iNDUSTRIAL SAFETY HANDBOOK

INDUSTRIAL SAFETY HAND BOOKRAMAN BOARDS LIMITED MYSORE OOTY ROAD, THANDAVAPURA - 571 302 MYSORE DISTRICT, KARNATAKA, INDIA... INDUSTRIAL SAFETY HAND BOOKRAMAN BOARDS LIMITED MYSORE OOTY

INDUSTRIAL SAFETY HAND BOOK

RAMAN BOARDS LIMITED

MYSORE OOTY ROAD,

THANDAVAPURA - 571 302

MYSORE DISTRICT, KARNATAKA, INDIA

INDUSTRIAL SAFETY HAND BOOK

RAMAN BOARDS LIMITED

MYSORE OOTY ROAD,

THANDAVAPURA - 571 302

MYSORE DISTRICT, KARNATAKA, INDIA

Released on 4th March 2005

Aroon Raman

Managing Director Raman Boards Limited

MESSAGE

It is now widely recognised that the well-being of the people serving

any organisation is a fundamental prerequisite for all companies that have

set global ambitions for themselves Safety of the working environment

lies at the core of this well-being However much we focus on training,

development and otherwise empowering our people, these positive effects

can be easily negated by poor safety in the working environment.

In order to ensure that the culture of safety takes firm roots in the

organisation, Raman Boards Limited has placed great emphasis on

improving its work culture through education and training, and executing a

large number of safety related projects in the plants on an on-going basis.

As you are all aware, we have also conducted audits by internal and external

agencies at periodic intervals, assessed the results and then taken various

corrective actions.

There is no doubt that we have made large strides in creating a

safe working environment, but is equally clear that this is a never-ending

journey One important milestone in this journey is our Safety Manual, which

lays down our Safety Policy in clear and comprehensive terms to all our

company employees and stakeholders.

It is my earnest request that all of you use this booklet as a guide to

ensure that our company remains at all times a safe place to work for you

and your colleagues Your valuable suggestions will also go a long way to

help improving this publication.

Aroon Raman

Managing Director

Cdr M S Chandrashekar

Vice-President (Operations) Raman Boards Limited - IMD

MESSAGE

I am pleased to note that the "Safety Committee" of Raman Boards Ltd., has decided to bring out a Safety Handbook during the occasion of National Safety Day - 4th March 2005.

The Handbook will serve as a ready reference and increase the awareness of Health and Safety among the industrial workforce.

I would like to emphasise here that, by following safe work methods,

an employee can ensure his own safety and thereby his family's future.

I would like to congratulate the safety committee for their endeavour

to bring out the safety Handbook on this occasion of safety day.

I would like to also wish all the employees of Raman Boards an accident free worklife.

Cdr M S Chandrashekar

Vice-President (Operations) Chairman - Safety Committee Raman Boards Limited - IMD

T.M Vikram Talaulikar

GM (Operations) Raman Boards Limited - FD

MESSAGE

I am pleased to note that Raman Boards Ltd., has decided

to release a safety hand book on the occasion of National Safety

These themes has drawn the attention of many agencies in view

of great hardship caused by them Therefore there is a need to address this issue on priority One of the tools is to educate the employer and their employees by enlightening them on the issues concerned.

In this context, Raman Boards Ltd., Safety Committee has brought out a safety instruction book on the occasion of celebration of 34th National Safety Day celebrated on 4th March 2005 at Thandavapura, Nanjangud The instruction book contains few tips with regard to Do's and Don'ts to be observed in day to day working in the factory and to prevent any incidents

24 Safety committee & its activities 61

25 Functions of safety committee 61

26 Obligation of Occupier 62

27 Obligation of workmen 64

SAFETY NEEDS INVOLVEMENT

OF EVERYBODY

the fear of meeting with accident!

known dangers & risk;

helps man to land on moon and come back to

mother earth, happily!)

positive Ends!

In all planning

remember the need

of safe working.

What is Accident ?

Accident is an unplanned, unexpected event,

which causes interference to work, may or may

not result in injury, damage to property and /or to

environment

"Accidents do not happen, they are caused"

natural calamities are due to man's actions!

Health is important to an individual Similarlytidiness is important to the working environment,There is no doubt that lack of tidiness andorderliness slows down work But this lack canalso cause serious accidents Therefore beforeyou start

place

safe and clean environment

ELECTRICAL SAFETY

The main cause for electrical accidents are

exposed live wires, bare live conductors, open

switches, temporary/loose/hanging wires; fuses,

inadequate knowledge and unsafe working

methods

DO'S

be allowed to undertake electrical works

by testing

damaged insulations, kinks or joints

loose

supply,

ensure that it is properly earthed, no leakage

of current though the body of the equipment

and insulated tools while working withelectricity

self-custody while undertaking repairs

"OFF" and are of appropriate amperage

atmosphere

Inspection of cords and related tools

Materials for complete protection Ensuresafety by personal observation and not byother persons report

proper covers and regularly cleaned

wire

If you don't monitor, you can't manage it!

DON'Ts

Circuit Breakers

connections, naked joints/wirings

the repercussions

Leave electrical repairs to authorized People.

Don't tamper

with the switch

when you are

on the job.

TIPS ON INSTRUMENTATION SAFETY

removing pressure & flow transmitters fromlines

after installing pressure, flow and temperaturesensors

before removing from panel

instrument and solenoid valves

removing Rotameter

bottom, mounted, diaphragm-type leveltransmitter

obtaining written permission from plant charge

spark off and create fire hazards

ACCIDENTS DO NOT HAPPEN: THEY ARE CAUSED!

BURNS:

body part comes within flashing distance of a

ELECTRICAL INJURIES

Electric Shock

Flow of electric current through human body is

the cause of electric shock Voltage, resistance

of the body to electricity, duration of current flow

are important

Alternating current(AC) is more dangerous than

DC; the former causes involuntary grip which

prolongs time of contact and therefore more

dangerous

On receiving an electric shock;

muscles causing disturbance in their normal

functions If the path is through the heart, the

accident can be fatal

his balance on getting a shock

level causing him bodily injury

high voltages current.

also

causing burns

In case of electric shock injury, give the victim

artificial respiration and call for a doctor

immediately, don't crowd around the victim; he

needs fresh air

HAND-TOOLS

Large number of injuries are caused from

hand-tools The main causes are use of unsuitable and

damaged tools

DO's

they are designed

dressed periodically to avoid

mushroom-heads

DON'Ts

as a screw-driver

between nut and spanner

working at heights, as it is a source of danger

to the persons working below

machines and on pathways

USE RIGHT TOOL FOR RIGHT JOB

CARE OF HAND-TOOL

There are a few rules that must be followed in thecase of hand-tools Proper care will make yourtools last longer; keep them always in workingcondition

Remember that the sign of a good worker is theexcellent condition of his tools!

The finest tools

In the world protect them

SAFETY IS A HORIZONTAL MOVEMENT

IN THE SHOP-FLOOR, NOT A VERTICAL

TALK IN THE BOARD ROOM.

FILE:

precautions are to be taken to avoid injuries

point can cause injury

only injure but also break it

break and at that time it throws off tiny bits ofsteel which may go into the eyes

SCREW DRIVER:

with a hammer as it may split or break andthe chip may enter the eyes

bends the blade, making it less efficient Abent blade is likely to slip out of the screwslot and may injure the hands

the tip will not slip to cause injury

one hand the material in which the screw is

to be inserted, as this may cause the tip toslide out of the slot and may injure the hand

CHISEL:

While using chisel, follow the precautions:

grease

chisel or hand is slippery, accidents are bound

to occur

prolonged use Such a hammer, when used,

will result in injury to nearby people

metal sheet or a wooden board as a screen

to prevent the chips flying far and causing

injury

DRILLING MACHINE:

size and see that the drill is running true

and large drills at low speeds

cast Iron

Always clamp the work to table

when power is put off and the machine has

come to dead stop

start drilling by hand

drill

moving part of the drilling machine

work

KEEP ALERT, DON'T GET HURT!

DAY DREAMS CAN BECOME NIGHTMARES

YOUR SAFETY IS, IN FACT, THE SAFETY OF YOUR FAMILY

GAS-CUTTING AND WELDING

DO's

hand gloves, shoes

upright position; they should be strapped or

chained

shelter and in ventilated area

cylinder-trolleys

strike against each other

functional

near-by

sand, water near-by

Your eyes Are worth protecting

MATERIAL HANDLING (MANUAL)

power and less effort

alone

move slowly with small steps

and lower the load slowly

OIL ON THE FLOOR, OPENS ACCIDENT DOOR!

to ensure safety of men and material

DO's

accessories at the beginning of each shift

of the lifting chain/wire rope

in emergencies

working

of the pendent-operated crane are in goodcondition

LIFTING MACHINES

There are different type of lifting machines such

as EOT cranes, HOT cranes, Chain Pulley blocks,

Hoists etc These are required to be used carefully

Hydrant system with Monitor to be installed.

area and to avoid Oil/Liquid spillage

handle Fork Lift trucks/ To follow instructions

as per Equipment manual

other than the truck operator To Drive at safespeed with caution

on and do not load such that visibility isrestricted Ensure proper Anchoring of theLoad on Vehicles

can be used

and equipment such as Hoist, Chain Pulleyblocks, Jacks etc., for handling heavy loads

load and movement of personnel below theoverhead load being carried

DON'Ts

it

When you work above, Remember The men below.

of the switches are clearlyvisible

required height

are in place whilehanding the load

is inspected and certified by a competent

person, once a year

MATERIAL STORAGE AND HANDLING

the wall and should be well with in 3 meters

height At least 1.5 meters around the

stacking must be kept clear for movement

and inspection on regular basis

ever applicable

available in the area

N Don't allow load to remain suspended.

capacity

signals

Keep clear of

suspended loads.

ACCIDENTS DO NOT HAPPEN; THEY ARE CAUSED!

SAFE WORKING WITH MACHINERY

must be properly guarded with provision ofemergency shut down

and moving equipment's to identify riskinvolved and corrective action taken

into consideration while ordering newmachinery and proper installation procedure

to be followed as per the manufacturerguidelines

PRESSURE VESSELS

Pressure vessel means any vessel which is used

to store, handle air, any gas, liquid or vapour underpressure greater than the atmospheric pressure

the pressure vessels are in working condition

the pressure vessel to be informed to thesupervisor, immediately

of the supervisor

MACHINE GUARDING

Machine guarding means providing adequate/

secured guards around the dangerous/rotating/

protruding parts

machine which are easily accessible, are

adequately guarded

maintenance/repair

vessel

being put to use

wheel

lesser than that of the wheel

from moisture

Your eyes are the windows of your world (Protect them, wear goggles)

SAFETY IN GRINDING

the face of wheel, say 0.3 mm

so designed

Keep fingers clear of moving machinery Use guards as intended

PROTECT YOUR EYES FROM FLYING FRAGMENTS.

PEDESTAL GRINDER

it up, especially if the wheel is new

the face of wheel, Check this distance

the wheel and break it

motion

the shaft or its peripheral speed is not safe

for the number of R.P.M of spindle Check

with the instructor for this information

excessively This may be a danger signal that

the wheel is not properly balanced or not

attached securely to spindle

it will not slip out of hand and cause hand/

fingers to come in contact with wheel

for grinding short pieces

grinder is provided with protective glass

shields

SURFACE GRINDER

installing them on? The spindle

stand at a safe distance to one side until youare sure that the wheel is sound

loading, unloading or checking work on thechuck, stop the machine

if it has a diameter greater than 1.5"

mounting a wheel

for the health of the grinder operator, See thatthey are properly adjusted at all times

FIRST-AID FOR SPECIFIC ACCIDENT

OR ILLNESS

TREATMENT FOR SUNSTROKE

thermometer

into a tub of cold water or give full bath or

apply wet sponge over his body

or clothes dipped in cold water

HEAT EXHAUSTION

Signs to look for: fatigue, irritability, headache,

feeling of faintness, cold, clammy skin and a lot

of perspiration

What to do:

shaded area or an air-conditioned room

Raise feet

of water) or cool sweetened drinks, especially

iced tea and coffee, every 15minutes until

person recovers

recovered Person should rest for a little

longer

TREATMENT FOR FAINTING

lower than the rest of the body

No matter how small the injury is, get first-aidfirst and then get medical aid

do not know

in operation to meet any eventuality and withperiodic fire fighting and emergency drill

by trained worker during office hours andimmediately to inform the concernedManager and HRD cell

to contact in case of emergency is notified

FIRE KILL FIRE BEFORE IT KILLS YOU

control it by using extinguishing media.

further action

specific type of fire

F ind,

I nform,

R esort,

E xtinguish,

By dismantling any one segment, the triangle is

incomplete and so the fire will not occur

Fire Safety instructions

By the combination of 3 elements:

Air (Oxygen)

Fuels (Combustible & flammable)

Heat (Heat Producing sources)

Heat producing sources like:

Welding, gas cutting, Electric Sparks,

Hot Metal, Hot Flames, Smoking etc.,

By removal of any one of the above elements.Best method is removal of Air or Heat

Water, Dry powder, Carbon dioxide Gas andSand

Removal of air: Blanketing Effect,Removal of Heat: Cooling Effect,

By keeping all combustible and flammablematerials away from heat sources

ALL BECAUSE ONE GUY WASN'T CAREFUL

Cigarettes are fire hazards

Carelessly discarded cigarette or "beedi" butts are major fire

starters They combine with the rubbish strewn about and

cause disasters

Suitable ash-trays containing water should be provided

These ash-trays must be cleaned before the time of closing,

Never throw cigarette ends or match sticks out of the window

Prevent smoking within the premises Strictly prohibit smoking

where chemicals and combustible materials are stored

workers/-Superiors/security department,

the ignition source

as may be appropriate

ACCIDENT PREVENTION TAGS

(1s:8095-1976)

an existing hazards till positive means can

be adopted to eliminate the hazard

method

language of State where tags are likely to beused

SAFETY & PRODUCTION

GO HAND-IN HAND!

"DO NOT START" TAGS

These should be placed inconspicuous position or insuch a manner that theyeffectively block the startingmechanisms which couldcause hazardous conditionsshould the equipment beenergized

"DANGER" TAGS

These shall be used onlywhere an immediate hazardexists All employees should

be instructed that it indicatesdanger and that specialprecautions should be takenfor safety