Introduction To Safety

MODULE - 1: INTRODUCTION TO SAFETY

Terms used:
Accident: An unpleasant, unexpected, unforeseen or unintended happening sometimes
resulting from negligence, that results in injury, loss, damage, etc. and is caused by a mistake
or machine failure or natural disaster, or sabotage.
Accidents may cause ‗Mishap, ruin, destruction, injury, death‘. Accidents must be prevented
by precautions and safety measures and safety management.
Safety: A quality or condition of being safe from ‗danger, injury, damage, loss, accident‘.
Hazard: To expose to, ‗danger, risk, chance of accident‘.
Safe: Free from injury, damage, accident and loss
Safety devices: Devices which ensure safety against injury or loss.
E.g. safety belt, Safety glasses, safety earthing, Safety enclosure, Safety fence.
Safety guard: Any person or thing or devices that prevents injury, loss and ensure safety and
security.
Security: State of sense or safety protection or defence against attack, interference,
espionage, sabotage etc.
Precaution: Care or measure taken beforehand against possible danger.
Caution: 1) A word or sign by which warning is given. 2) Act or practice of being cautious.
Appliance: Electrical device which performs specific task (e.g. stove, iron, shaver, heater.)
Slip: Lose one's footing and slide unintentionally for a short distance.
Trip: Falling over due to catching one's foot on something.
Fall: Move from a higher to a lower level, typically rapidly and without control.

Ladders and scaffolding: Scaffold is a temporary wooden or metal framework or platform

for supporting workmen/material during construction, erection, repair and painting of a
building/structure.
Following scaffolds are used in practice:
— Welded frames
— Mobile Scaffolds mounted in castor wheels
— Two point suspension (swinging) scaffold.
— Tube and coupler scaffolds
Factor of safety for designing scaffolds is 4 to 6. Scaffolds should not fall by weight or
unsteady support.

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Figure 1. Safety in ladder placement

 Scaffold must be sound, rigid and sufficient to carry its own weight plus four times
the maximum intended load without settling or displacement. It must be erected on
solid footing.
 Unstable objects, such as barrels, boxes, loose bricks or concrete blocks must not he
used to support scaffolds or planks.
 Scaffold must not be erected, moved, dismantled or altered except under the
supervision of a competent person.
 Scaffold must be equipped with guardrails, mid-rails and toe-boards.
 Scaffold accessories such as braces, brackets, trusses, screw legs or ladders that are
damaged or weakened from any cause must be immediately repaired or replaced.
 Scaffold platforms must be tightly planked with scaffold plank grade material or
equivalent.
 A ―competent person‖ must inspect the scaffolding and, at designated intervals, re-
inspect it.

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 Rigging on suspension scaffolds must be inspected by a competent person before each

shift and after any occurrence that could affect structural integrity to ensure that all
connections are tight and that no damage to the rigging has occurred since its last use.
 Synthetic and natural rope used in suspension scaffolding must be protected from heat-
producing sources.
 Employees must be instructed about the hazards of using diagonal braces as fall
protection.
 Scaffold can be accessed by using ladders and stairwells.
 Scaffolds must be at least 3 metres from electric power lines at all times.

Ladders used during construction, erection, repair, painting etc. should be strong.
Ladders and stairways are another source of injuries and fatalities among construction
workers. OSHA estimates that there are 24,882 injuries and as many as 36 fatalities per year
due to falls on stairways and ladders used in construction. Nearly half of these injuries were
serious enough to require time off the job.
Solutions to prevent the hazards:
 Use the correct ladder for the task.
 Have a competent person visually inspect a ladder before use for any defects such as:
1. Structural damage, split/bent side rails, broken or missing
rungs/steps/cleats and missing or damaged safety devices;
2. Grease, dirt or other contaminants that could cause slips or falls;
3. Paint or stickers (except warning labels) that could hide possible defects.
 Make sure that ladders are long enough to safely reach the work area.
 Mark or tag (―Do Not Use‖) damaged or defective for repair or replacement, or
destroy them immediately.
 Never load beyond the maximum intended load or beyond the manufacturer‘s rated
capacity.
 Be sure the load rating can support the weight of the user, including materials and
tools.
 Avoid using ladders with metallic components near electrical work and overhead
power lines.
Double cleat ladders are mandatory for construction. The cleats provide positive support to
the horizontal members of the ladder. Ladder should be anchored to the vertical wall/structure
and prevented from sliding by appropriate stoppers.

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Ladder design is based on experience and judgment. Ladder should not be too weak or two
heavy. A weak ladder is dangerous. Over designed heavy ladder is difficult to handle safely.
A long, heavy ladder is usually more hazardous when a person climbs on it. Ladders must be
manufactured to exact approved specifications.
It is unsafe to ascend or descend a ladder with climber facing away from the ladder. Ladders
should be tall enough for reaching the work point. Proper slant should be provided for ladder
(1 m horizontal for 4 m vertical). It is a safe practice to tie-off the upper end and to provide non-
slip base stopper at the bottom. Ladder must not be taken inside a charged HV switchyard.
Fixed Ladders are the permanent fixed ladders which are used on vertical walls/structures
for permanent use (e.g. reaching observation platform/roof). The members of the ladder
should he anchored with the reinforcement in the pillars. Intermediate landing must he
provided for very long heights.

Figure 2. Fixed ladder

Precautions in use of ladders:

 Detective ladders must never be used.
 Ladders must be of strength to carry double the strain of the heaviest load that would
be placed upon them.
 Wooden ladders shall not be painted so as to obscure a defect in the wood; only a
clear, nonconductive finish shall be used.
 Ladders must be kept free front dirt, grease, and paint spots.

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 When straight portable ladders are used on hard surfaces, they must be held or firmly
locked in addition, anti-slip shoes must be used where provided.
 A ladder shall not he placed against an unsafe support.
 Ladders must be stored upon brackets and in sheltered locations. Ladders should
never he left in place when workmen leave the worksite for an extended period of
time. They shall be laid on the ground or floor in a safe location or kept In the storage
position.
 Ladders must not be placed in front of doors opening towards the ladder or against
window sashes unless the door is open, locked, or guarded.
 Step ladders must be fully opened before being used.
 Two ladders must not he spliced together.
 Workmen must face ladders when ascending or descending over the, and must have
both hands free and must not slide down or try shunts on ladders.
 Ladders must be periodically inspected; Ladders with weakened, broken, or missing
steps, broken side rails, or other defects shall be repaired or removed from service.
 Straight, portable ladders must be placed at safe angle about 75 degrees with the
horizontal. In other words, place the foot of a 4m ladder 1m from the object it leans
against.
 Straight ladders shall not be climbed beyond the third step from the top.
 Workmen shall use the safety belt tied to the ladder whenever both hand must be used
for the job or a possibility of the employee falling from an elevated position exists.
 As far as possible portable metal ladders shall not be used in the vicinity of exposed
energized lines and equipment.
 Only one person shall work from a ladder at one time. If two persons are required, a
second ladder shall be used.
 Ladders are not meant to be used as scaffolding platforms.
 Other makeshift arrangements for the purpose of ladders like using boxes, chairs, etc.,
shall not be resorted to.
 Use of step ladders above 6 m is prohibited and the use of extension ladders above 7
m is discouraged. When an employee is working on a step ladder more than 3 m high
the ladder shall be held by another person.
 Step ladder legs shall be fully spread and the spreading bars locked in place. Step
ladders shall not be used as straight ladders.

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Material Safety Data Sheet (MSDS):

A material safety data sheet is a technical document which provides detailed and
comprehensive information on a controlled product related to:
 health effects of exposure to the product
 hazard evaluation related to the product‘s handling, storage or use
 measure to protect workers at risk of exposure
 emergency procedures.
In other words, MSDS is a document that contains information on the potential health effects
of exposure to chemicals, or other potentially dangerous substances, and on safe working
procedures when handling chemical products.
MSDSs are a widely used system for cataloguing information on chemicals, chemical
compounds, and chemical mixtures. MSDS information may include instructions for the safe
use and potential hazards associated with a particular material or product. The MSDS should
be available for reference in the area where the chemicals are being stored or in use.
The MSDS contains the following information:
 Hazards identified (i.e. those known about when the product is used in the way the
manufacturer intends)
E.g. Irritating to eye and skin. Keep away from children
 First aid measures.
E.g. If the chemical got into the eyes - irrigate with water 10-15 minutes. For skin –
remove gloves and wash with water
 Fire fighting measures
 Measures for spillage or accidental release
 Handling and storage
E.g. Store away from food. Store in tightly closed containers
 Exposure controls and personal protective equipment (PPE)
 Physical & Chemical Properties
 Toxicological information
 Disposal considerations
 Transport information
Occupational Safety and Health Administration (OSHA):
OSHA stands for the Occupational Safety and Health Administration, an agency of the U.S.
Department of Labour formed in 1971. OSHA‘s responsibility is to improve worker safety

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and health protection. The mission of OSHA is to assure safe and healthful working
conditions for working men and women by setting and enforcing standards and by providing
training, outreach, education and assistance.
OSHA provides the following rights to the worker working in any hazardous environment.
 Have a safe and healthful workplace
 To know about hazardous chemicals
 To report the injury to the employer
 Complain or request hazard correction from employer
 Training
 Hazard exposure and medical records
 File a complaint with OSHA
 Participate in an OSHA inspection
An Employer has the following responsibilities under OSHA;
 Provide a workplace free from recognized hazards and comply with OSHA standards
 Provide training required by OSHA standards
 Keep records of injuries and illnesses
 Provide medical exams when required by OSHA standards and provide workers
access to their exposure and medical records
 Provide and pay for essential personal protective equipment (PPE)
World Health Organization (WHO):
The World Health Organization (WHO) is a specialized agency of the United Nations that is
concerned with international public health. It was established on 07 April 1948
headquartered in Geneva, Switzerland. The WHO is a member of the United Nations
Development Group.
The objective of WHO is the attainment of the highest possible level of health by all the
people. According to the WHO, health is defined as a state of complete physical, mental, and
social well-being and not merely the absence of disease or infirmity.

Lockout and Tagout:

Lockout and tagout procedures are required to prevent injuries from the unexpected
energization, activation or release of hazardous energy during servicing or maintenance of
machinery or equipment. Failure to lockout equipment can result in serious injuries from:

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 Contact with live circuits.

 Entanglement with belts, pulleys, shafts, rollers, impellers, chains.
 Contact with hot parts or materials.
 Fire or explosion.
 Sudden pressure release.
General Guidelines for Lockout and Tagout:
 Only authorized employees are permitted to perform lockout/tagout procedures.
 All machinery, equipment or processes that are to be worked on or serviced, must be
locked out to ensure the work can be safely performed.
 If an energy isolating device is capable of being locked out, then it must be locked
and tagged.
 If an energy isolating device is not capable of being locked out, then it must be tagged
out.
 Prior to commencing servicing or work, equipment and machinery shall be inspected
to verify the equipment or machinery can be effectively isolated.
 All potential sources of hazardous energy (e.g. gravity, electrical, mechanical,
pneumatic, pressure etc…) must be considered when determining lockout/tagout
procedures.
 Each person performing servicing or work on a machine must apply their own lock.
After the lock has been applied, the key must be retained by the person who applied
the lock.
Lockout/Tagout Procedure:
1) Prepare for Shutdown
 Identify the machine, equipment or process to be isolated and inform all affected
employees.
 Identify the type and magnitude of hazardous energy to be controlled and all isolation
points and energy isolation devices to be locked out. Ensure remote computer and/or
programmable computer logic controllers are considered.
 Obtain locks, tags, lockout devices and other equipment required to perform the work.
 Wear appropriate personal protective equipment.
2) Equipment Shutdown

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 Notify all affected employees of the lockout and shutdown the equipment following
the normal stop or rundown procedures. (e.g. push ON/OFF or START/STOP buttons
or switches).
3) Isolation
 Locate all energy isolation devices required to control the hazardous energy.
 Operate the energy isolation devices to isolate the machine or equipment from energy
sources. This usually involves opening a disconnect switch, circuit breaker or closing
valves.
4) Apply Lockout/Tagout Devices
 Apply locks and tags to each energy isolation device to ensure it is held in OFF
position.
 Where a lockout device is required for an energy isolation device, install the lockout
device and apply locks and tags to ensure it is held in the ―OFF‖ position.
5) De-Energization (Stored Energy Release or Restraint)
 After application of lockout devices, all stored or residual energy must be relieved,
disconnected, blocked, bled, restrained or otherwise made safe.
6) Verification
 Ensure all affected employees are cleared of the machine or equipment.
 Before beginning any work, verify the machine or equipment is isolated and cannot be
activated or restarted by one or more of the following actions:
 Manually operating control buttons or switches to start or operate the machine
or equipment. Return controls to their off or neutral position.
 Using test instruments to test circuits.
 Visually inspecting the position or movement of parts such as gears, rotating
parts, shafts, flywheels to ensure movement has ceased; inspecting gauges or
other indicators.
7) Release from Lockout/Tagout
 Ensure all non-essential equipment or parts have been removed from the machine and
the machine is operationally intact and safe to be operated.
 Ensure the machinery, equipment and surrounding area is clear of anyone who could
be harmed by the start-up.
 Ensure each person who applied a lockout device and tag removes these from each
energy isolation device.

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 Energize the machine, but do not start it up.

 Notify all affected employees the machine or equipment is ready to be started.
 Re-start the machine or equipment.

Safe Material Handling and Storage:

Materials handling is a job that is performed by almost every worker in the workforce as sole
duty or part of regular work and either by hand or with mechanical help. Materials handling
is conducted in every department, warehouse, office, or facility of a company. Mechanized
materials-handling equipment is commonly used in many industries for assisting with
materials handling and storage due to higher efficiency and productivity at lower cost.
Although mechanical handling creates a new set of hazards, it improves productivity and
reduces cost.
Handling of material accounts for 20% to 45% of all occupational injuries. Injuries can occur
in any part of the operation, not limited to stockroom or warehouse. Strains, sprains,
fractures, and contusions are the most common form of injuries resulting. Certain items of
protective equipment are desirable for the prevention of various types of material handling
injuries. Since the toe and finger injuries are among the most common types of injuries,
handlers should wear safety shoes and stout gloves, preferable with leather palms. Other
personal protective equipment such as goggles and aprons are recommended for the handling
of certain materials.
Manual Material handling (Best Practice):
Manual material handling involves lifting, lowering, and carrying objects. If ergonomics
principles are ignored, stresses on the muscles, joints, and disks in the back can eventually
lead to injury. For objects that are too heavy or bulky for safe manual handling by employees,
mechanical lifting devices must be used for lifting and moving.

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Figure 3. Safe manual material handling technique

1. Assess the situation.

a. How far will you have to carry the load? Is the path clear?
b. Once the load is lifted, will it block your view?
c. Can the load be broken down into smaller parts?
d. Should you wear gloves to get a better grip?
2. Size up the load.
a. Test the weight by lifting or sliding one corner. If it is too heavy or
awkward, STOP!
b. Can you use a mechanical lift or hand truck?
c. Can you lift the load safely, or is it a two- or more person lift? If you doubt you can
lift the load safely, ask for help.
3. Use good lifting techniques.
a. Get close to the load with your feet shoulder-width apart.
b. Get a good handhold, and pull the load close to you
c. Bend at your knees and hips, keep the inward curve in your back, and lift with your
legs.
d. If you need to lean forward, support your upper body weight with one hand.

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Tools and Accessories for Manual Handling:

For safe and efficient handling of materials, a variety of hand-operated accessories is
available. Each tool or device should be kept in good repair and used only for the job for
which it is designed. Most common hand tools used are hooks, crowbars and rollers.
Mechanised material handling equipment such as jacks, hand trucks are widely used to
improve the efficiency of material handling. Proper safety precautions have to be taken while
using these equipment.
• Jacks
• Check capacity plate and load information.
• Workers should inspect jack before and after use.
• Workers should use protective footwear when operating the jack
• Hand trucks (dollies): There are two types of hand trucks namely, two-wheeled trucks
and four-wheeled trucks. Following safety measures to be considers while using hand
trucks.
• Keep center of gravity of load as low as possible. Place heavy objects below
lighter objects.
• Place load well forward so weight of load will be carried by axle not the
handles.
• Place load so it will not slip, shift, or fall and fill only to an appropriate height.
• Let the truck carry the load. Operator should only balance and push.
• Control truck at all times and stay at a safe speed.

Storage of Materials:
Storage of materials should be secure, neat, and orderly to eliminate hazards and conserve
space. A good plan for storing materials reduces the amount of handling needed both to bring
materials into production and to remove finished products from production to shipping.
 Safety measures in materials Storage:
a. Allow adequate ceiling clearance under sprinklers.
b. Keep automatic sprinkler system controls and electrical panel boxes free and clear.
c. Make sure material does not obstruct fire hoses or fire extinguishers.
d. Keep exits clear at all times.
e. Use bins or racks to facilitate storage and reduce hazards.
f. Material stored on racks, pallets is easily movable with less damage and fewer injuries
to employees.

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Storage of Liquids: Liquids should be safely stored in drums, tanks, pipelines portable and
containers.
• Drums
• Store filled drums containing hazardous liquids in a protected area out of the
sun.
• Tanks
• Storage tanks for hazardous liquids are preferably stored outside.
• Review and ensure building structure is safe for tanks.
• Pipelines
• Install pipelines in trenches or tunnels that carry chemicals.
• If they must be installed overhead, isolate them so they will not drip.
• Pipelines that carry flammables should not be installed in tunnels.
• Portable Containers
• Drums, barrels etc.
• Keep only a minimum amount of liquid at point of operation.
• If corrosive, provide isolation protection and protect from spilling.
• Storage area must be well ventilated.
• Separate racks for each material if stacked in racks.
• Tank cars
• Isolate tank cars on sidings by derails and by blue stop flags or blue lights.
• Secure tank car.
• Bond tank car before car is opened.
• Ground the track and loading or unloading rack.
• Properly follow procedures for specific materials during unloading process.
• Use proper safety measures to monitor process.
Storage of Solids: Solids are stored in conical containers like silos, portable containers and
magazines. Following safety measures to be considered while using these storage devices.
1. Silos
• Check silo structural integrity for materials.
• Fall protection to be checked.
• Dust problems must be avoided
• Check for proper ventilation
While storing the combustible solids in the silos following precautions to be taken.

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• Keep temperature below lower explosive limit.

• Good housekeeping is required.
• Sources of ignition must be properly controlled.
• Prevention of electrical shock to metal frames must be incorporated.
• Fill the silos with inert gas to remove oxygen and thereby preventing fire.
Storage of Gas:
Various types of gases are stored at high pressure in metal cylinders. Following safety
precautions must be followed while handling compressed gas cylinders.
• Compressed gas cylinders should be stored in an upright position on a smooth floor
with valve covers in place.
• All cylinders should be chained or otherwise fastened firmly against a wall, post, or
other solid object.
• Different kinds of gases should be separated by aisles or stored in separate sections of
the building.
• Store empty cylinders away from full cylinders.
• Restrict traffic activity and handle with care.
• Follow OSHA, Compressed Gas Association, and other agency standards.

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