and technical repairs. The operators are responsible for
upkeep of their equipment to prevent it from deteriorating.
1. Preparation of employees.
2. Initial cleanup of machines.
3. Take counter measures
4. Fix tentative JH standards
5. General inspection
6. Autonomous inspection
7. Standardization and
8. Autonomous management.
1. Train the Employees : Educate the employees about TPM, Its advantages, JH
advantages and Steps in JH. Educate the employees about abnormalities in
equipments.
2. Initial cleanup of machines :
o Supervisor and technician should discuss and set a date for
implementing step1
o Arrange all items needed for cleaning
o On the arranged date, employees should clean the equipment completely
with the help of maintenance department.
o Dust, stains, oils and grease has to be removed.
o Following are the things that has to be taken care while cleaning. They
are Oil leakage, loose wires, unfastened nits and bolts and worn out
parts.
"Kai" means change, and "Zen" means good ( for the better ). Basically kaizen is for
small improvements, but carried out on a continual basis and involve all people in the
organization. Kaizen is opposite to big spectacular innovations. Kaizen requires no or
little investment. The principle behind is that "a very large number of small
improvements are move effective in an organizational environment than a few
improvements of large value. This pillar is aimed at reducing losses in the workplace
that affect our efficiencies. By using a detailed and thorough procedure we eliminate
losses in a systematic method using various Kaizen tools. These activities are not
limited to production areas and can be implemented in administrative areas as well.
Kaizen Policy :
Kaizen Target :
Achieve and sustain zero loses with respect to minor stops, measurement and
adjustments, defects and unavoidable downtimes. It also aims to achieve 30%
manufacturing cost reduction.
1. PM analysis
2. Why - Why analysis
3. Summary of losses
4. Kaizen register
5. Kaizen summary sheet.
Loss Category
9. Management loss
10.Operating motion loss
11.Line organization loss Loses that impede human work efficiency
12.Logistic loss
13.Measurement and adjustment
loss
14.Energy loss
Loses that impede effective use of production
15.Die, jig and tool breakage loss resources
16.Yield loss.
Classification of losses :
Specialists in process
engineering, quality
Usually the line personnel assurance and maintenance
Corrective action in the production can attend people are required.
to this problem.
It is aimed to have trouble free machines and equipments producing defect free
products for total customer satisfaction. This breaks maintenance down into 4
"families" or groups which was defined earlier.
1. Preventive Maintenance
2. Breakdown Maintenance
3. Corrective Maintenance
4. Maintenance Prevention
With Planned Maintenance we evolve our efforts from a reactive to a proactive method
and use trained maintenance staff to help train the operators to better maintain their
equipment.
Policy :
It is aimed towards customer delight through highest quality through defect free
manufacturing. Focus is on eliminating non-conformances in a systematic manner,
much like Focused Improvement. We gain understanding of what parts of the
equipment affect product quality and begin to eliminate current quality concerns, then
move to potential quality concerns. Transition is from reactive to proactive (Quality
Control to Quality Assurance).
Policy :
Data requirements :
Quality defects are classified as customer end defects and in house defects. For
customer-end data, we have to get data on
In-house, data include data related to products and data related to process
2.5.6PILLAR 6 - TRAINING :
It is aimed to have multi-skilled revitalized employees whose morale is high and who
has eager to come to work and perform all required functions effectively and
independently. Education is given to operators to upgrade their skill. It is not
sufficient know only "Know-How" by they should also learn "Know-why". By experience
they gain, "Know-How" to overcome a problem what to be done. This they do without
knowing the root cause of the problem and why they are doing so. Hence it become
necessary to train them on knowing "Know-why". The employees should be trained to
achieve the four phases of skill. The goal is to create a factory full of experts. The
different phase of skills are
Target :
1. Achieve and sustain downtime due to want men at zero on critical machines.
2. Achieve and sustain zero losses due to lack of knowledge / skills / techniques
3. Aim for 100 % participation in suggestion scheme.
1. Setting policies and priorities and checking present status of education and
training.
2. Establish of training system for operation and maintenance skill up gradation.
3. Training the employees for upgrading the operation and maintenance skills.
4. Preparation of training calendar.
5. Kick-off of the system for training.
6. Evaluation of activities and study of future approach.
Office TPM should be started after activating four other pillars of TPM (JH, KK, QM,
PM). Office TPM must be followed to improve productivity, efficiency in the
administrative functions and identify and eliminate losses. This includes analyzing
processes and procedures towards increased office automation. Office TPM addresses
twelve major losses. They are
1. Processing loss
2. Cost loss including in areas such as procurement, accounts, marketing,
sales leading to high inventories
3. Communication loss
4. Idle loss
5. Set-up loss
6. Accuracy loss
7. Office equipment breakdown
8. Communication channel breakdown, telephone and fax lines
A senior person from one of the support functions e.g. Head of Finance, MIS, Purchase
etc should be heading the sub-committee. Members representing all support functions
and people from Production & Quality should be included in sub committee. TPM co-
ordinate plans and guides the sub committee.
Inventory reduction
Lead time reduction of critical processes
Motion & space losses
Retrieval time reduction.
Equalizing the work load
Improving the office efficiency by eliminating the time loss on retrieval of
information, by achieving zero breakdown of office equipment like telephone
and fax lines.
P Q C D S M in Office TPM :
Office TPM supports the plant, initially in doing Jishu Hozen of the machines (after
getting training of Jishu Hozen), as in Jishu Hozen at the
1. Initial stages machines are more and manpower is less, so the help of
commercial departments can be taken, for this
2. Office TPM can eliminate the lodes on line for no material and logistics.
This is essential, but only after we have done as much as possible internally. With
suppliers it will lead to on-time delivery, improved 'in-coming' quality and cost
Target :
1. Zero accident,
2. Zero health damage
3. Zero fires.
In this area focus is on to create a safe workplace and a surrounding area that is not
damaged by our process or procedures. This pillar will play an active role in each of
the other pillars on a regular basis.
3.2Indices of Reliability
Reliability can be specified by two parameters namely:
1. Mean time between failures (MTBF)
MTBF is the critical characteristic for repairable system and is the mean or average
time between two successive failures of the system. MTBF can be obtained by running
an item or equipment for a predetermined length of time under specified conditions
and calculating the average length of time between failures.
If for example, an item fails six times in an operating period of 60,000 hrs, MTBF
is 10, 000 hrs. However, if the identical items operating under similar conditions are
studied, MTBF
is given by:
MTBF = (Total operating hours of all items)/Total number of failures that occur
For example if 20 identical items operate for 5, 000 hrs during which 40 failures occur
and are
rectified,
MTBF =40
5000× 20
= 2, 500 hrs
MTBF can also be expressed as the inverse of failure rate, λ as follows:
MTBF =1/λ
The exponential distribution, the most basic and widely used reliability prediction
formula, models machines with the constant failure rate, or the flat section of the
bathtub curve. Most industrial machines spend most of their lives in the constant
failure rate, so it is widely applicable. Below is the basic equation for estimating the
reliability of a machine that follows the exponential distribution.
Where:
R(t) = Reliability estimate for a period of time, cycles, miles, etc. (t).
e = Base of the natural logarithms (2.718281828)
λ = Failure rate (1/MTBF)
If for example, we assume a constant failure rate of 0.1 for a prime mover and running
for six years without a failure, the projected reliability is 55 percent, which is
calculated as follows:
R(6) = 2.718281828-(0.1* 6)
R(6) = 0.5488 = ~ 55%
In other words, after six years, about 45% of the population of similar prime mover
operating in similar application can be expected to fail. It is worth reiterating at this
point that these calculations project the probability for a population. Any given
individual from the population could fail on the first day of operation while another
individual could last 30 years. That is the nature of probabilistic reliability projections.
3.3Failure Rate
Failure is any event that adversely affects system criteria. For example, the
criteria could include output in a sold-out condition, or maintenance cost or
capital resources in a constrained budget cycle, environmental excursions or
safety, etc.
Failure rate is the time rate of change of the probability of failure. Since the
latter is a function of time, failure rate is also a function of time. However, in
terms of failure rate, one can obtain physical information as to which factor is
controlling the failure behavior and/or when it is controlling the failure
behavior.
Failures do not generally occur at a uniform rate, but follow a distribution in time
commonly described as a "bathtub curve." The life of a device can be divided into three
regions:
(i) Infant Mortality Period: This period is that of ‘running in’, where the failure rate
progressively improves.
The failure rate is generally high but short before decreasing due to design or
manufacturing errors, defective parts, defects in materials, misuse,
misapplication, out of manufacturing tolerance. Failure at this period can be
avoided by subjecting the product to specified period of simulated tests, in hope
Systems in Series
In the series system, the ability to employ subsystem B depends upon the operating
state of subsystem A. If subsystem A is not operating, the system is down regardless of
the condition of subsystem
To calculate the system reliability for a system is series, there is the need to multiply
the estimated reliability of subsystem A at time (t) by the estimated reliability of
subsystem B at time (t). The basic equation for calculating the system reliability of a
simple series system is:
Where:
Rs(t) – System reliability for given time (t)
R1-n(t) – Subsystem or sub-function reliability for given time (t)
So, for a simple system with three subsystems, or sub-functions, each having an
estimated reliability of 0.90 (90%) at time (t),
Where:
Rs(t) – System reliability for given time (t)
R1-n(t) – Subsystem or sub-function reliability for given time (t)
The simple parallel system in our example with two components in parallel, each
having a reliability of 0.90, has a total system reliability of 1 – (0.1 X 0.1) = 0.99.
Therefore, the system reliability was significantly improved.
The total time, T does not include planned operational shutdowns due to production
schedules or routine preventive maintenance.
The maintainability, which is a factor of the time required and resources needed to
restore equipment in case of failure, in conjunction with reliability determine the
availability of a machine. If the average repair time is T , the availability of the
machine, AV in terms of MTBF is
Maintainability function: A plot of the probability of repair within a time given on the
y-axis, against maintenance time on the x-axis and is useful to predict the probability
that repair will be completed in a specified time.
Safety is the state of being "safe" the condition of being protected against
physical, social, spiritual, financial, political, emotional, occupational,
psychological, educational or other types or consequences of failure,
damage, error, accidents, harm or any other event which could be considered
non-desirable.
Safety can also be defined to be the control of recognized hazards to achieve an
acceptable level of risk. This can take the form of being protected from the event
or from exposure to something that causes health or economical losses. It can
include protection of people or of possessions.
This memo amends and supplements the existing instructions on the reporting of
accidents and dangerous occurrences both for internal purposes and to comply with
the Reporting on Injuries, Diseases and Dangerous Occurrences Regulations (NI)
1997. (RIDDOR)
ACCIDENT INVESTIGATION
4 There are many legal and economic reasons for investigating accidents. The results
of any investigation should however be used to help prevent a recurrence by indicating
modification to procedures, premises, training or supervision.
6. The manager or officer in charge should investigate any accident. These officers will
be referred to in this memo as IO.
The IO should visit the scene of the accident as soon as possible. Where the accident
has occurred on DEL premises, the IO should question witnesses, carry out physical
tests as necessary and clarify technical queries within his/her competence. When
problems arise outside the IO’s competence he/she should seek advice from a
technical officer with the necessary expertise to deal with the matter.
7. It should be made clear to any witness(es) at the commencement of the enquiry that
the object is to prevent a recurrence of the accident and not to apportion blame. There
is no legal power to compel a witness to answer questions. All witnesses are entitled, if
they wish, to be accompanied by anyone of their choice when being questioned. If,
during the course of the investigation, any breach of statutory requirements, DEL
safety instructions or staff rules is identified remedial action should be taken
immediately.
8. When all enquiries have been completed, the IO should consider what local
instructions (if any) are necessary to prevent recurrence of the accident
ACCIDENT RECORDING
9. A record of an accident must be made in the accident book, BI510. Persons who are
covered by the Social Security Act 1975 may use the BI510 to give notice to their
employer of an accident resulting in injury. Persons who are not covered by that Act
have similar rights under DEL procedures in being able to enter the details of injuries
All correspondence to with regards to registration of and grant of licence shall be made
either to the concerned area Inspectors or to the Chief Inspector of Factories and
Boilers whose addresses are available in this website.
Any further clarifications or assistance required in these matters, one may contact the
concerned officers at their respective offices after 3.00 P.M on all the working days.
ASME offers the public and private sectors a comprehensive portfolio of codes and
standards offerings, which govern elevators and escalators. The Society develops and
maintains eight major codes addressing safety in design, construction, installation,
operation, inspection, testing, maintenance, alteration, and repair of elevators,
dumbwaiters, escalators, moving walks, material lifts, and dumbwaiters with
automatic transfer devices, wheelchair lifts, or inclined-stairway chair lifts. Thus,
ASME extends its broad perspective on safety across a full range of industry products
and applications.
ASME continues to set the pace in the elevator-and-escalator industry. Its A17
Elevator and Escalator Committee has successfully released a series of bi-national
codes in concert with the Canadian Standards Association. One of these new bi-
national codes, A17.7-2007/CSA B44.7-07, serves as a model for the parallel
existence of a prescriptive technical code and a performance-based standard, covering
the same equipment within a regulated industrial sector. This combination introduces
flexibility to an industry that is sometimes best served by clearly defined rules
(prescriptive) and other times needs performance targets that can be met by a wide
range of solutions, encouraging competition in the industry. ASME is pleased to add
this progressive approach to its own proven methodologies as yet another contribution
to fostering international trade and technology transfer. ASME's codes and standards
offerings in elevators and escalators are detailed in the following pages. These include
codes and standards in both print and digital formats, along with companion training
courses and videos. We strive to provide the codes-of-choice for your company…and
your country.
ASME plays an active role in protecting the public through the development of Safety
Codes and Standards, which are managed by the Board on Safety Codes and
Standards (BSCS). The BSCS is responsible for the management of all ASME activities
related to codes, standards, and accreditation and certification programs directly
applicable to safety codes, safety standards, and related accreditation and certification
activities. The BSCS oversees the following:
A13 Scheme for the Identification of Piping Systems
A17 Elevators and Escalators
A18 Platform Lifts and Stairway Chairlifts
A90 Safety Standards for Man lifts
A120 Safety Requirements for Powered Platforms for Building Maintenance
B20 Safety Standards for Conveyors and Related Equipment
B30 Safety Standards Committee for Cableways, Cranes, Derricks, Hoists, Hooks,
Jacks, and Slings
BTH Standards Committee, Design of Below-the-Hook Lifting Devices
IS 1991 : 1988 Part 4 Safety requirements for the use, care and protection of
abrasive grinding wheels: Safety guards.
IS 3233 : 1965 Glossary of terms for safety and relief valves and their
parts
IS 6044 : 2000 Part 1 Code of Practice for Liquefied Petroleum Gas Storage
Installations – Part 1 : Commercial and Industrial
Cylinder Installations
IS 8324 : 1988 Code of practice for safe use and maintenance on non-
calibrated round steel link lifting chains and chin
Safety risks can be caused by both physical dangers and health hazards.
Physical hazards include, for example, heavy objects falling, panels breaking and
electrical hazards. Health hazards are often less obvious and include, for example, the
fungus and mildew that can grow on building materials after they get wet. Most people
have little or no intuitive sense for what situation spose health hazards. Some of these
hazards may be immediate and some may have a delayed effect. In addition,
hazardous health effects can occur from a single exposure or as a result of long-term
exposure.
Thus, this part of safety awareness depends heavily on education. Warning labels and
MSDSs are the primary initial sources of health hazard information
Forklift Safety
Board products and ceiling tile will first be moved by a forklift or similar device. It is
absolutely essential that the equipment be rated capable of handling the loads. The
forks should always be long enough to extend completely through the width of the
load. Forks should also be extended far enough apart to support the load so that it will
not break or fall. Gypsum panels are brittle compared to other building products, such
as lumber. If not properly supported, individual panels or a whole lift can break
.SHEETROCK Brand Gypsum Panels, SHEETROCK Brand HUMITEK Gypsum Panels,
and GRAND PRIX Brand Veneer Plaster Base:– Fork spacing between supports should
be one-half the length of the panels or base being handled so that a maximum of 1220
mm extends beyond the supports on either end.
– Fork spacing should be similar to the above except that a maximum of only 915 mm
should extend beyond the supports on either end. Fork carriage spread in the range of
1170 to 2130 mm (46 to 84) is suitable for handling most common lengths of board
and panels. Sometimes gypsum board manufacturers offer to band lifts of board at
each end. This will aid in preventing deflection of the board when it is picked up with a
forklift but it is not a substitute for proper for spacing. Banding will not prevent board
from breaking if the forks are not spaced far enough apart.
– Never move the forklift with the load elevated more than a few inches above the floor
or ground surface;
– In heavy traffic areas, use a spotter to regulate forklift, pedestrian and other traffic.
Stacking Board
Gypsum Association literature states unequivocally that board should be stacked flat
because stacking boards vertically against a wall poses a safety hazard. See “Handling
Gypsum Board,” Gypsum Association “Stacks of gypsum board are very heavy and can
become unstable if proper stacking and handling procedures are not followed. Workers
must always be extremely careful when stacking or working in an area
where gypsum board is stacked. long by 12.7 mm (one-half-inch) thick gypsum board
can weigh over 36 kg (80 pounds); this means a stack of only 28 boards weighs
over a ton.” “Gypsum board should always be stored flat. Placing it vertically on edge
for an extended period may damage the edges and can also cause the board to warp.
Additionally, board stacked on edge can easily become unstable and accidentally fall
over. Stacking gypsum board flat will lower the potential for a safety hazard.”
Storage Conditions
Protecting wallboard and other products from rain, snow, sunlight and wind is
important. Not only can the weather damage the board by soaking it, but exposure to
weather can do other harm not immediately obvious. For example, moisture could
affect the bond of the face paper to the gypsum core in a way that later creates
problems in application and finishing. Also, ultraviolet (UV) exposure from sunlight
will ruin the ability of plaster base panels (blue board) to act as a substrate for some
veneer plasters.
Eye Protection
Eye protection should be worn at all times, not just when using power equipment.
Some products, such as plasters containing lime, pose the risk of a chemical burn of
the eye which could result in the loss of sight. However, even without a chemical burn,
the mere physical impact of a trowel full of plaster dropped on the eye can cause
severe injury or blindness. Eye protection (safety glasses or goggles) also protects the
eyes from dust
1. Be sure that all machines have effective and properly working guards and
covers, and that they are always in place when machines are operating.
3. A hands-on skills assessment is done where the users must show competency in
use of that machine and that they understand the basics of safe operation.
4. A log is kept on the progress of the user’s experience. This is based on hours or
number repetitions a user does specific operations. These logs are the last page of the
BUST documents (see list below)
5. Below 4 hours (and/or below 8 repetitions of specific tasks), the users must be
supervised during set-up and during certain operations. Log kept on last page of BUST
document.
6. After logging 4 hours (and/or above 8 repetitions of specific tasks), the users are
allowed to perform those specific tasks (only) without direct supervision. Log kept on
last page of BUST document.
7. In either case, the Shop Manager must be informed of what tasks and/or operations
the user wants to perform.
8. Users are to ALWAYS ask, and get assistance with, any new or unusual work to be
done in the machines.
9. Regardless of user experience, the amount of time before they can use the machine
without supervision is still at the discretion of the Shop Manager.
10. Advanced users are NOT allowed to perform tasks during evening hours that they
have not been trained to do.
11. Any unsafe or improper use of machine, not listening to or following instructions,
or lack of judgment will result in a warning and possibly loss of shop use privileges.
Introduction
If pressure equipment fails in use, it can seriously injure or kill people nearby and
cause serious damage to property. This leaflet describes what employers need to do to
minimize the risks when working with systems or equipment which contain a liquid or
gas under pressure. It will also be useful to employees and their safety
representatives. As an employer or self-employed person, you have a duty to provide a
safe workplace and safe work equipment. Designers, manufacturers, suppliers,
installers, users and owners also have duties. The leaflet does not cover gas cylinders
(now called transportable pressure receptacles or transportable pressure vessels), or
tanks and tank containers. The main regulations covering pressure equipment and
pressure systems are the Pressure Equipment Regulations 1999 and the Pressure
Systems Safety Regulations 2000. Employers have a further duty to consult any safety
Arc Welding Safety Standards address the various aspects of arc welding and
the safety considerations that accompany them, such as cutting noise. In
addition to arc welding safety standards published by national standards
Personal Protection Standards frequently come into play when welding due
to the inherent dangers associated with welding. While welding equipment
can be made safer, certain dangers are best protected against with the use
of personal protection equipment such as eye and face protection.
Sometimes, personal protection standards for use in welding applications
add on to standards used in industries with lower safety requirements, while
others are developed specifically for welding when the dangers involved are
unique to welding .
Fire Prevention
Fire prevention requires segregating the three elements of the fire triangle. In practice,
a method to achieve that goal is to post—and enforce—no-smoking signs around
flammable liquids and gases and have fire watches on all work involving torch-
applied materials of a minimum of two hours after the last torch is turned off.
Flammable liquids that are extremely viscous, or difficult to pour, like single- ply
adhesive, can be left in their original shipping containers. Similarly, OSHA allows the
use of original containers of flammable liquids that are in quantities of one gallon or
less.
Static electricity may be generated when transferring liquids, gases or solids through
pipes or hoses. It is important to dissipate this electric charge when handling
flammable and combustible materials. When transferring flammable or combustible
liquids from one container to another, the two containers must be “bonded” together.
The bonding process involves attaching a wire with alligator clips on each end to both
containers. The clips must penetrate
the container coating and touch metal. You may need to score the paint with the
alligator clips. To dissipate static, the container receiving the liquid must be in contact
with the ground and not insulated from contact with the ground. For example, plastic
or composite pickup truck bed liners prevent the flow of static electricity to ground
because the liner does not conduct electricity. The receptacle container must have a
clear path to ground, by direct contact or use of a grounding strap or wire, to
effectively eliminate static.
Service or fueling areas at job sites must have a 20BC-rated fire extinguisher within
75 feet of each pump.
Safety cabinets allow for greater quantities of flammable and combustible liquids to be
stored safely inside buildings. Up to 60 gallons of a flammable liquid or as much as
120 gallons of a combustible liquid may be stored indoors in a safety cabinet. Each
cabinet must be labeled “Flammable— Keep Fire Away.” Up to three cabinets may be
stored in one room. Without a safety cabinet, only 25 gallons of either flammable or
combustible liquids are allowed to be stored inside a building.
5.6.1Liquefied Petroleum Gas
Liquefied petroleum gas (LP gas) is used widely in the roofing industry to heat kettles
and torches. Because LP gas is a compressed gas, fairly large quantities can be stored
in relatively small containers. As a point of reference, LP gas expands at a ratio of 270-
to-1. This means that one liquid drop of LP gas would expand to a gas state 270 times
greater in volume.
LP gas collects in low-lying areas because its vapor density is heavier than air.
Employees should be warned that if they suspect a leak in a cylinder, they must not
Employees should not attempt to extinguish fires involving LP gas. If an LP gas fire
breaks out, employees should evacuate the area immediately and call the fire
department. Fighting an LP gas fire requires specialized training that only the fire
department can provide. Employee attempts to extinguish the fire could create larger
hazards.
A roofing contractor’s emergency action plan for the job site must include:
5.6.2Employee Training
5.6.3Fire Extinguishers
In buildings, all fire extinguishers will be mounted on a wall and properly marked.
When at a job site, all employees will know the location of each fire extinguisher.
Before using an extinguisher, all employees will be trained and familiar with the PASS
method of firefighting.
Each fire extinguisher will be inspected monthly to make sure it is in its designated
location and has not been tampered with or actuated.
Each fire extinguisher will be clearly visible with nothing obstructing or obscuring it
from view.
All fire extinguishers will be examined at least yearly and/or recharged or repaired to
ensure operability and safety. A tag must be attached to show the maintenance or
recharge date and the signature or initials of the person performing the service.
An emergency exit in a structure is a special exit for emergencies such as a fire: the
combined use of regular and special exits allows for faster evacuation, while it also
provides an alternative if the route to the regular exit is blocked by fire, etc.
It is usually a strategically located outward opening door with a crash bar on it and
with exit signs leading to it. The name is a reference to when they are frequently used,
however a fire exit can also be a main doorway in or out. A fire escape is a special kind
of emergency exit, mounted to the outside of a building.
UNIT -1
1. Define maintenance.
2. What are the objectives of the maintenance?
3. Define the term Preventive Maintenance.
4. Define predictive maintenance.
5. What are the functions of maintenance?
6. What is zero hour maintenance?
7. What are the seven elements of preventive maintenance?
8. What is meant by repair cycle?
9. What are the advantages of predictive maintenance?
10. Define lubrications.
11. What are the different types of lubrications?
12. Define thick film lubrications.
13. Define thin film lubrications.
UNIT -2
UNIT -3
1. Define reliability.
2. How the reliability is classified?
3. Define mean time between failure.
4. What is meant by mean time to failure?
5. Define failure rate.
6. What is meant by infant mortality period?
7. What is meant by wear out period?
8. What is meant by availability ratio?
9. Define Maintainability.
10. What are the different types of system reliability?
11. Define downtime.
12. Define serviceability.
UNIT -4
1. Define safety.
2. List out the reason for the cause of accidents.
3. What is meant by accident consequence analysis?
4. What is meant by emergency plan?
5. What is meant by hot work?
6. What is meant by accident?
7. List the different types of accident.
8. Define safety audit.
9. What is the function of safety organization?
10. Define threshold quantity.
UNIT -5
UNIT -1
UNIT -2
UNIT -3
UNIT -4
UNIT -5