r - safety manual

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HARDROCK FABRICATION (P) LTD.JAMSHEDPUR

SAFETY MANUAL

PHA SE VI, INDUSTRIAL AREA, GAMHARIA, JAMSHEDPUR

Doc. No.: HF / SM / EMR 1


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OUR SAFETY PLEDGE

We, the members of HARDROCK family,

solemnly affirm and pledge that we will, at all

times, in our every work of life, whether be at

works, home, society or our nation, practice

safety and always respect and follow rules,

regulations and enactments made for safety

so that we have accident-free environmentthrough out our life.



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SAFETY POLICY

1. PREAMBLE

It is our embedded care and firm belief that safety and healthy workingconditions are most important to members of HF family so that production,quality, cost and other aspects of industrial and related activitiescompletes its destined cycle to the satisfaction of our members andultimately our customers. It calls for planning and well coordinated effortsof all our members at all level. Safety of our members, clean and greensurrounding is important to all, i.e. to the HF members, their family and tothe organization.

2. OBJECTIVE

a. Increase safety consciousness amongst HF members at all levels.

b. We shall strive to manufacture all products and handle anddispose off allmaterials in a responsible manner without creating unacceptablerisks to healthy, safety and the environment.

c. We shall comply with all rules, regulations and enactments, andissuesconnected with safety shall be treated with the samethoroughness and scientific approach as applied to manufacturingactivities.

d. Resources required for safety, health and environment protectionshall receive top priority.

e. All available information pertaining to safety and hazards shall beshared to the extent necessary and appropriate.

f. IAL members shall receive training in safety and environmentprotections required for their task and encourage theirparticipation and involvement so as to make work place safer.

g. Ensure zero incident causing injury, permanent disability or fatalityfrequency rate and total loss control progressively



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h. Ensure safety decisions are taken while purchase, erecting,

commissioning and running of plant, equipment, machinery andmaterial as well as selecting and placement of personnel.

3. RESPONSIBILITY, AUTHORITY & ACCOUNTABILITY

a. Prevention of hazards to lives and limbs of all employees isattainable with proper planning, organizing, directing andcontrolling of activities through efforts by persons at all levels.

b. Safety is essentially a line responsibility and a staff function.Safety is everybodys business, which will be, accepted as a basicresponsibility by the entire staff and line management right upto

the workmen on the shop floor.

c. Safety and Health accident reduction activities will be planned andexecuted under the guidance and advice of Manager under theFactories Act.

d. Manager under the Factories Act will be overall Incharge of Safetyand Health activities. He will be assisted by all concernedpersonnel in different activities such as Accident Investigation,Safety Surveys, Compilation and Analysis of Accident Data andFeedback on relevant aspects thereof at all levels.

e. Prevention of incidents and occupational diseases at the place ofwork shall be the responsibility of HODs of respective operations.

f. Specific responsibilities will be assigned to the subordinate staff by

respective HODs.

g. The contractors, sub-contractors, transporters and any otheragencies which enter the companys premises will be observe allsafety precautions and will ensure safety of their persons. Theywould know the safety instructions applicable to them from thedepartment which is contracting the work to them.

h. SAFETY COMMITTEE : The Safety Committee which includesWorkers Representatives should meet regularly and reviewmatters pertaining to health and safety, investigation of accidentsand give relevant suggestions on these matters.

i. TRAINING : Appropriate education and training in various aspectsof safety



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including fire fighting, first aid will be provided at each level. Thedepartmental heads should encourage individuals to get

appropriate training.

j. MOTIVATION : The Management will endeavor to introducesuitable motivational activities like Safety Award Scheme,Contests, Display of Departmental Accident Record, SuggestionScheme, etc, which will create and maintain a climate of safetyconsciousness throughout the plant. For maintaining this climate,the Management will not hesitate to enforce Safety discipline, ifnecessary.

k. The Management intends to take into account health and safety

performance at the individual levels while considering the careeradvancement.

l. The Management will seek cooperation of all concerned inachieving the objectives and is of the view that the enforcement ofsafety discipline will be an exception.

m. The Management will devise suitable accountability in due course.

4. REIVEW OF POLICY

The policy will be reviewed periodically so as to make it compatible withchanges in technology, working conditions, processes, layouts,legislations, etc.

5. CONCLUSION

The Management sincerely believes that accidents and occupationaldiseases at work places can be prevented and the well-being ofemployees and the environment can be ensured. Apart from statutoryand other measures taken by Management, it is the conscious approachof all concerned and belief in SAFETY that can make this organisation a

safe to work in.

()BASE TEAM CO-ORDINATOR & MANAGER

UNDER THE FACTORIES ACT



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My dear colleagues,

We are delighted to present you Safety Manual for our colleagues so thatsafety practices in working environment form a part of your routine life.

A minor slip could cost anywhere between injury and ones life and it hasbeen always our endeavor that our members work in a safe and healthyenvironment to have accident-free life ahead by adopting safety proceduresand practices same in their every breath of life.

Safety Manual is intended to acquaint out members with the safe practices,which are to be strictly followed, as they are tool for your protection. We

would like to impress our members that your safety is a precious asset toyour family members, whom we treasure as much as you are for us.

In case any aspect are not covered is not clear in this Manual, please feel freeto ask us and ensure that you are working always safely.

Safety is everybodys business. The continued safety if yourselves must,therefore, rely to large extent on conscientious observance of safetyinstruments by one and all.

Apart from statutory and other measures taken by Management to promote

safety, it is your belied in safety that can make our Group a safe place towork in. Safety consciousness should become our habit and part of life withyou.

At the end, I would like to say that every IAL Group member shall live to enjoythe fruit of his duties; that his mother shall have the comfort of his arm in herold age; that his wife shall always have her life support; that his children shallalways have a strong father to tender and care; and that happiness and joy ofassociation with IAL Group endures for ever.

With best wishes for YOUR safe life always,

Ravi Kant PandeyManager - Safety



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1. GENERAL

1. Wear the proper dress and use all necessary protective equipment anddevices recommended for the job. E.g. Safety shoes, hand gloves whilematerial handling.

2. Obey all warning tags and signs.

3. Observe good personal hygiene.

4. Do not report for duty in an intoxicated condition.

5. Do not play practical jokes.

6. Report unsafe conditions to your superiors.

7. Report accidents minor or major injury or no injury to your superiors.Obtain proper medical aid in case of injury.

8. Keep your work place clean and tidy and leave it safe behind you whenleave.

9. Obey all traffic rules while moving on public road.

10. Get yourself trained in Safety, Fire Fighting, First Aid, etc.

11. In case of any dangerous occurrence such as Fire, Leakage of Gas, fall ofbuilding etc, report to Security, Safety and Maintenance.



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2. MACHINERY

1. Never operate machine unless you are qualified, authorized and familiarwith its operation.

2. Before starting a machine, make sure that the guards are in place andsafety devices are in working condition.

3. Do not wear rings, chains, long sleeves or loose clothing when operatingmachinery.

4. Use eye protective equipment for jobs where flying particles are

encountered, e.g. grinding, drilling, etc.

5. Use the machine for the job for which it is intended.

6. Stop machinery before oiling, gauging or making adjustments.

7. Do not attempt to slow down moving machinery with your hand.

8. Use suitable brush, hook to remove chips, cuts from machine. Do not usehands or compressed air.

9. Before starting repairs on a machine, first isolate it from the source ofpower by removing fuse and place a tag on the switch.

10. Report any unusual sound or abnormal performance of a machine to yoursuperiors.

11. Clear chips and turnings regularly from floor and put them in designatedcontainers.

12. Clamp the jobs safely on the machines before attempting machining.

13. Do not use hand gloves while working on machines such as lathes,drilling machines, milling machines, etc.



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3. HAND TOOLS

1. Use only tools, which are in good condition and of good quality. Do notuse tools with mushroomed heads or without handles.

2. When using the tool, do not place your hand where it can get injured if thetool slips.

3. Use a tool only for the purpose for which it is designed and in a prescribedmanner.

4. Ensure that pliers, screwdrivers and other hand tools used in electrical

work have adequate insulation.

5. Keep tools clean. Always carry them in a toolbox or bag.

6. Store all tools only in places meant for them. Do not leave them on thefloor of the work place.

7. Inspect all hand tools periodically. Repair and replace defective tools.

8. Use right tool for the right job.



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4. PORTABLE POWER TOOLS

(Electrical & Pneumatic)

1. All portable electric tools should be earthed, connect to power using a 3-pin plug only.

2. Attend to wiring of portable electrical tools only if you are authorized.

3. Inspect extension cords for kinks, breaks in the insulation and exposedstrands.

4. Keep guards of portable power tools in place while it is in use.

5. Use portable electrical tools working on low voltage to ensure safety.

6. Check the wheel for crack or damage before mounting. Make sure thatwheel fits freely and easily on the spindle but loosely fitting.

7. Use only sound, strong hose with secure couplings and connections. Donot tie the joints with wires, threads, etc.

8. Do not leave with air power ON at near switch, but turn OFF at themains.

9. When crossing passageways, either suspend cable, hose or guard withboards or runways.

10. Store all the tools in their designated place. Do not leave them on thefloor of the work place.

11. Inspect all the tools periodically. Repair and replace defective tools.

12. Select nearest power point for electrical and tools to avoid insulationdamage of cable while crossing passages, etc.



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5. MATERIAL STORAGE

1. Maintain neatness and orderliness in permanent and temporary storageareas. Do not pile up or throw around material in haphazard way

2. Do not exceed the limits of floor loadings while storing heavy materials.

3. Keep access to fire extinguishers, electrical switches, first aid boxes, freewhile storing material.

4. Keep aisles, exits clear.

5. Do not smoke in storage areas.

6. Before accepting any consignment of materials check the condition of thecontainer. Do not accept leady containers for storage.

7. Store incompatible chemicals separately.

8. Store bagged material in cross-tied manner with mouth towards inside ofthe pile.

9. Remove bagged material from top of the pile and not half way up or from

corner.

10. Stock glass panes on their edges with suitable supports.

11. Wear suitable personal protective equipment such as safety shoes, handgloves, etc while handling material.

12. Keep paint varnishes, lacquers, thinners and other flammable materials inproperly sealed or closed containers. Store these containers in a wellventilated area away from excessive heat, smoke, sparks or flame.

13. When barrels are piled on their ends , separate the layers by planks. Donot store barrels more than three high.

14. Store small diameter pipes (less than 7.5 cms) and bar stocks in racks.Do not keep the rack near to aisles or doors.



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15. Store large diameter pipes( more than 7.5 cms) and bark stocksseparately on floor. Provide stops at ends to present rolling.

16. Store grinding wheels on their edges in racks and not on their slides. Donot drop them while handling.

17. Do not store glass wares, lamps on top shelves of racks. But store themin lower shelves as to avoid damage in case of fall.

18. Maintain good housekeeping.

19. Store full and empty containers separately.

20. Use proper racks for storage of material.

21. Use proper bins for storage of fasteners.

NO JOB IS SO URGENT AND NO SERVICE SO URGENT THAT IT

CANNOT TAKE TIME TO PERFORM THE WORK SAFELY.

6. MATERIALL HANDLING(MANUAL & MECHANICAL)



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1. Wear personal protective equipment recommended for the job, such as

leather hand gloves, safety shoes, etc.

2. Use the proper method of lifting to avoid back strain. When two or morepersons are lifting together, coordinate the movement of the object.

3. Secure the load properly. Do not over speed and overload materialhandling/lifting equipment.

4. Do not operate forklift unless you are trained and authorized to do so.

5. Use the correct size and type of sling for given load. Do not use V belts

as a sling.

6. Do not use a sling that is damaged or a hook that is spread. Do notexceed the safe working load.

7. When handling unwieldy loads, attach a rope to control their movements.

8. Avoid taking the loads over persons working below.

9. Observe the prescribed limits of lifting load for manual lifting.

SAFETY ASSURANCE IS YOUR BEST INSURANCE

7. MATERIAL HANDLING(FORK LIFT OPERATION)

1. Observe all signals, instructions and traffic rules.



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2. Drive only on roadways with sufficient capacity and are in good condition.

3. Always slow down on curves.

4. Brakes are for safety, apply them gently and carefully.

5. Always apply hand brake when fork lift truck is not being used.

6. Do not overload and over speed your fork lift truck. Keep at safe distancefrom

other vehicles.

7. Do not give rides to any person.

8. Always look in the direction of travel and do not put your arms, hand orlegs outside your fork lift truck.

9. Always drive the fork lift truck with the elevated mast tilted backwards.

10. When going down hill, put the fork lift truck in reverse gear and driveslowly backwards.

11. Watch out for heights of doorways.

12. Do not drive the fork lift truck with its forks in elevated position. Theground clearance of fork should be approx 15-20 cms. This is irrespectiveof whether they are loaded or empty.

13. Do not pass underneath elevated forks.

14. Do not put your arms or legs between the mast. While doing maintenanceor repairs job, support it securely.

15. Do not smoke while the battery is being charged.

16. Be careful while raising, lowering or changing the position of forks.

17. The battery weight of an electric fork lift or stacker can affect stability ofthe equipment. While replacing the battery, it should be of same weightand dimensions.



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18. Place the forks flat on floor when the truck is parked.

19. If you find any defect in your fork lift truck, report immediately to yoursuperiors.

20. Do not handle molten metal with forklift.

21. Do not use the forklift for dragging the load.

22. Follow the instructions regarding the load center while lifting the load.

MACHINES CANT THINK; ITS UPTO YOU TO PREVENTACCIDENTS



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8. WELDING AND CUTTING

1. During the welding or cutting operation, protect your eyes with hoods,shields or goggles fitted with filter glasses of suitable shade numbers.Use leather gloves to prevent hand injuries.

2. Ensure that no combustible/flammable materials are present in theimmediate vicinity.

3. Make sure that fire extinguisher is nearby and you know its operation.

4. Keep partition screens around the welding area to protect others workingnearby.

5. Before doing hot work on vessels which contained flammable gases /liquids, get them certified as safe for the work.

6. Keep oil, grease, etc. away from oxygen cylinder fittings since these reactexplosively with oxygen. Do not lubricate cylinder valves and otherfittings.

7. Before fitting the regulator on the cylinder valve, especially on oxygencylinders, momentarily release the gas and close the valve (cracking) inorder to dislodge any dirt lying inside.

8. Use red hoses for flammable gases and black for oxygen. Replacedefective and worn out hoses immediately.

9. Do not hang welding torches on regulators or other fittings attached tocylinders.

10. In electric arc welding do not allow the welding cables to get entangledwith power cables. Ensure that cables are not damaged by materialmovement.

11. Keep the welding area clean and dry.

12. Do not use pipe lines containing flammable gases or liquids or conduits

carrying electrical conductors or earthing strips of machines as part ofground return circuits.

13. Use of approved and right type of regulator and torch recommended forthe job.

14. Do not weld the fuel tank when petrol resisting paint is wet.



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15. Do not weld under base or other material by keeping them on emptybarrel of thinner, N.C. cleaner, paints, etc.

16. Always keep acetylene cylinders in vertical position.

ACETYLENE (C2H2) IN CYLINDERS

Important Properties

Colour : Colourless

Odour : Odourless when pure. Commercial gradeshave a

garlic-like odour.

Physical Rate : Gas

Boiling Point : -83 degree C

Explosive Limits : 2.5% to 82% by volume in air

Auto ignition temp- : Varies depending on factors like gas-air mixturecomposition, pressure, water vapor content andinitial temperature. Mixtures containing 30% or

more acetylene with air at atmospheric pressurecan ignite around 305 deg C.

Vapor density : 0.91 (air = 1)

Miscibility : Moderately miscible in water and many organicLiquids. Highly miscible in acetone.

Toxicity : Non-toxic when pure. Mildly anesthetic inmixture

with oxygen.

Chemical reactivity : Forms explosive compounds with copper, silver andMercury; may explode violently when mixed withChlorine or fluorine in the presence of sunlight.



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FIRE EASY TO START, HARD TO STOP

FIRE AND EXPLOSION HAZARDS

Because of its wide explosive range, even a small leakage of acetylene oncontact with a spark can lead to an explosion. Explosions of acetylene developpressures higher than explosions of most other gases and are, therefore, moreviolent and damaging. Acetylene can also decompose violently (especially whenunder pressure) when subjected to heat or shock, even in the absence of air.With metals such as copper, silver and mercury, it reacts spontaneously to form

explosive acetaldehydes. Its mixtures with chlorine and fluorine can explodeviolently in the presence of sunlight.

HOW CAN ACETYLENE CYLINDER BURNS

The manner in which an acetylene cylinder may burn depends upon the location,size of the leak and the pressure within the cylinder. Small leaks from gasescaping through packing glands on valves or around fuse plugs will burn ifignited but may not grow in size if the heat of the flame is insufficient to melt thefusible metal in the relief device. Larger leaks from cylinder valve or regulatorconnection, may become ignited and create sufficient heat to cause melting ofthe fusible metal in fuse plug.

With fusion of metal in such a manner from the relief device, a rather loud noisemay be heard when gas is released. Most bystanders tend to exaggerate themagnitude of this sound and often erroneously refer to it as an explosion.When fuse plug releases, a large volume of acetylene will rush out and may getignited by a nearby source of ignition.

PREVENTION OF FIRE AND EXPLOSION

Cylinder, filter material and solvent (acetone) should conform to standardrequirements. Never attempt to transfer acetylene from one cylinder to anotheror mix acetylene with other gases in a cylinder, or fill any other gas in anacetylene cylinder. When acetylene is used through torches or other devicesequipped with shut-off valves on acetylene supply connections, the pressure ofacetylene should be reduced through a suitable pressure regulator attached tothe cylinder valve.

Identify leaks in cylinders, rectify them by tightening glands, nuts, etc; if possibleremove them to a place well away from any possible ignition and allow the gasto escape. Place warning signs in the area to preclude persons from



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approaching the site with a naked flame. Notify the supplier. Never point aburning acetylene torch towards an acetylene cylinder. Cylinders should be

removed from the working areas and put in a store at the end of working period.Valve protection caps should always remain in place before and after the use ofcylinders. Keep valves closed even for cylinders supposed to be empty.

HANDLING LEAKSIdentify leaks in cylinders and fittings by application of soap solution. Try torectify leaks by tightening glandnuts. If leak persists, remove cylinder to anisolated place.

FIRE FIGHTING

When the fire brgade arrives, they should be informed of all cylinders. Thefollowing may be taken before the arrival of the brigade, if no undue risk isinvolved.

1. Cylinders which have not become heated, should be moved to a safe place asquickly as possible making sure that valves are shut.

2. Cylinders which have become hated should be cooled by spraying water froma safe position (A solid jet should not be applied). The area should lbeevacuated if cylinders cannot be cooled.

3. Burning gas from a leak should be extinguished only by shutting off the leak

4. A cylinder involved in a fire should not be used without consulting thesuppliers.

RECOMMENDED STORAGE AND HANDLING PRACTICE

Cylinders should be stored and handled in upright position.

Only cylinders meant for acetylene should be used to fill acetylene.

Cylinders should be stored under cover to protect them against direct rays of thesun. The cylinders stores should be of suitable construction, preferably withexplosion venting facility.

Cylinders of chlorine and oxygen should not be stored with acetylene cyllnders.

Empty cylinders should be marked and stored separately. Before the regulatoris removed from a cylinder, the cylinder valve should be closed and all gas



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released from the regulator. Exits from stores should be easily accessible andfree from any obstruction.

Cylinders should not be allowed to come into violent contact with one another orwith any hard object.

If cylinders are lifted by cranes, rope slings should be used to lift a platform,cage or cradle with the cylinder housed and secured in vertical position.Cylinders with damaged valves or threads should immediately be labelledappropriately and returned to the supplier. Cylinders invariably should be keptaway from acids and other corrosive substances.

For movement in a brand trolley, secure the cylinder in a relatively upright

position.

PERSONNEL PROTECTION

When entering confined spaces suspected to have acetylene gas, personsshould use suitable breathing equipment. For very high concentrations, everyeffort should be made to provide sufficient ventilation to dilute the gas beforeentering the space.

Persons entering such spaces should not use shoes with exposed iron nails orsimilar items, which may cause sparking.

Persons affected by exposure to acetylene should be removed to fresh air andkept warm. If symptoms persist, first-aid/medical aid should be summoned.



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WORK PERMIT

Sr. No.__________ Date________________

International Auto Ltd.,JAMSHEDPUR.

Please allow Mr ____________________________ of M/s / Dept ________________________________ to carry out welding/gas cutting in ________________ (specify areafrom operation to be carried out) for ________________________________ purpose.

INCHARGE OPERATION---------------------------------------------------------------------------------------------------------------

TO BE FILLED IN BY THE HOD

Certified that the area specified above has been / cannot be cleared of all thecombustible / damageable material and is made safe/not safe to carry outwelding/gas cutting operations, with/without due additional safety precautions.

HOD---------------------------------------------------------------------------------------------------------------

TO BE FILLED BY P&A

Satisfied that the necessary precautions have been taken. Hence, permission tocarry out the welding / gas cutting is hereby granted.

P&A---------------------------------------------------------------------------------------------------------------



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PRECAUTIONARY MEASURE

1. Security Guard Mr __________________________________________________ ofM/s _______________________________________ posted from ___________ to_________ am / pm.

2. _________________________________ Extinguishers kept.

3. __________________________________________________________________

---------------------------------------------------------------------------------------------------------------AFTER COMPLETION OF THE WORK

Welding/gas cutting work completed safely at ____________am/pm on_______________.

OR

The following happened when the work was in progress:

1. __________________________

2. __________________________

HOD---------------------------------------------------------------------------------------------------------------



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9. WORK AT HEIGHTS

1. Obtain Work Permit for working at heights, or on roofs.

2. Ensure that a scaffold used for working at heights is secure and safemeans of access is available. Never climb on cross bracings.

3. Before stepping on a scaffold, make sure that planks are secure and willnot tilt.

4. Ensure that guard rails and toe boards are provided at the open edge ofthe working platforms.

5. Ensure that platforms and gangways are free from obstruction, projectingnails, slippery condition, etc.

6. Use sturdy ladders of right type with non-slip shoes. Discard or repairdefective ladders.

7. Do not keep the base of the ladder away from the wall at a distance morethan one fourth of its length.

8. Do not use metal ladders around electrical lines.

9. While using ladder, have somebody to hold the ladder at bottom or tie orlash it at the top.

10. When climbing ladders, use both hands. Do not over-reach.

11. Carry the tools in a bag or have them hauled up.

12. Use helmets, safety belts, and safe ladders while reaching/working atheight andwhere danger of free fall exists.

13 Keep face towards the ladder while climbing up or down the ladder.

FATE SAVES ONCE A TIME, SAFETY SAVES ALL THE TIME



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HARDROCK FABRICATION PVT. LTD.JAMSHEDPUR

Dept: Date:________________

PERMIT TO WORK ON ROOF

S No Name Employee No or ContractorsName

1

2

3

4

is / are permitted to work on proof over _______________________________________

for the purpose of ________________________________________________________.

He will go up at _____________hrs on ___________________ and finish / come downby ________hrs on __________.



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10. ELECTRICITY

1. Do not work on electrical lines / equipment unless you are trained andproperly equipped.

2. Use three pin plug for tapping power. Use minimum length of cable andwithout joints.

3. Ground all electrical equipment properly, preferably with double earthing.

4. Do not work on electrical equipment if standing on wet floor or hands arewet. Obtain dry boards to stand on if necessary.

5. Inspect the cables periodically. Replace/rectify the damage ones.

6. Cables and wires should not be laid directly on the floor, but if it isrequired, it should be taken through GI/MS pipes etc.

7. Do not use a fuse of higher rating than specified.

8. Follow supervisors instructions for specialized work. Obtain work permitfor carrying out work on major electrical installations.

9. Ensure that hand lamps are provided with protective guards.

10. Switch off power supply to machines and lighting fixtures, etc. when notin use or at the end of work.

11. Use tools with non-conducting handles and ladder of non-conductingmaterial.

12. Use adequate insulated protective equipment such as shoes, gloves andsafety belt for working at height.

13. Use CO2 fire extinguishers on electrical fires. Do not use water.

14. Discharge capacitors, HV bushings/terminals after switching them off. Do

not work on them unless they are discharged.

ELECTRICITY BEFRIENDS NO ONE WHO VIOLATES ITSORDNANCES



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11. LABORATORIES

1. Know the hazards and properties of chemicals to be handled.

2. While handling chemicals, wear suitable personal protective equipmentsuch as gloves, face shields, etc.

3. Store hazardous chemicals in a cool area away from source of heat.

4. Do not store incompatible chemicals together.

5. Wash your hands regularly after handling chemicals and before taking

food.

6. In case of spillage of chemicals on your body, wash thoroughly withcopious amount of water.

7. Ensure that all chemicals are identified by suitable labels. Keep thequantities

of chemicals to the bare minimum.

8. Do not apply mouth suction for pipe ting. Use a pipette.

9. Do not handle volatile solvents near an open flame or electrical mantle orhot plate.

10. Use fume hood for all peat ions with toxic/flammable materials.

11. Examine all glass wares before use. Reject damaged ones.

12. Use a piece of cloth when inserting glass tubes or rods into rubber tubingor stopper.

13. Do not leave heating operation unattended.

14. While disposing of chemicals in the sink, dilute them with plenty of water.

15. Switch off electricity and service lines before leaving the laboratory.



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HARD WORK OR LIGHT WORK, SAFETY MUST BE THE NETWORK

12. COMPRESSED GAS CYLINDERS

1. Know the properties of the gas before using it.

2. Keep the gas cylinders in a cool, dry and well ventilated place away fromsources of heat and not exposed to direct sun light or rain.

3. Keep the cylinders of acetylene and liquefied gases always in uprightposition.

4. Keep gas cylinders in their stands secured with chain.

5. Keep the valve caps in place while transporting cylinders.

6. Drop cylinders only on soft pads such as tyres. Do not drag or rollcylinders. Use trolleys for moving them.

7. Do not use the cylinders without a regulator attached to the valve.

8. Use the standard key to operate the valve spindle. Do not use excessiveforce such as by hammering.

9. Check the valve regularly for gas leakage using soap solution.

10. Do not lubricate cylinder valves and fittings.

11. Mark empty cylinders plainly as EMPTY. Keep full and empty cylinderseparately.



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ONES OWN CARE IS THE BEST KNOWN SAFETY DEVICE

13. COMPRESSED AIR

1. Do not play practical jokes wit compressed air. It can be fatal.

2. Never use compressed air to clean clothing, hair or body, or chips frommachine.

3. Never point the hose at anyone and always see that nearby workers areout of the line of airflow.

4. When not actually using the air, point the hose downwards and to theside of the feet.

5. If the hose comes part and only then seize at some distance frombusiness end, block by bending it, switch off and reconnect.

6. When crossing passageways, either suspend the hose or guard it withboards or runways.

7. Do not leave with air ON at the near switch or valve but turn off at the

main.

8. Use only sound, strong hose with secure couplings and connections.

9. Wear suitable protective equipment goggles, face shields, etc.

10. Remember normal work clothing is no protection against compressed air.



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NEGLECT IS FOREVER OF REGRET

14. PACKING AND DESPATCH

1. Take help while carrying long boards. Exercise care at corners and crosswalks.

2. Use safe and sturdy ladders while reaching upper wooden cases formoving them. Do not overreach.

3. Avoid carrying loads over persons working below.

4. Do not allow nails to protrude out of board of wooden case.

5. Keep aisles, passages clear while stacking material.

6. Do not sack wooden cases more than two high. Maintain sufficient gapbetween two stacks for movement of persons.

7. Do not smoke in wood working area.

8. Use suitable personal protective equipment such as safety shoes, hand

gloves while working.

9. Do not drag the load while loading / unloading.

10. Do not allow reversing of the heavy vehicle without assistance in thefactory premises.

11. Do not allow movement of outside vehicles (rickshaws/tempo etc) in theshop

floor for any purpose.

12. Do not move the packed cases by standing behind it. Clear view of thearea in front should be available.



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HURRY NEVER GIVES MORE, TAKES MORE

15. PESTICIDES

1. Pesticides are generally poisonous substances.

2. Do not chew, eat or smoke at the place where pesticides are handled andused.

3. Keep food and drink away from pesticides.

4. Use personal protective equipment, e.g. gloves, aprons, safety shoes,etc. while handling pesticides.

5. Clean yourself with soap and water before taking food or leaving thefactory.

6. Do not use any container that has contained a pesticide as a pot for foodor drink.

7. Do not handle any pesticide with bare hands. Use a handled scoop.

8. Avoid spilling pesticide on body, floor or table.

9. Maintain scrupulous cleanliness of body and clothing and of yoursurroundings.

10. Do not store large quantities of pesticides at the place of work. Keeponly required quantities at work place.



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THERE ARE HAZARDS IN EVERY TRADE,THAT IS WHY SAFETY RULES ARE MADE.

16. HEAT TREATMENT OPERATION

1. Use hand gloves while handling heat-treated components.

2. Carry out the heat treatment and quenching operation in a well-ventilated area.

3. Maintain oil level in quenching tank.

4. Stir the oil/water continuously to avoid local overheating duringquenching.

5. Provide the drip trays for components while cooling.

6. Dispose off carefully liquid waste after heat treatment operation Followthe required procedure while disposing the waste.

7. Use suitable respiratory protective equipment.

8. Keep hot jobs in vertical position.

9. Keep quenching bath very near to the furnace.



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CAUTION IS THE ELDEST CHILD OF WISDOM

17. FIRE FIGHTING

1. In case of fire, report immediately to your superiors & securitydepartment.

2. Sound the siren to alert all.

3. Tackle the fire immediately using appliances of suitable type(refer ChartI).

4. In the event of electrical fires, switch off the supply. Do not use water.

5. Familiarize yourself with position and mode of operation of extinguisherlocal to your job.

6. Do not obstruct fire extinguishers, electrical panels, and switch boards.Keep them easily accessible.

7. Do not obstruct emergency exit doors, internally and externally.

8. Keep oily rags, separate from other waste preferably in closed container.

9. Do not smoke at a place of work. Dispose off cigarette butts safely.

10. Keep containers of solvent always covered. Store only required quantityat place of work.

11. Maintain good housekeeping.

12. Ensure periodical inspection of fire fighting equipment.



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SAFETY IS THE BEST SECURITY

CLASSIFICATION OF FIRES & EXTINGUISHMENT MEDIUM

Sr.No

Type ofFire

DescriptionExtinguishing

MediumReference

s

1.CLASS

(A)

Fire that occur inordinary combustible

material like wood, rags,paper, textile etc wherecooling effect of water is

essential forextinguishing of fire.

Soda acid typeextinguisherWater type

extinguisher(gaspressure).Water type

extinguisher

(constant airpressure)

IS 934

IS 940

IS 6234

2.CLASS

(B)

Fires that occur inflammable liquids like

oils, solvents, petroleumproducts, varnishes,paints, etc. where

blanketing effect isessential.

Foam typeextinguisher

Carbon dioxide typeextinguisher

Dry chemical powder

type extinguisher

IS 933IS 2878

IS 2171

IS 4308

3.CLASS

(C)

Fires involving gaseoussubstances under

pressure where it isnecessary to dilute theburning gas at a veryfast rate with an inert

gas or powder

Carbon dioxide typeextinguisher

Dry chemical powdertype extinguisher

IS 2878

IS 2171IS 4308

4.CLASS

(D)

Fire involving metals likemagnesium, aluminum,

zinc, potassium, sodiumetc. where burning metalis reactive to water andwhich requires specialextinguishing media or

technique.

Special dry powdertype extinguisher

IS 2171IS 4861

5. CLASS(E)

Fires that occur inelectrical equipment,

Carbon dioxide typeextinguisher.

Dry chemical powder

IS2878



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lines, switches, etcwhere the electrical non-

conductivity of theextinguishing media is of

first importance

type extinguisher.

When electricalequipment is de-

energised same as forclasses A & B.

IS 2171IS 4308

SAFETY INSTRUCTIONS

FIRST AID

1. Know the location of first aid box and the person who is in charge of it.

2. Give first aid in time. Arrange for quick transfer of the patient to thedispensary/ hospital.

3. In case of bleeding, control it by direct pressure. Cover the wound withdry dressing only.

4. In case of fracture, immobilize the injured part by splinting.

5. If breathing falls or becomes feeble, start artificial respiration andcontinue till a doctor takes over.

6. In case of thermal burns, immerse the part in cold water for upto 10minutes and then cover with dry dressing.

7. In the event of chemical burns, wash the affected part with plenty ofwater.

8. In case of chemicals splashing into eyes, wash thoroughly with water.

9. Do not try to remove foreign body from eye by yourself. Do not rub theeyes. Get the help of doctor.

10. In case of electric shock, switch off the line and release the victim fromthe circuit. Give artificial respiration and cardiac massage as required.

11. If overcome by noxious gases, remove the victim to fresh air and giveartificial respiration if breathing has stopped.



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BE SAFE

LIVE SAFE

LIVE HAPPY

r - safety manual

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