LearningMaterial-245

8/12/2019 LearningMaterial-245

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Shrikant Deshpande

Asst Manager (Safety)

Gammon India Limited


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Cotton godown

Blow room / Mixing

Carding

Combers

Draw frames

Speed frames

Ring Frame

Auto coners

Packing

Warehouse


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Cotton comes in thetextile mills in theform of compressedbales which are stored

in the godown andreleased to the processas and when required Average weight of

cotton bale is 200 to250 kgDimension of bale is0.75 X0.75X1.25 meter


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Since the space islimitation so balesare stacked as high

as roof height.Either manuallyand in few casesmechanically.


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Accidental falling of bales

At the time of stackingensure that the stack is inadequate equilibriummeans it should be suchthat when one bale isdisturbed for unloadingthe stack should notcollapse this is usuallyachieved by stacking themin along and across inalternate layers like bricksplaced in the wall


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Accident by contactwith sharp edges ofthe straps on thebales.

Fire due to improperwiring

Smoke in the godowndue to moving of

forklift Chance s of accidents

by fork lift


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Bales are transported from godown to blowroom either manually , or by means of trolleysor by means of forklifts.

Blow room consists of Hopper openers

Bale breakers

Beaters and condensers

Feeding unit assembly


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Through pneumatic line section lumped masscotton in the form of bales is opened , beatenup, torn apart and converted into soft, fluffy

lap of cotton.

Here major part is to remove

Stalk

Motes

Some sand

Dust

Etc.


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Transmission machine parts

Belts

Pulleys

Gears

Shafts

Revolving

Beaters Spiced lattices or apron

Other moving parts


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Generally blow room consists of units ofhopper openers , bale breakers, beaterscondensers and feeding unit assembly and

cotton is transferred from one unit to other bypneumatic section. Using these units the lumpmass of cotton in the bales is opened , beatenup, torn apart and converted into a soft fluffy

lap of cotton. In this process the major part ofimpurities such as bits of leaves, stalk, motessome sand , dust etc get removed from thecotton


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Sudden opening of cotton bale results intosudden disengage of steel strap and chances ofaccident.

Since all the machinery consists of belts , pulleys,gears, shafts and they are rotating so as per TheFactories act 1948 all the transmission machineryand other dangerous parts should be made

inaccessible by proper guards. All gears and toothed wheels which do not

required frequent adjustment should be fullyenclosed.


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Suitable and safe belt shifting device andemergency stopping device should be providedto all the machinery.

On all these machines the beater covers andother openings which provide access to thedangerous parts should be effectivelyinterlocked.

Opening gibing access to dust chambers shouldbe so fenced that while light is admitted to thechambers access to the beater guard isprevented.


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Chances of accidents while releasing chokesand removing dirt from under casing of beatersand such opening must be interlock effictively.

Absence of ladder for reaching on certainpoints of machine may result into falling ofperson.

Improper housekeeping also may lead toaccident and fire in the cotton textile industry.


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Carding Machine consists of

Cylinder

Doffer

Licker in

Calendar roll nip

Here cotton comes in the form of lap and leavesthe machine as sliver.

Sliver rope is about an inch in diameter and

made up of clean while fiber.


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Accident due to cylinder

Interlock guard to be provided to the stripping

door on cylinder. Door cannot be open withoutcylinder stopping and cylinder can not be startwithout securely closing the stripping door.


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Accident in licker in

Access to licker in securely closed by panels

Gauging clearance Clearance between cylinder, licker in or doffer or flat

is done by using feeler gauges . AT the time of thisactivity following steps to be followed in order to

prevent accident.


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1) Stop the machine before using filler gauge andshould never be done when parts of machine is inmotion.

2) Operator should not remove fluff, lint, frommoving parts of machine specially fromcylinder, licker in doffer and flat.


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In this process cotton in

the form of ribbon lapsis combed in short

length of about 6mmby a series of needlesplaced on revolvingcylinders. . The fiberbecome longer,straighter and brighteras compare to those in

card sliver.


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To provide guard to the unguardedtransmission parts and other gears

To provide interlock arrangement in order to

avoid contact with cylinder needles. To provide interlock guard to the nipper knife

in order to avoid dropping of nipper knife.


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Sliver from comber andcarding machine arepassed through series of

rollers which draw thesliver and render thefiber more parallel andblending and mixing

also accomplished.


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Head stock gears.

Provide interlock arrangement to head stockgears such that machine can not be started

without cover and covers can not be liftedwithout stopping the machine.

Calendar gears to be guarded properly.

Avoid jam to calendar rollers.


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Sliver is converted into roving in this process,sliver through two sets of rollers into a thicksoft roving and also impart strength to it bytwisting before the roving is wounded on the

bobbins.


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A) Gears.

There are large numbers gears which needsfencing on these machine

Lifter rack and pinion should be well guardedso that access to the nip is prevented bothwhen rack lifts and fall.

B) Flyers Injury by hitting the flyer at the time of

removing fluff and cleaning work.

Inter locking to be provided at the rotating

zone of flyers.


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Roving converted into yarn in this process,


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Accident while piecing broken ends, operatorsusually hold the bobbin at its bottom endbetween their left hand fingers to stop it.

Chances of accidents due to sharp edges onbobbin come in contact with fingers causesaccident.

1) Provide finger caps

2) Educate workers to hold the runningbobbins

3) Provide stopping mechanism such as breaks

for individual spindles.


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Falling of bobbins from creel tops: - Whilecreeling average Indian workers may not reachto the bobbin holder easily and they tstep on

the railing which expose them to the serioushazards.

Accidents at the time of handling of Knife.

To remove fluff or waste yarn on rollers operators do

use knife. And improper use of knife result intoserious cut injury to fingers.


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Sharp edges of damaged cans Cutting of bale hoop iron band by chisel and

hammer may results into injury, proper baleopener should be used.

Maximum material is handled in the boxes andon the trolley so remove jams on the wheels ofthe trolley on regular intervals to avoid falling

of trolley and material boxes to be kept inproper manner.

Wheels of trolleys provided with breaks inorder to blocked them at the time of loading

and unloading.


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Over loading of trolleys , boxes and treys to beavoided.

material to be stored in proper and allocated

position.


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Nails from bales

Hoop iron strip

Ring travelers

Bobbins on the floor may create hazard andperson may fall

Damaged floor may fall trolleys and cans at thetime of material shifting

Cans trolleys kept haphazardly on the floor sochances of striking against these objects.


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Maintain good housekeeping

Regular maintenance of electrical equipmentsand periodic checkup is necessary

Risk of overheating of bearings can reduced byproviding efficient lubrication.

Day to day monitoring and maintenance of all

moving parts Smoking to be prohibited

Electrical equipments must comply IndianStandard and maintained in safe working

condition


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Metal detection and diversion system at blowroom

CO2 Flooding system at beaters and carding

section Provision fire doors to maintain sepretion of

two departments

Fire extinguishers Fire hydrant system

Smoke detection and alarm system


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Noise

Cotton dust

Exposure to chemicals

Exposure to UV rays

Working in Humid atmosphere


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Pre employment and periodical mediaclcheckup

Colour blindness checkup

Noise induced hearing loss Lung function test


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Ear plug

Nose mask

Safety shoes

Goggles for specific jobs

Hand gloves

Etc


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Safety policy

Recruitment of safety officer

Safety committee

Accident reporting investigation and analysissystem

Safety audit , inspection and followup for

action taken. Identification of unsafe acts and conditions

Safety training and education

Safety campaign etc..


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Thank you

LearningMaterial-245

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