Safety in Engineering Industry

 General Safety Rules.

Personal Protection:
1. Eye protection must be worn at all times when in the workshop. This applies regardless if you
are working on machinery or not. Activities of others can affect your safety.
2. Obtain first aid immediately for any injury. Report all accidents/injuries to a monitor and/or
instructor, no matter how insignificant they may seem at the time. This will help us to mitigate
hazards in the future.
3. Do not operate machinery that you have not been authorized to use. This will protect both you
and the equipment from harm.
Dress Code:
1. No open-toed shoes or high heels allowed. To provide secure footing, choose shoes with
softer soles and stable platforms. Wearing appropriate footwear will help protect feet from falling
objects and hot sparks or chips.
2. No loose clothing allowed. This includes but is not limited to ties, scarves and loose-sleeved
shirts. Short sleeves or sleeves rolled above the elbow are preferred. When welding, long sleeves
are required for protection from arc-flash and metal sparks.
3. No shorts, short dresses or skirts allowed when working in the Boliou metal shop or anywhere in
the Mudd Instrument shop. Burred edges of freshly cut metal, such as sheet stock, are razor sharp.
Wearing of long pants will protect you and those around you. Additionally, hot chips will burn/cut
exposed skin, potentially startling the operator.
4. Remove all jewelry that could be caught in moving machinery. This includes rings and loose
bracelets. Remove necklaces and the like, if not securely restrained.
5. Restrain all hair, including beards, that has potential for entanglement with moving machinery.
6. Wearing of gloves when working on moving machinery is prohibited. Gloves can easily become
entangled in moving machinery and thus are not allowed.
Machine Maintenance:
7. Do not attempt to oil, clean, adjust or repair any machine while it is running. Performing
maintenance on moving machinery exposes you to additional hazards.
8. Ensure that all machine guarding is in place and functioning properly. Inform the monitor if the
guarding is damaged or malfunctioning.
9. Do not leave machines running unattended. Others may not notice the machine is running and
may be injured by moving parts.
10. Do not try to stop the machine with your hands or body. Stopping the machine with your body
can result in entanglement. Let the machine come to a stop naturally.
11. Always keep hands, hair, feet, etc. clear of all moving machinery at all times. Be aware of all
moving parts, especially cutting tools and chucks.
12. Remove chuck keys, wrenches and other tools from machines after making adjustments. Chuck
keys left in the chuck when the machine turns on become dangerous flying objects.
13. Listen to the machine(s) if something does not sound right, shut it down. If the machine sounds
abnormal to you, it probably is not operating properly. Inform the shop monitor of problems.
14. Never use compressed air for cleaning machinery. This will embed particulates into the
precision machine parts and will drastically reduce the life of the machine. Use the supplied chip
brushes and rags to clean machinery.
15. Never use compressed air to clean your clothes or any part of your body. Particles can become
embedded in skin and eyes. In extreme cases, air can be introduced into the bloodstream.
16. Double check that tooling and work pieces are properly supported and clamped prior to starting
a machine.
17. Heavy or unwieldy work pieces often require special support structures to machine safely. Ask
for help if you are unsure if your work piece requires additional support.
18. Do not lean against the machines; it is poor etiquette. If you need arrest, grab a chair.
19. be sure you have sufficient light to see clearly when performing any job. Well lit workspaces
are much safer and less straining on the operator.
20. Work at a pace that is comfortable for you. Rushing will compromise safe working practices,
along with part quality, and will increase the chance of damaging equipment.
Shop Cleanliness Rules
21. Keep floors free of sawdust, oil, grease or any other liquid. Cleanup spilled liquids
immediately, they are slipping hazards.
22. Store materials in such a way that they cannot become tripping hazards. Immediately return
all excess material to its proper storage place.
23. Put tools away when not in use. This prevents loss of tools and also makes them available to
others.24.Place all scrap in scrap containers.
  Electrical guards.
Electrical Safety:
 Inspect equipment, power cords, and electrical fittings or damage prior to each use.
 Report any equipment defects to the supervisor so it can be repaired or replaced.
 Repairs should be performed by a trained professional.
 Switch equipment OFF before connecting them to a power supply and before making
adjustments. Ensure that electrical equipment is properly grounded or double-insulated. The
ground equipment must have an approved 3-wire cord with a 3-prong plug. This plug should be
plugged in a properly grounded 3-hole outlet.
 Keep power cords clear of the equipment during use.
 Securely suspend power cords over aisles or work areas to eliminate tripping hazards.
 Tools or other equipment capable of conducting electricity should not be used in such
proximity to any live electrical installation or equipment that they might make electrical contact
with the live conductor.
 Do not bypass the switch and operate the tools by connecting and disconnecting the power
cord.
 Do not use AC powered electric tools in wet conditions or damp locations, unless the tool is
connected to a GFCI. Do not clean electric equipment and tools with flammable or toxic
solvents.
 Do not carry electrical tools by the power cord.
 Do not tie power cords in knots. Knots can cause short circuits and shocks. Do not plug several
power cords into one outlet.
 Do not disconnect power supply by pulling or jerking cord from the outlet. Pulling the cord
causes wear and may cause a shock. Disconnect by pulling the plug, not the cord.
 Do not use extension cords as permanent wiring.
 Do not allow carts and trolleys to pass over unprotected power cords. Cords should be put in
conduit or protected by placing planks alongside them.
 Safety protection while inspecting the machines with rotary parts.
 Safety during inspecting drilling machines, planning machines, milling machine, turning
machine and grinding machines.
 Safety Guarding of machineries.
 Good guarding systems
 Safety Guarding.
 Zero mechanical state.
 Machine Guarding.
 Leak detection techniques.
 Classification of welding processes.
 Safety precautions in brazing, soldering & metalizing.
 Personal Protective Equipment used for safe working culture.
 Safety norms with hand or foot operated presses.
 Safety precautions in Gas furnace operation, Cupola, Crucibles, Ovens.
 Safety norms with Hot Working Operations &cold forming process.
 Safety norms with guards in hot rolling mills.
 Radiography & radiation hazards.

Industrial radiography is a method of non-destructive testing where many types of manufactured

components can be examined to verify the internal structure and integrity of the specimen.
Industrial Radiography can be performed utilizing either X-rays or gamma rays. Both are forms of
electromagnetic radiation. The difference between various forms of electromagnetic energy is
related to the wavelength. X and gamma rays have the shortest wavelength and this property leads
to the ability to penetrate, travel through, and exit various materials such as carbon steel and other
metals.
Prior to conducting any testing the nearby area should always first be cleared of all other persons
and measures taken to ensure that people do not accidentally enter into an area that may expose
them to a large dose of radiation.
The safety equipment usually includes four basic items:
 a radiation survey meter (such as a Geiger/Mueller counter),
 an alarming dosimeter or rate meter,
 a gas-charged dosimeter, and
 a film badge or thermo luminescent dosimeter (TLD).
When these safety devices are properly calibrated, maintained, and used, it is virtually impossible
for a radiographer to be injured by a radioactive overexposure. Sadly, the elimination of just one of
these devices can jeopardize the safety of the radiographer and all those who are nearby.
 Safety measures in Roll turning & Repairing Shop.
 Importance of safety in any industrial activity.
 Safety in Maintenance & operations of Blast Furnaces
 Engineering and Administrative controls for safety precautions.
1. Engineering Controls
Engineering controls include guards, controls, and general ventilation, local ventilation, and dust
collection systems.
Machine Guards
Where machine equipment has an exposed moving part, an in-running biohazard, or material being
processed in a way that creates a hazard, the machine should be equipped with a guard or other
device that prevents access to the moving part or pinch point. There are three main types of barrier
guards that physically prevent a worker from reaching around, over, under, and through the guard
to the danger area. At least one type of guard can provide protection rom most machine hazards.
Fixed Guard: refers to a guard that is a permanent part of the machine, but is not dependent upon
moving parts of the machine to perform its guarding function. A fixed guard that can be manually
set into the appropriate position before machine operation is sometimes referred to as an
“adjustable guard”. A fixed guard that completely separates the user from the hazard is often called
an “enclosed guard”. Fixed barrier guards must be secured with at least one fastener requiring a
tool or removal.
Interlocked Guard: refers to guards that are connected to a mechanism that cuts power to the
machine when the guard is tripped or moved out of position. This allows the guard to be moved for
the user to access the point of operation and disables the control system until the guard is put back
in place and the control system reset.
Self-adjusting Guard: refers to a guard that adjusts automatically to the thickness and movement of
the stock material. Where barrier guards are impracticable, other safeguarding devices can be
considered. This can include two-hand controls, interlocked gate guards, presence-sensing devices
(light curtains, pressure-sensitive mats), restraint device, speed limiters, and so on.
The following diagram (adapted from WorkSafeBC) demonstrates a decision chart that may assist
when reviewing what safe guarding devices would be most effective for the equipment:
Machine Controls
Machine controls, should be conspicuously identified and, located in a safe position and within
easy reach of the operator. Emergency or ‘E-Stop’s is a red mushroom shaped stop manually
depressed in the event of an emergency condition or accident. Emergency stops should not be
considered a primary safeguarding device, as it requires intentional activation, and seldom prevents
accidents. It should also be located within immediate and unimpeded reach of the operator,
mushroom-shaped and red in color and designed to allow immediate activation with any part of the
body.
General Ventilation
All machine shops or areas where machines are used should be adequately ventilated. General
ventilation systems are not substitutes for local ventilation where local ventilation is required.
Local Ventilation
Where processes may produce dust, mists, fumes, or vapors which may be hazardous or may form
explosive mixtures, local exhaust ventilation should be used to remove the hazardous material. For
instance, when chemical or flammable liquid work is performed, additional ventilation may be
required in addition to the building general ventilation. This may include fume hoods or other
type’s of local exhaust ventilation.
Dust Collection Systems
Dust collection systems remove sawdust or other particles from the shop or work area. The
particles are generally collected in a bag or other container for disposal. Where woodworking or
other dust generation activities are conducted, it is recommended that an appropriate dust
collection system be put in place. Dust collection systems must be properly maintained, and care
must be taken in disposing of dust which may be toxic, flammable, or pose other hazards.
Administrative Controls/Work Practice
Administrative controls include training, standard operating procedures, access control to machines
and the shop, maintenance activities, and shop guidelines. Each shop/department should establish
these guidelines, put them in writing, make them readily available, and post their location at the
entrance to the shop.
Examples of Administrative controls include:
 Sensors, signs and alarms (restricted access, visible lights, signage on machines/area)
 Prevent body part contact (location separation, push sticks)
 Preventative inspections/testing (pre-use testing and inspection, documented annual
service/maintenance)
 Work Procedures, training and supervision.