APM_ET_13eslides - National Safety Council

©2009 National Safety Council

ACCIDENT PREVENTION MANUAL FOR BUSINESS & INDUSTRY

Engineering & Technology

1

Chapter 1

Safety Through Design




2

1-1. The Model for Safety Through Design




3

1-2. Hierarchy of Controls

To achieve the greatest effectiveness in hazard avoidance, elimination, or control, companies should apply the following priorities to all design and redesign processes:

First Priority:

Eliminate or reduce risk in the design and redesign process

Fourth Priority:

Provide warning systems

Second Priority:

Reduce risks by substituting less hazardous methods or materials

Fifth Priority:

Apply administrative controls

Sixth Priority:

Use personal protective equipment

Third Priority:

Incorporate safety devices




4

1-3. Benefits of Safety Through Design

• Significant reductions in injuries, illnesses, and damage to the environment

• Improved productivity

• Reduced operating costs

• Avoidance of expensive retrofitting to correct design shortcomings




5

Chapter 2

Buildings and Facility Layout




6

2-1. Design for Safety

General Design Considerations Factors to Consider in the

• Illumination

Design of Tools & Equipment

• Noise and Vibration Control • Construction and Procedures

• Product Flow • Visual Displays, Signs, Labels

• Ventilation • Protective Features and Guards

• Control of Temperature and

Humidity

• Controls and Handles

• Maintenance and Service Needs

• Employee Work Positions and

Movements

• Safety Signs

• Supervision and

Communication

• Support Requirements




7

2-2. Factors Affecting Site Selection

• Relationship of Structure to Climate and Terrain

• Space Requirements

• Type and Size of Buildings

• Necessary Disposal Facilities

• Transportation to and from Facilities

• Market

• Labor Supply

• Hazards to the Community




8

2-3. Factors Affecting Size, Shape & Type of Structure

• Nature of the Business and Processes

• Nature of the Production Materials

• Maintenance

• Heating, Ventilation, and Air-conditioning Equipment

• Working Conditions

• Shipping and Receiving Materials

• Economic Considerations




9

Chapter 3

Construction of Facilities




10

3-1. Role of the Field Engineer

• Identify site-specific safety hazards to contractors

• Establish that the contractors recognize hazards and are prepared to deal with them

• Coordinate the interfaces between contractors

• Coordinate the interfaces between contractors and operating facilities

• Verify that the contractor is performing to agreed-upon contract requirements




11

3-2. Elements of a Safety Plan

A successful plan must address:

• Site-specific hazards

• Safety expectations regarding safe work practices

• Clearly defined safety roles and responsibilities




12

Chapter 4

Maintenance of Facilities




13

4-1. Stairs and Exits

Note the following items, and repair or correct any defects found during a maintenance inspection:

• appropriate exit signs

• improper or inadequate design, construction, or location

• lack of handrails

• handrails placed too low or rough handrails

• improper lighting (including emergency lighting)

• obstructions

• locked doors

• doors that open in the direction of an exit

• poor housekeeping

• wet, slippery, or damaged surfaces

• faulty treads or mats on stairs

• lack of curbing on ramps

• differentiation between

– the exit access

– the exit

– the exit discharge




14

4-2. Components of Facility Maintenance

• Proper long-term care of the buildings, grounds, and equipment

• Routine care to service and appearance

• Repair work required to restore or improve service and appearance




15

Chapter 5

Boilers and Unfired Pressure Vessels




16

5-1. Common Causes of Explosions in Pressure Vessels

Anticipate and avoid the following common causes of explosions in pressure vessels:

• errors in design, construction, and installation

• improper operation, human failure, and improper training of operators

• corrosion or erosion of construction materials

• mechanical breakdown, failure, or blocking of safety devices, and failure or blocking of automatic control devices

• failure to inspect thoroughly, properly, and frequently

• improper application of equipment

• lack of planned preventive maintenance




17

5-2. Safety Devices for Pressure Vessels

• Safety Valves—the spring-loaded type is commonly used on vessels containing air, steam, gases, and liquids

• Rupture Disks—commonly used in chemical processing plants, these devices are designed to open and relieve pressure on a vessel or system of vessels

• Vacuum Breakers—may be spring-loaded or weight-balanced, these are used on vessels working intermittently between pressure and vacuum

• Water Seal—a U-pipe filled with water used on vessels that operate on low pressure or under slight vacuum, such as alcohol stills and gas holders

• Vents—relieves contents of a vessel before excess pressure builds

• Regulation (or Reducing) Valves—reduces high-pressure steam to the pressure required for a specific operation




18

Chapter 6

Safeguarding




19

6-1. Characteristics of a Proper Guard

The characteristics of a proper guard include:

• integrated as a part of the machine

• well constructed, durable, and strong

• able to accommodate workpiece feeding and ejection

• protective

• easy to inspect and maintain

• relatively tamper-proof or foolproof

On the other hand, a guard should not:

• create another hazard

• interfere with production

• cause work discomfort




20

6-2. Safeguarding the Point of Operation of a Power Press




21

Chapter 7

Personal Protective Equipment




22

7-1. Permissible Noise Exposures




23

7-2. Suggested Outline for Selecting

Respiratory Protection Devices




24

Chapter 8

Industrial Sanitation and Personnel Facilities




25

8-1. Infectious Waterborne Diseases Caused by

Contaminated Water




26

8-2. Five Industrial Health Areas That Must be

Kept Sanitary for Employee Health

1. Water supplies must be potable

2. Sewage and garbage must be properly disposed of

3. Personal service facilities should be conveniently located

– drinking fountains

– washrooms

– locker rooms

– showers

– toilets

4. Food service (including eating areas and kitchens) must adhere to sanitary regulations and practices

5. Heating, cooling, and ventilation should be properly checked and maintained




27

Chapter 9

Occupational Medical Surveillance




28

9-1. Components of an Occupational Surveillance System

• Gather information on adverse health events and exposure circumstances

• Distill and analyze data

• Disseminate data to interested parties

• Intervene on the basis of the evidence provided by the data to alter factors that produced the hazards and adverse health outcomes




29

9-2. Steps for Implementing Medical Screening Programs

1. Assess the hazards

2. Identify organ toxicity

3. Select medical tests

4. Interpret data and develop action criteria

5. Standardize the testing process

6. Perform the test

7. Interpret results

8. Confirm results

9. Determine work fitness

10. Notify workers

(confidentially) of results of the screening tests

11. Diagnose and evaluate

12. Evaluate and control exposure

13. Keep and maintain records




30

Chapter 10

Electrical Safety




31

10-1. Effects of Electrical Contact




32

10-2. Electrical Equipment Selection and

Installation Checklist

• Selecting Electrical Equipment

– follow recommendations of established codes & standards

– check state & local codes for zoning requirements

• Installing Electrical Equipment

– interlocks

– barriers

– warning signs

– guarding

• Switches

– knife switches

– pendant switches

– push button or snap switches

– flush switches

– surface switches

• Protective Devices

– fuses, link fuses, plug fuses, cartridge fuses

– circuit breakers

• Ground-Fault Circuit

Interrupters

• Control Equipment

• Motors

– dust, oils, moisture

– misalignment and vibration

– overloads

– friction and wear




33

10-2. Electrical Equipment Selection and

Installation Checklist (continued)

• Extension Cords

– portable tools

– heating devices

– flexible cords

– extension lamps

• Test Equipment

– ammeter

– voltmeter

– megohmmeter

– ground-fault indicators and locators

– wattmeter

– industrial analyzer

– receptacle circuit tester

– receptacle tension tester

– voltage detector

– recording instrument

– specialized testing instruments




34

10-3. Voltage Detector




35

Chapter 11

Fire Protection




36

11-1. Objectives of a Fire Protection Program

1. Preventing fires

2. Detecting and responding to fires

– early detection

– initiating appropriate alarms

– responding quickly to alarms

3. Controlling, suppressing, and extinguishing fires

4. Recovering from fires




37

11-2. Fire Extinguisher Classification Markings




38

11-3. Common Types of Sprinklers and

Water-Spray Systems

• Automatic Sprinklers—the most extensively used fixed fire extinguishing system, considered by most fire protection engineers as the most important fire-fighting tool

• Wet-Pipe Systems—accounts for the greatest percentage of sprinkler installation, this system works when heat fuses the fusible link on a sprinkler head, immediately releasing water over the area below

• Dry-Pipe Systems—a substitute for the wet-pipe system commonly used in areas where piping is exposed to freezing temperatures

• Pre-Action Systems—similar to dry-pipe systems, this sprinkler system works faster because a pre-action valve, actuated by a separate fire detection system, controls the water supply

• Deluge Systems—commonly designed for facilities that contain large quantities of flammable materials and where great quantities of water must be applied over large areas. These systems are recommended wherever quickly spreading fires (flash fires) are possible




39

Chapter 12

Flammable and Combustible Liquids




40

12-1. Hazards of Flammable and Combustible Liquids

The degree of potential hazard from flammable and combustible liquids depends on four elements:

• The flash point of the liquid (lowest temperature at which liquid gives off enough vapor to create a flammable mixture near the surface of the liquid)

• The concentration of vapors in the air (whether the vapor-air mixture is within the flammable range)

• The availability of a source of ignition at sufficient temperature to enable ignition

• The degree to which ventilation prevents accumulation of vapors




41

12-2. Potential Health Hazards Associated with

Flammable Liquids

• Skin irritation

• Intoxication or illness from inhaling vapors

• Oxygen deficiency in closed containers used to store these liquids




42

Chapter 13

Workers with Disabilities




43

13-1. Disabled Individual

ADA defines a disabled individual as a person who has one of the following:

• a physical or mental impairment that substantially limits one or more of the person’s major life activities, such as:

– ambulation

– communication

– education

– employment

– housing

– self-care

– socialization

– transportation

– vocational training

• a record of such impairment, or

• a perception of having such an impairment.




44

13-2. Physical or Mental Impairment

The term physical or mental impairment would include, but not be limited to, the following conditions:

• diseases and infections

• orthopedic impairment

• visual, speech, and hearing impairments

• cerebral palsy

• epilepsy

• muscular dystrophy

• multiple sclerosis

• HIV

• cancer

• heart disease

• diabetes

• mental retardation

• emotional illness

• drug addiction

• alcoholism




45

13-3. General Responsibilities of the

SH&E Professional to the Disabled

• Maintaining close liaison with the equal employment opportunity

(EEO) manager-coordinator and with medical and personnel departments when placing disabled individuals

• Making a job safety analysis of existing work based on the abilities and limitations of the disabled employee or applicant when employing, transferring, promoting, and selecting workers with disabilities

• Making recommendations for safety modifications of tools, processes, and procedures when a company must make reasonable accommodations for the disabled individual

• As required, cooperating with the facility or mechanical engineer and the planning, production, and maintenance departments when disabled employee accommodations are being evaluated




46

Chapter 14

Nanomaterials in the Workplace




47

14-1. Steps for Clearing Use of

Nanomaterials in the Workplace

1. Investigate and determine the physical and chemical properties

(size, shape, solubility, etc.) that influence the potential toxicity of the nanoparticle

2. Evaluate short- and long-term effects nanomaterials may have on organ systems and tissue

3. Determine biological mechanisms for potential toxic effects

4. Create and integrate models to assist in assessing potential hazards

5. Determine if a measure, other than mass, is more appropriate for determining toxicity




48

Chapter 15

Materials Handling and Storage




49

15-1. Rules for Lifting

1. DO engineer manual lifting and lowering out of the task and workplace.

2. DO be in good physical shape.

3. DO think before acting.

4. DO get a good grip on the load.

5. DO get the load close to the body.

6. DO NOT twist the back or bend sideways.

7. DO NOT lift or lower awkwardly.

8. DO NOT hesitate to get mechanical help or help from another person.

9. DO NOT lift with the arms extended.

10. DO NOT continue lifting when the load is too heavy.




50

15-2. Guidelines for Lifting

Two limits are provided based on epidemiological, biomechanical, physiological, and psychophysical criteria:

1. Maximum Permissible Limit

(MPL) is defined to best meet four criteria:

• Musculoskeletal injury and severity rates increase significantly in populations where work is performed above MPL

• Biomechanical compression forces on the spinal discs are not tolerable over 1,230 lbs (650 kg) in most workers

• Metabolic rates exceed 5.0 Kcal/min for most individuals working above

MPL

• About 25% of men and less than 1% of women have the muscle strength capable of performing above MPL

2. Action Limit (AL)—the large variability in capacities between individuals in the population indicates the need for administrative controls when conditions exceed this limit based on:

• Musculoskeletal injury incidence and severity rates increase moderately in populations exposed to lifting conditions described by the AL

• A 770-lb (350 kg) compression force on the spinal discs can be tolerated by most young, healthy workers

• Metabolic rates would exceed 3.5 for most individuals working above AL

• More than 75% of women and more than 99% of men could lift loads described by AL




51

Chapter 16

Hoisting and Conveying Equipment




52

16-1. Unsafe Conditions for Overhead Traveling Cranes

• bearing: loose, worn

• brakes: shoe wear

• bridge: alignment out of true

(indicated by screeching or squealing wheels)

• bumpers on bridge: loose, missing, improper placement of

• collector shoes or bars: worn, pitted, loose, broken

• controllers: faulty operation because of electrical or mechanical defects

• couplings: loose, worn

• drum: rough edges on cable grooves

• end stops on trolley: loose, missing, improper placement of

• footwalk: condition

• gears: lack of lubrication or foreign material in gear teeth

(indicated by grinding or squealing)




53

16-2. Unsafe Conditions for Overhead Traveling Cranes

(continued)

• guards: bent, broken, lost

• hoisting cable: broken wires

• hook block: chipped sheave wheels

• hooks: straightening

• lights (warning or signal): burned out, broken

• limit switch: functioning improperly

• lubrication: overflowing on rails, dirty cups

• mechanical parts (rivets, covers, etc.): loose

• overload relay: frequent tripping of power

• rails (trolley or runway): broken, chipped, cracked

• wheels: worn (indicated by bumpy riding)




54

16-3. Hazards of Aerial Baskets

The most frequent causes of unintentional incidents while using mobile aerial baskets include the following:

• not observing proper precautions against electrical hazards to personnel both in the basket and on the ground

• improper positioning of vehicle or outriggers, lack of sufficient blocking under outriggers, or overloading the boom, causing the apparatus to overturn or fall

• overreaching from basket or other improper work procedures

• not using proper personal protective equipment, including safety belts

• moving the truck while the boom is raised, or moving where there is inadequate clearance for the boom

• structural or mechanical failure, or control jamming

• swinging the boom or basket against overhead obstructions or energized equipment

• moving the boom into positions that interfere with traffic

• inadequately training personnel




55

Chapter 17

Ropes, Chains, and Slings




56

17-1. Factors to Consider When Choosing Rope




57

17-2. Wire Rope Cross Section

• Wire rope is made from a number of individual wires grouped in strands, then laid together over a core member (fiber core, an independent wire core, or strand core).

• The number of wires per strand and the number of strands per core depend on the expected working conditions and the amount of flexibility required.




58

Chapter 18

Powered Industrial Trucks




59

18-1. Typical Pallet-Loading Patterns




60

18-2. Lift-Truck Maneuvers

A. turning a sharp corner

B. turning across an aisle

C. turning in an exceptionally narrow aisle

D. turning around in a narrow passage

A B


C



D

61

18-3. Distribution of Load

• (Left diagram) With forks spread wide, the load is well distributed and tends to bind together.

• (Right diagram) With forks positioned too close together, the pallet tends to seesaw.




62

Chapter 19

Haulage and Off-Road Equipment




63

19-1. General Safety Requirements

Prevent accidents to heavy equipment by:

• maintaining safety features on equipment

• systematically maintaining equipment and making repairs

• training operators

• training repair and maintenance personnel

• training employees

• planning work processes




64

Chapter 20

Hand and Portable Power Tools




65

20-1. Safety Practices

By observing the following six safety practices, most unintentional incidents with hand tools and portable power tools can be eliminated.

1. Provide proper protective equipment.

– eye and face protection

– hand and arm protection

– respiratory protective equipment

– hearing protection

2. Select the right tool for the job.

3. Know if a tool is in good condition and keep it in good condition.

4. Properly ground power tools, using a ground-fault circuit interrupter (GFCI) protected circuit.

5. Use tools correctly.

6. Keep tools in a safe place.




66

20-2. Safety Program Objectives

• Train employees to select the right tools.

• Establish regular tool inspections.

• Train and supervise employees to correctly use tools.

• Establish a procedure to control company tools.

• Provide proper storage areas.

• Enforce the use of proper personal protective equipment.

• Plan each job well in advance




67

20-3. Inspection Checklist for Portable Electric Tools




68

20-4. Types of Hammers

Hammers are made in different shapes and sizes, with different configurations and varying degrees of hardness. Each hammer has a specific purpose.

Types of Hammers

• common nail hammers

• nail hammers

• ball peen hammers

• sledgehammers

• hand-drilling hammers

• bricklayer’s hammers

• riveting and setting hammers

• other hammers

– scaling

– chipping

– soft-face

– nonferrous

– magnetic

– engineer’s

– blacksmith’s

– spalling hammers

– woodchopper’s mauls




69

20-5. Rules for Selecting and Using Hammers

• Always wear eye protection

• Always strike a hammer blow squarely-avoid glancing blows, overstrikes, and understrikes.

• When striking another tool, the striking face of the hammer should have a diameter approximately 3/8-inch larger than the struck face of the tool.

• Always use a hammer of suitable size and weight for the job.

• Never use a hammer to strike another hammer.

• Never use a hard-surface hammer to strike another harder surface.

• Never use a hammer with a loose or damaged handle.

• Discard any hammer if it shows dents, cracks, chips, mushrooming, or excessive wear.




70

Chapter 21

Woodworking Machinery




71

21-1. Rules for Safe Operation of Woodworking Tools




72

21-2. Rules for Safe Operation of Woodworking Tools




73

21-3. Maintaining Circular Saws

The following conditions may cause unsafe, difficult, or unsatisfactory operation:

• blade out of round

• blade not straight, out of plane

• blade out of balance

• improper hook or pitch of teeth

• improper or uneven set

• dull blades

• gummed blades

• improper bushings

• cracked blades




74

Chapter 22

Welding and Cutting




75

22-1. Pulmonary Irritants and Toxic Inhalants

• beryllium

• cadmium

• chromium

• copper

• fluoride

• lead

• magnesium

• manganese

• mercury

• molybdenum

• nickel

• titanium

• vanadium

• zinc




76

22-2. Protective Clothing for Welders

• flame-resistant gauntlet gloves—leather or other suitable material (may be insulated for heat)

• aprons made of leather or other flame-resistant material to withstand radiated heat and sparks

• for heavy work, fire-resistant leggings, high boots, or similar protection

• safety shoes, whenever heavy objects are handled (because of spark hazard, avoid using low-cut shoes with unprotected tops)

• for overhead work, capes or shoulder covers of leather or other suitable material. Skull caps of leather or flame-resistant fabric may be worn under helmets to prevent head burns. Also, for overhead welding, ear protection is sometimes desirable.

• safety hats or other head protection against sharp or heavy falling objects




77

Chapter 23

Metalworking Machinery




78

23-1. Rules for Safely Operating Machine Tools

The following rules apply to safely operating any machine tool. Be sure that operators know and follow these rules:

• Never leave machine tools running unattended, unless the machine has been designed to do so.

• Never wear jewelry or loose-fitting clothing, especially loose sleeves, loose shirt or jacket cuffs, and neckties.

• Keep long hair that could be caught by moving parts covered.

• Wear eye protection. This rule extends to others in the area, such as inspectors, stock handlers, and supervisors.

• Do not throw refuse into or spit into the machine tools’ coolant. Such actions foul the coolant and might spread disease.

• Do not manually adjust and gauge

(caliper) work while the machine is running.

• Use brushes, vacuum equipment, or special tools for removing chips. Do not use hands.

• Understand the differences in machining ferrous and nonferrous metals, and know the health or fire hazards of working with these metals.

• Use the proper hand tools for each job.




79

23-2. Grinder Checklist




80

Chapter 24

Cold Forming of Metals




81

24-1. Point of Operation Safeguarding Devices

• Fixed Die-Enclosure Guards—provide the most complete protection for the operator because the die is completely enclosed and the guard is a permanent part of it

• Fixed-Barrier Guards—should be attached to the frame of the press or to the bolster plate

• Interlocked Press-Barrier Guards—provide ready access to the die because they are designed with a pivoting, sliding, or removable section

• Adjustable-Barrier Guards—may be used when a dieenclosure guard or fixed-barrier guard is too time consuming to use, impractical, or both




82

24-2. Procedure for Removing Dies

1. Ensure the work space is cleared of all stock, containers, tools, and other items

2. Disconnect the power and lock out the switch

3. Dismantle or disconnect the point-of-operation safety devices

4. Clean off the bolster plate

5. If the die is to be operated with an air pad, shut off the air supply and open release valve

6. Remove bolts and clamps holding the die in place

7. Ensure that the die is loose

8. Raise the arm slowly

9. Block the ram in its highest position

10. Place the die truck close to the press and ensure that the truck is stable

11. Inspect, repair, and protect dies before storing them




83

24-3. Types of Power Press Brakes

General Purpose—operated by one individual with a single operating control station

• mechanical press brakes

• hydraulic press brakes

Special Purpose—operated by one or more operators. Each operator should have a control station appropriate to the piece-part production system in use




84

Chapter 25

Hot Working of Metals




85

25-1. Magnesium Dust-Collection System

The system converts dust into wet sludge for later removal.




86

25-2. Maintenance Checklist for Steam Hammers




87

25-3. Nondestructive Testing Methods

• magnetic particle inspection

• penetrant inspection

• ultrasonic methods

• triboelectric method

• electromagnetic tests

• radiography




88

Chapter 26

Automated Lines, Systems, or Processes




89

26-1. Flowchart for Hazard and/or Risk Assessment




90

26-2. Five Rules for Safe Chemical Processing Operations

1. Never start adding a reactant at a lower or higher temperature than is called for in the process.

2. Do not add at a rate faster than specified.

3. During scale-up, make sure enough cooling capacity has been supplied.

4. Have specific, written plans on what to do if an emergency occurs. (See Chapter 18, Emergency Preparedness, in the

Administration & Programs volume.)

5. If material is being added and the agitator has stopped, do not restart without first consulting with technical personnel.




91

26-3. Five More Rules for Safe

Chemical Processing Operations

1. Be extremely cautious with spill or low flash-point materials.

Make sure the proper personnel understand and practice those plans.

2. In flammable and toxic liquid service, eliminate as much as practical the use of glass and other breakable materials.

3. Use nitrogen purges or other equivalent, recognized means on vapor spaces containing explosive materials.

4. Do not undercharge or overcharge reactants if a mistake has been made without consulting with technical personnel.

5. Watch for unusual incidents and for temperature, pressure, or other process parameter extremes that could make the reaction uncontrolled or dangerous.




92

Chapter 27

The Computer as a Safety Information Tool




93

27-1. Uses of Electronic Information by the

SH&E Professional

1. As a reference tool—provides a less expensive and less time consuming way to keep track of rapidly changing regulations and technologies

2. As a networking tool—provides quick access to technical issues in specific fields, tips on how to approach specific problems, identifies prospective partners and/or consultants

3. As a marketing and education tool—organization’s web sites may provide for online training, a reference library, and a way to provide safety awareness

4. As an information management tool—enables data from specific environmental sampling instruments to be collected, organized, and managed effectively and efficiently




94

27-2. Safety-Related E-Mail Lists

• SAFETY—worldwide discussions of safety issues

(Safety@List.UVM.edu)

• BIOSAFTY—discussions related to biohazards and biosafety

(Listserv@Mitvma.MIT.edu)

• RADSAFE—radiation safety discussions

(Listserv@Romulus.ehs.uiuc.edu)

• CCOHS—discussions related to news and product announcements from the Canadian Centre for Occupational

Health and Safety—(www.ccohs.ca)

• OCC-ENV-MED-L—discussion on occupational and environmental medicine (Listserv@listserv.duhc.duke.edu)




95

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