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Contents

1.1.1. Safety Introduction: ..................................................................................... 5

General Requirements for a Safe Practice: ............................................... 5

1.1.2. Human and Environmental Factors That May Lead To an Accident: ........... 7

1.1.3. Identification and Use of Materials: ............................................................ 9

Dangers associated with some materials: ................................................ 9

1. Compressed Gases ................................................................................ 9

2. Cryogenic Materials: ............................................................................. 9

3. Explosives: ........................................................................................... 10

4. Salt Bath: ............................................................................................. 10

1.1.4. Need for Eye Protection: ............................................................................ 11

1. How can we control eye hazards at the source .................................. 11

1.1.5. Hazardous substances: .............................................................................. 12

1.1.6. Types of fire: .............................................................................................. 13

1. Class A ................................................................................................. 13

2. Class B ................................................................................................. 13

3. Class C ................................................................................................. 13

4. Class D ................................................................................................. 13

1.1.7. Types of Fire Extinguisher: ......................................................................... 15

1. Water Extinguishers: ........................................................................... 15

2. Foam: .................................................................................................. 15

3. Carbon dioxide: ................................................................................... 15

4. Dry chemical (powder): ....................................................................... 15

5. First Aid: .............................................................................................. 16

1.1.8. Electrical Safety: ......................................................................................... 17

1. Methods of protection from electrical danger: .................................. 17

Insulation: ............................................................................................... 17

Grounding: .............................................................................................. 18

Circuit Protection Devices: ...................................................................... 18

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Residual current device: ......................................................................... 19

2. First aid procedures: ........................................................................... 19

Mouth To Mouth Resuscitation: ............................................................. 19

Dealing with Electric Shock: .................................................................... 20

Dealing with eye and other types of physical injury ............................... 20

1.1.9. Safety Procedures: ..................................................................................... 21

1. Proper Lifting Procedures: .................................................................. 21

2. Manual Lifting: .................................................................................... 21

3. Use of Lifting Equipment: ................................................................... 23

4. Procedures for the safe handling and storage of materials: .............. 26

1.1.10. WORKSHEET: ............................................................................................ 27

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Learning Outcomes

After completing this learning unit trainee will be able to:

1. Identify hazards and safety facilities in aworkshop.

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1.1.2. Human and Environmental Factors That May Lead To an Accident:

tiredness carelessness

improper behavior

Behavior in workshop should be proper and dress code should be followed strictly

unsuitable clothing

Playing around in the workshop and running should be avoided

lack of training

While training the worker must listen or read the instructions and must understand the

symbols used in industry to represent the things that are placed in the surrounding and signs

of danger.

unguarded or faulty tools and machinery lack of adequate ventilation

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Faulty machines and tools might cause accident when using them by the workers

Unguarded machine and tool might cause accident when using them by the workers

Inadequate ventilation might produce uncomfortable temperature and humidity which

will increase the fatigue of the worker

Keep work areas clean

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1.1.3. Identification and Use of Materials:

Dangers associated with some materials:

1. Compressed Gases

There are two types of hazards associated with the use, storage and handling of

compressed gas cylinders: the chemical hazard associated with the cylinder contents

(corrosive, toxic, flammable, etc.) and the physical hazards represented by the presence of a

high pressure vessel in the work place.

All compressed gases are hazardous

because of the high pressures inside the

cylinders. Gas can be releaseddeliberately by opening the cylinder valve,

or accidentally from a broken or leaking

valve or from a safety device. There have

been many cases in which damaged

cylinders have become uncontrolled

rockets or pinwheels and have caused

severe injury and damage.

2. Cryogenic Materials:

Cryogenic materials are commonly used in

the workplace for a variety of purposes, such

as refrigeration and medical applications.

Due to their extremely cold temperatures,

cryogenic materials can be hazardous if

handled and stored incorrectly. Any

employees handling cryogenic materials must

wear personal protective equipment.

If employees are exposed to the extreme

cold of cryogenic materials they should

receive treatment immediately to prevent

permanent injury. In the event that an

individual inhales cryogenic materials, he

should seek immediate attention to

prevent serious injury or death.

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3. Explosives:

Explosives can be set off by heat, friction

(rubbing), shock (for example due to an

item containing explosives being dropped)

or static electricity. Explosives can

become easier to set off accidentally as

they get older and deteriorate or if they

are contaminated with rust, grit or other

materials. Some explosives become more

dangerous if they are wet. So do not apply

water to suspect items.

4. Salt Bath:

Salt bath is a heating device used in some work places. Common dangers associated with

salt baths include:

Explosive generation of steam due to water or moisture being inadvertently introduced

into the molten salt.

Fires caused through the hot molten salts coming into contact with combustible

materials.

Burns resulting from contact with the molten salt. These are especially hazardous when

caused by molten cyanides since absorption via body tissues can lead to fatal poisoning.

Accidental ingestion of cyanide salts.

Overheating and eventual explosive decomposition of nitrate salts at temperatures

above 600 0C.

Explosive reactions between molten nitrates and aluminum or magnesium alloys under

certain conditions.

Molten nitrates and cyanides may decompose explosively if mixed together

Salt bath furnace

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1.1.4. Need for Eye Protection:

Eye protection is important to protect against dust particles sparks or even liquid splashes.

Particular attention should be made to selecting the right type of protection. The most

common hazards to the eyes are:

dust and dirt blown around by the wind;

flying particles from drilling, cutting, digging and other similar operations;

ultraviolet radiation from welding and electrical work;

splashes; fibers from insulating materials, such as fiberglass; and

Irritants and corrosives.

1. How can we control eye hazards at the source?

Use protective screens and wire mesh grids to protect yourself from flying particles.

Install safety glass guards on machines to prevent injuries caused by flying chips or

splashing liquids.

Place moveable shields around grinders, lathes and other similar machines to protect

other workers.

Enclose sources of fine dusts, mists or vapors.

Control dust and fumes using general or local ventilation systems.

Isolate hazardous operations in separate areas.

For outdoor work, damp down work areas and seal dusty surfaces.

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1.1.5. Hazardous substances:

All people working in the area should be familiar with the hazards of the experiment and the

appropriate emergency response procedures. It is must to wash face, hands, neck and arms

after using the toxic materials.

Very Toxic materials are substances that may cause serious harm to an individual if it enters

the body. Whenever possible, it is always best to avoid using a very toxic material either by

eliminating its use (by changing the method or process for example) or by substituting the

very toxic material with a less hazardous material.

To prevent exposure to a very toxic material, strict control measures are required. Ventilation

is a very important control measure for very toxic materials. Well-designed and well-maintained ventilation systems remove the very toxic vapors, fumes, mists or airborne dusts

from the workplace before workers are exposed.

For the storage of very toxic materials, ensure that the storage area is clearly identified with

warning signs, is clear of obstructions and is accessible only to trained and authorized

personnel.

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1.1.6. Types of fire:

Fire is an exothermic reaction between fuel

and oxygen. Fire is a process that requiresthat a combustible material subjected to

sufficient heat and has access to oxygen.

Fire is a process that requires that a combustible material subjected to sufficient heat and

has access to oxygen. To illustrate how these three elements are dependent on one

another, we can put them together in a triangle, which we call the fire triangle.

The fuel must be heated to its

ignition temperature for combustion tooccur. The reaction will keep going as

long as there is enough heat, fuel and

oxygen. This is known as the fire triangle.

1. Class A

Fires involve solid materials of an organic

nature such as wood, paper, cloth, rubber

and plastics that do not melt.

2. Class B

Fires involve liquids. They include petrol,

diesel, thinners, oils, paints, wax, cooking

fat and plastics that melt.

3. Class C

Fires involve electricity.

4. Class D

Fires involve flammable metals such as

magnesium, aluminum, titanium,

sodium and potassium.

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Task:

Each type of f ire poses its own particular risk. Try and answer these questions, explaining

your answer.1. Would you use water on a type C fire?

2. Would you use water on a chip pan fire?

3. Copy and complete the table:

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1.1.7. Types of Fire Extinguisher:

There are four main types of fire extinguishers used for fighting fire:

Water

Foam

Carbon dioxide

Powder

Fire extinguisher used to be different colors but now, in a workplace, they must be all red. To

tell them they all have different flash on them.

1. Water Extinguishers:

Suitable for most Class A fires, caused by the combustion of materials such as wood, straw,

textiles, paper, coal etc.

2. Foam:

Ordinary solid combustibles, Flammable liquids and gases (Petrol, grease and oil fires are

included in this class.)

3. Carbon dioxide:

Flammable liquids and gases (Petrol, grease and oil fires are included in this class.), fires

involve combustible metals and fires involving electrical appliances.

4. Dry chemical (powder):

Ordinary solid combustibles, flammable liquids and gases, energized electrical equipment.

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5. First Aid:

First-aid is the assessment and interventions that can be performed by a first aider during

an emergency with minimal equipment until appropriate medical personnel arrive. The life of

an injured or ill worker or member of the public within the vicinity of the workplace may

depend on proper first-aid being given within the first few minutes of an accident or an

illness. Besides saving lives, first-aid treatment is important in preventing further

complications from injury and pain and in promoting recovery. It is also important for minor

injuries such as burns, sprains, cuts, etc.

While it is important to understand that first aid has its limitations and does not take the placeof professional medical treatment, if a person is sick or injured, then they need help

immediately. Sometimes people worry about doing the wrong thing, so dont act at all or act

too slowly. However it is also important that the first aider is not panicking. Careful and

deliberate action undertaken without too much delay is most beneficial to the casualty. Try to

remain calm and think your actions through. A calm and controlled first aider will give

everyone confidence that the event is being handled efficiently and effectively.Each

emergency is different, so it is impossible to provide you with a precise list of things you

need to do for every situation. However if you follow the principles of first aid, you should

deliver appropriate care, even if you are not sure of what the underlying problem is.

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1.1.8. Electrical Safety:

Exposure to electrical hazard will be minimal unless the operator becomes involved with

machine repair. The machine operator is mostly concerned with the on and off switch on themachine tool. However, if adjustments or repairs must be made, the power source should be

disconnected. If the machine tool is wired permanently, the circuit breaker should be

switched off and tagged with an appropriate warning statement. Most often the power source

will not be disconnected for routine adjustment such as changing machine speeds. However,

if a speed change involves a belt change, make sure that no other person is likely to turn on

the machine while the operators hands are in contact with belts and pulleys.

An electrical shock is received when electrical

Current passes through the body.

You will get an electrical shock if a part of your Body completes an electrical circuit by

touching a live wire and an electrical ground, or touching a live wire and another wire at a

different voltage.

1. Methods of protection from electrical danger:

Insulation

Earthing

circuit breakers

fuses residual current devices (RCD)

Insulation:

All electrical cords should have sufficient

insulation to prevent direct contact with

wires. It is particularly important to check

all cords before each use, since corrosive

chemicals or solvent vapors may erode

the insulation.

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Damaged cords should be repaired or

taken out of service immediately,

especially in wet environments such as

cold rooms and near water baths.

Grounding:

Only equipment with three-prong plugs should be

used. The third prong provides a path to ground thathelps prevent the buildup of voltages that may result

in an electrical shock or spark. This does not

guarantee that no one will receive a shock, be

injured, or be killed. It will, however, substantially

reduce the possibility of such accidents, especially

when used in combination with other safety

measures.

Circuit Protection Devices:

Circuit protection devices are designed to automatically limit or

shut off the flow of electricity in the event of a ground-fault,

overload, or short circuit in the wiring system. Fuses, circuit

breakers, and ground-fault circuit interrupters are three well-

known examples of such devices.

Fuses and circuit breakers prevent over-heating of wires and

components that might otherwise create hazards for operators.

They disconnect the circuit when it becomes overloaded. Thisoverload protection is very useful for equipment that is left on for

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extended periods of time, such as stirrers, vacuum pumps, drying ovens and other electrical

equipment.

Residual current device:

A residual current device is a safety device that switches off electrically automatically if there

is a fault. RCDs are far more sensitive than a normal fuse or circuit breakerand provide

additional protection against electric shock. Additional protection by means of an RCD can

be a lifesaver. An RCD constantly monitors the electric current flowing along a circuit. If it

detects electric current flowing down the unintended path, such as through a person who

has touched the live part, it will switch the

circuit off very quickly, thereby significantly

reducing the risk of death and seriousinjury.

Using electrical appliances, while wet,

significantly increases the risk of electric

shock. RCD can protect you from

electrical shocks.

2. First aid procedures:

Mouth To Mouth Resuscitation:

Make sure the person is lying on a hard, flat surface. Look into the mouth and throat to

ensure that the airway is clear .If an object is present, try to sweep it out with your fingers

(wear disposable surgical gloves if they are available).

Tilt the person's head back by placing your hand on his forehead and lifting his chin with the

first two fingers of your other hand.

Look, listen, and feel for air coming out of the victim's mouth by bending your own ear down

to his mouth. Tilt your head towards the victims feet, so you can also look to see if his chest

is rising and falling. Continue to tilt the head back with both hands as you look, listen and

feel for air.

Take a deep breath, pinch the victim's

nose closed with the hand that is holding

the forehead, seal your lips around the

victim's mouth and give him several deep

breaths. Pause in between each one to

inhale shortly.

Look, listen and feel for breathing from

your victim. Continue to give him mouth-

to-mouth at steady, regular intervals,

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pausing only to take breathe. Always look

to see if the chest is rising and falling, to

ensure your breaths are getting through.

Dealing with Electric Shock:

If someone in your presence receives an electric shock and is still in contact with its source,

turn off the current at once either by pulling out the plug or switching off at the socket or

consumer unit.

If this is not possible, do not take hold of the person or the current may pass through you

too. Pull the victim free with a scarf or dry towel or something like that, or knock their hand

free of the electrical equipment with a piece of wood.

As a last resort, free the victim by taking hold of their loose clothingbut without touching

the body.Do not attempt to move anyone who has fallen as a result of electric shockexcept to place

them in a recovery positionas they may have sustained other injuries.

Wrap them in a blanket or coat to keep them warm until they can move themselves.

Once the person can move and is no longer in connect with the electrical equipment, treat

their electric burns by reducing the heat of the injury under slowly running cold water. Then

apply a dry dressing and seek medical advice.

Dealing with eye and other types of physical injury

Blows to the Eye

Apply a cold compress without putting pressure on the eye. Crushed ice in a plastic bag can

be taped to the forehead to rest gently on the injured eye.

In cases of pain, reduced vision, or discoloration (black eye), seek emergency medical care.

Any of these symptoms could mean internal eye damage.

Foreign Objects

If a foreign object becomes stuck in the eye, let the eye tear in an effort to naturally flush it

out. The alternative is to flush the eye with clean, drinkable water.

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1.1.9. Safety Procedures:

1. Proper Lifting Procedures:

Using improper lifting procedures may result in a permanent back injury. Back injury can be

avoided if the correct lifting procedures are followed. When lifting heavy or large objects, get

some assistance or use a hoist or forklift.

Objects within your ability can be lifted safely as long as the following procedures are

followed:

Aware the safe working load of the equipment and use loads up to that limit

Use equipment with test certificate

Do periodic testing and inspection on the machine

Maintain the equipment in good condition

Always check the safety and secure of lifting points of the equipment

Get awareness on handling and slinging methods on the machine and use them

appropriately

Get awareness on crane signaling and use them at appropriate time

Follow given safety procedures when using the equipment

Use protective equipment including helmet, footwear and gloves

2. Manual Lifting:

When lifting a load manually:

Keep the feet apart and knees bend position

Grasp the load firmly and Keep the arms close to the body

Lift the weight by straightening the bent knees without bending the back

Twisting of the body while lifting should be avoided

Use the leg muscles to do the work and lift slowly. Do not bend over the load as this

will put excessive strain on your spine.

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3. Use of Lifting Equipment:

When lifting a heavy load lifting equipment used. Lifting equipment should be designed so

that it is safe to use under all conceivable operating conditions. When using lifting equipmentprecautions to be observed are:

Check for the availability of mechanical aids before lifting or moving loads.

Select the right equipment to complete the task.

Do not operate any equipment if you are not trained to use it.

Keep the equipment in good and safe operating condition. It saves effort while

transporting loads.

Make sure equipment is maintained properly and inspected regularly.

Visually inspect the equipment for any defects such as loose wheels or damaged

platforms before use.

Use rolling platforms to assist in carrying and handling heavy objects where limited space

does not allow for comfortable body position.

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Use a hand truck to move bulky objects.

Use a shelf truck to move a variety of objects.

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Use a platform truck to move heavy, irregularly shaped objects.

Use a semi-live skid for temporary storage of work.

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4. Procedures for the safe handling and storage of materials:

Provide proper storage facilities such as:

Storage boxes and containers that can be

Lifted mechanically rather than requiring manual handling

Avoid deep shelving that make retrieving or placing a load difficult

Racks or shelf trucks to store material, thus eliminating the need for lifting the

containers

Storage bins and containers with fold down sides for easier access to loads

When storing loads, employees should:

Store loads in easy to access locations Store loads between knuckle and shoulder height

Use storage techniques to ease material handling; store loads at waist level, use wall

brackets or shelving of appropriate height

Ensure filing cabinets and storage shelves are secured to a fixed object

Store heavy items at an appropriate height for ease of handling

When moving items do not carry too many items at once

Store supplies inside cabinets, not on top of them

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1.1.10. WORKSHEET:

1. In order to comply with safe working practices it is essential that employees should

a) Keep their working area tidy b) arrive at work punctuallyc) Treat their colleagues with respect d) do not waste resources

2. Which one of the following is essential when carrying out oxy-acetylene welding?

a )Leather aprons. b) Radiation detectors

c) Protective footwear d) Eye protection.

3. A chemical foam type of fire extinguisher must never be used on a burning

a) Cardboard box b) paint tin

c) Petrol container d) television set

4. When a small particle of grit becomes lodged under a person's eyelid, the first course of

action must be to

a) Ring for an ambulance b) provide a painkiller tablet

c) Apply eye drops d) rinse the eye with clean water

5. Which one of the following fire extinguishers should, not be used to fight an oil fire?

a) Carbon dioxide b) water

c) Foam. d) Dry Powder

6. An electric soldering iron is earthed to

a) increase its efficiency b )provide fault protection

c) Protect against over-current d) increase the temperature of the bit

7. When lifting a very bulky item manually, which one of the following is the safe procedure?

a) Bend down very slowly

b) Get help from a colleague

c) Always wear leather gloves

d) Put on training shoes, to avoid slipping

8. A human factor that may lead to an accident in the work place,

a) Lack of money b) Lack of trainingc) Carefulness d) Proper behavior

9. Electrical hazards are often caused by,

a) Using cable management systems

b) Fuses with too high a rating

c) Voltages too low for the equipment

d) Terminal screws which are too tight

10. When using mouth to-mouth resuscitation, the patient's head should be tilted

a) Forwards b) backward c) Tothe left side d) to the right side