Chinmoy Pathak Choudhury_IOCL Internship report

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  1. 1. WINTER INTERNSHIP IN INDIAN OIL CORPORATION LIMITED, BONGAIGAON REFINERY SUBMITTED BY CHINMOY PATHAK CHOUDHURY 2nd JAN, 2013 17th JAN, 2013 DEPARTMENT OF CIVIL ENGINEERING ASSAM ENGINEERING COLLEGE, JALUKBARI GUWAHATI 781013
  2. 2. Table of Contents Chapter 1 Occupational safety and health in construction industry 1 1 Hazards and their solutions 2 2 Safety checklists for Personal Protective Equipment (PPE) 6 3 Common violations on-site 7 4 Safety rules 11 5 Overview of statutes applicable to construction industry 13 Chapter 2 Structural welding 14 1 Welding terminology 14 2 Common types of welds 16 3 Welding positions 20 4 Weld symbols 21 Chapter 3 Storage of cement bags in warehouse 23
  3. 3. P a g e | 1 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 CHAPTER 1: OCCUPATIONAL SAFETY AND HEALTH IN CONSTRUCTION INDUSTRY Construction Sector is very essential and an integral part of Infrastructure development which gives tremendous boost to our countrys economy. The construction industry had registered enormous growth worldwide in recent years. Although the development of technology is rapid in most of the sectors, construction work is still labour intensive. In India, the construction sector employs around 33 million people, which is next to agriculture. The construction workers are one of the most vulnerable segment of the unorganized labour in our country. Workers being exposed to wide variety of serious hazards, the rate of fatal accidents in this industry is 4 to 5 times to that of manufacturing. The workers are also exposed to a host hazardous substances which have a potential to cause serious occupational diseases such as asbestoisis, silicosis, lead poisoning, etc. There is also a serious potential of fires dues to the storage and use of flammable substances and a potential for disasters due to collapse of the structures and the subsidence of the soil on which the construction activity is being carried out. There are numerous challenges of Construction Industry in construction activities in India. Some of them are listed as the following. 1. Transport 2. Infrastructure 3. Migrating Work force 4. Social hazards at site 5. Culture 6. Competent Man power 7. Awareness 8. Unorganized Sector 9. Labour Camps 10. Training Infrastructure Each year, there are thousands of injuries and triple-digit numbers of fatal accidents related to machine and equipment operation. A lot of these accidents involve the operator, but over half involve people on the ground - spotters, co-workers, laborers, shovel hands, passers- by and sidewalk superintendents who get too close. And because of the forces and physics involved, these are usually not first-aid injuries; there is often an ambulance called to the jobsite.
  4. 4. P a g e | 2 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 Potential hazards for workers in construction include: Falls (from heights); Trench collapse; Scaffold collapse; Electric shock and arc flash/arc blast; Failure to use proper personal protective equipment; and Repetitive motion injuries. 1. Hazards and their solutions: Some hazards and their solutions are enumerated below. 1.1. Scaffolding: When scaffolds are not erected properly, fall hazards can occur. Solutions: Scaffold must be sound, rigid and sufficient to carry its own weight plus four more times thr 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 be used to scaffolds or planks. Scaffolds must not be erected, moved, dismantled or altered except under the supervision of a competent person. 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. A competent person must inspect the scaffolding and, at designated intervals, reinspect it. Synthetic and natural rope used in suspension must be protected from heat-pruducing sources. Scaffolds must be at least 10 feet from electric power lines at all times. Fig 1: A Scaffold
  5. 5. P a g e | 3 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 1.2. Fall Protection: Each year, falls consistently account for the greatest number of fatalities in the construction industry. A number of factors are often involved in falls, including unstable working surfaces, misuse or failure to use fall protection equipment and human error. Studies have shown that using guardrails, fall arrest-systems, safety nets, covers and restraint systems can prevent many deaths and injuries from falls. Solutions: Use of aerial lifts or elevated platforms to provide safer elevated working surfaces. Erecting guardrail systems with toeboards and warning lines or installing control line systems to protect workers near the edges of floors and roofs. Using safety net systems or personal fall arrest systems (body harnesses). Fig 2. A worker with fall protection equipments 1.3. Hazard Communication: Failure to recognize the hazards associated with chemicals can cause chemical burns, respiratory problems, fires and explosions. Solutions: Maintain a Material Safety Data Sheet (MSDS) for each chemical in the facility. Make this information accessible to employees at all times in a language or formats that are clearly understood by all affected personnel. Train employees on how to read and use the MSDS. Follow manufacturer's MSDS instructions for handling hazardous chemicals. Train employees about the risks of each hazardous chemical being used. Provide spill clean-up kits in areas where chemicals are stored. Have a written spill control plan. Train employees to clean up spills, protect themselves and properly dispose of used materials. Provide proper personal protective equipment and enforce its use. Store chemicals safely and securely.
  6. 6. P a g e | 4 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 1.4. Stairways: Slips, trips and falls on stairways are a major source of injuries and fatalities among construction workers. Solutions: Stairway treads and walkways must be free from dangerous objects, debris and materials. Slippery conditions on stairways and wlakways must be corrected immediately. One should make sure that the treads cover the entire step and landing. Standways having four or more risers or rising than 30 inches must have at least one handrail. 1.5. Ladders: Ladders are another source of injuries and fatalities among construction workers. Solutions: Using the correct ladder for the task. A competent person should inspect a ladder before use of any defects such as structural defects; grease or dirt that could cause slip or fall; paints or stickers that could hide possible defects. It should be ensured that the ladders are long enough to reach the work area. One should mark or tag damaged or defective ladders for repair or replacement, or destroy them immediately after coming into notice that the same ladder in unsuitable for use. Never load ladders beyond the maximum intended load or beyond the manufacturers rated capacity. Avoid using ladders with metallic components near electrical work and overhead power lines. Fig 3. A worker using a ladder
  7. 7. P a g e | 5 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 1.6. Trenching: Trench collapses cause dozens of fatalities and hundreds of injuries each year. Solutions: One should never enter an unprotected trench. Employ a registered professional engineer to design a protective system for trenches 20 feet or greater. Always provide a way to exit the trench wall at an angle inclined away from the excavation not steeper than a height/depth ratio of 11-2:1, according to the sloping requirements for the type of soil. Keep spoils at least two feet back from the edge of the trench. 1.7. Cranes: Significant and serious injuries may occur if cranes are not inspected before use and if they are not used properly. Often these injuries occur when a worker is struck by an overhead load or caught within the crane's swing radius. Many crane fatalities occur when the boom of a crane or its load line contact an overhead power line. Solutions: All crane controls should be checked to ensure proper operation before use. Inspecting wire rope, chains and hook for any damage. Knowing the weight of the load that the crane is to lift. Ensuring that the load does not exceed the crane's rated capacity. One should not move a load over a workers. Barricade accessible areas within the crane's swing radius. Watch for overhead electrical distribution and transmission lines and maintain a safe working clearance of at least 10 feet from energized electrical lines. Fig 4: A Crane
  8. 8. P a g e | 6 Chinmoy Pathak Choudhury Assam Engineering College, Jalukbari Guwahati - 781013 2. Safety Checklists for Personal Protective Equipment (PPE): The Following checklist helps to take steps to avaoid hazards that causes injuries, illnesses and fatalities. 2.1. Eye and Face Protection: Safety glasses or face shields prevents foreign objects from getting into the eye such as during welding, cutting, grindling, nailing. Eye and face protectors are selected based on anticipated hazards. Safety glasses and shields are worn when exposed to any electrical hazards including work on energized electrical systems. 2.2. Foot Protection: Construction workers should wear safety shoes or boots witgslip-resistant and puncture- resistant soles. Safety-toed footwear is worn to prevent crushed toes when working around heavy equipment or falling objects. 2.3. Hand Protection: Gloves should fit snugly. Workers should wear the right gloves for the job (for example, heavy-duty rubber gloves for concrete work, welding gloves for welding, i