INDUSTRIAL SAFETY HAND BOOK

RAMAN BOARDS LIMITEDMYSORE OOTY ROAD,

THANDAVAPURA - 571 302MYSORE DISTRICT, KARNATAKA, INDIA

INDUSTRIAL SAFETY HAND BOOK

RAMAN BOARDS LIMITEDMYSORE OOTY ROAD,

THANDAVAPURA - 571 302MYSORE DISTRICT, KARNATAKA, INDIA

Released on 4th March 2005

Aroon RamanManaging DirectorRaman Boards Limited

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

any organisation is a fundamental prerequisite for all companies that haveset global ambitions for themselves. Safety of the working environmentlies at the core of this well-being. However much we focus on training,development and otherwise empowering our people, these positive effectscan be easily negated by poor safety in the working environment.

In order to ensure that the culture of safety takes firm roots in theorganisation, Raman Boards Limited has placed great emphasis onimproving its work culture through education and training, and executing alarge 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 externalagencies at periodic intervals, assessed the results and then taken variouscorrective actions.

There is no doubt that we have made large strides in creating asafe working environment, but is equally clear that this is a never-endingjourney. One important milestone in this journey is our Safety Manual, whichlays down our Safety Policy in clear and comprehensive terms to all ourcompany employees and stakeholders.

It is my earnest request that all of you use this booklet as a guide toensure that our company remains at all times a safe place to work for youand your colleagues. Your valuable suggestions will also go a long way tohelp improving this publication.

Aroon RamanManaging Director

Cdr. M. S. ChandrashekarVice-President (Operations)Raman Boards Limited - IMD

MESSAGE

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

The Handbook will serve as a ready reference and increase theawareness 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 endeavourto bring out the safety Handbook on this occasion of safety day.

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

Cdr. M. S. ChandrashekarVice-President (Operations)Chairman - Safety CommitteeRaman Boards Limited - IMD

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T.M. Vikram TalaulikarGM (Operations)Raman Boards Limited - FD

MESSAGE

I am pleased to note that Raman Boards Ltd., has decidedto release a safety hand book on the occasion of National SafetyDay on 4th March 2005.

A handbook such as this will go a long way in increasing peoplesawareness of safety.

Industrial safety today is imperative and goes hand in hand withindustrial progress.

My best wishes to the committee members for this safety handbook.

T.M. Vikram TalaulikarGM (Operations)

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PREFACE

The work ambience in industries is amplyallied with unsafe working conditions and risks. It isthe knowledge that industrial accidents areculminating in loss of life, limbs and damage toenvironment. To prevent and eliminate theseaccidents there are various enactment in force. Theenactment alone do not bring any changes unlessthe process, safe procedure of work are understoodand inclulcated in its letter and spirit by all the

concerned alike. The recent incident world over has revealed that most ofthe accidents are due to either human failure or deviations in the setprocedures.

These themes has drawn the attention of many agencies in viewof great hardship caused by them. Therefore there is a need to addressthis issue on priority. One of the tools is to educate the employer and theiremployees by enlightening them on the issues concerned.

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

It is opined that this instruction book will be of immense help anduseful for all the concerned.

Wishing you a happy, safe, risk-free work environment.

D. C. JAGADEESHDeputy Director of Factories

Mysore Region, Mysore

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CONTENTS

1. Introduction 72. House-keeping 103. Electrical Safety 114. Tips on Instrumentation Safety 165. Hand-tools 176. Gas cutting & Welding 237. Material Handling 248. Lifting machines 259. Material storage and handling 2710. Pressure Vessels 3011. Machine guarding 3112. Safety in grinding 3113. Surface grinder 3414. First-Aid 3415. Fire 3616. Danger tags 4017. Boiler Safety 4118. L.P.G safety at home 4419. GAS hazards 4820. Working at Height 5121. Contractor role in the plant 5622. General Points 5623. Red slips 5824. Safety committee & its activities 6125. Functions of safety committee 6126. Obligation of Occupier 6227. Obligation of workmen 64

SAFETY NEEDS INVOLVEMENTOF EVERYBODY

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RIGHTKEYS

SAFETY IS A CATALYST TO GET THEDESIRED RESULTS!

INTRODUCTION

What is Safety?

* Safety is freedom from accident, freedom fromthe fear of meeting with accident!

* Safety is that which gives protection fromknown dangers & risk;

* Safety helps to take calculated risk (and evenhelps man to land on moon and come back tomother earth, happily!).

* Safety is a pro-active Means to achieve thepositive Ends!

In all planningremember the needof safe working.

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What is Accident ?Accident is an unplanned, unexpected event,

which causes interference to work, may or maynot result in injury, damage to property and /or toenvironment.

"Accidents do not happen, they are caused".*Main Causes of accidents are:*Unsafe Actions - 80%*Unsafe Conditions - 18%*Natural Calamities - 2%*Recent revelations indicate that some of thenatural calamities are due to man's actions!

YOUR DOWNFALLIS DUE TO YOUR OWN CARELESSNESS.

HOUSE-KEEPING"A Place for everything & Everything in its place"

GOODHOUSE KEEPING

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.

S Plan for tools, implements, materials etc.S Ensure clearance and cleanliness at work

place.S Minimize hazards from sharp/pointed objects.S Beware of oily and slippery surfaces.S No haste's and short cuts.S Maintain control over activities and task's.S Concentrate on the task on hand.S To follow 5S Practice strictly to ensure proper,

safe and clean environment.

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ELECTRICAL SAFETY

The main cause for electrical accidents areexposed live wires, bare live conductors, openswitches, temporary/loose/hanging wires; fuses,inadequate knowledge and unsafe workingmethods.

DO'S

F Only qualified & experienced persons shouldbe allowed to undertake electrical works.

F Treat all circuits as live unless ensured deadby testing.

F Ensure extension cords are free from cuts,damaged insulations, kinks or joints.

F Ensure that pins of the socket/plug are notloose.

F Ensure easy access to put off the powersupply,

F While using any portable electrical equipment,ensure that it is properly earthed, no leakageof current though the body of the equipment.

F Report all electrical hazards to the competentperson.

F In case of short-circuit or fire, put off mainswitches immediately.

F CO2 / DCP are the extinguishing mediums incase of fire.

F Place rubber mats in front of the distributionboards.

F Use protection such as rubber gloves, shoesand insulated tools while working withelectricity.

F Remove the fuse cut-outs and keep them inself-custody while undertaking repairs.

F Label the feeders.F Use switches which clearly indicate "ON"/

"OFF" and are of appropriate amperage.F Use work permit in areas of flammable

atmosphere.F Know First-Aid procedures.F Remember, AC is more dangerous than DC.F Do not meddle with the Interlocks with regular

Inspection of cords and related tools.F Avoid temporary connections. Use Standard

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

F Cable ducts and trenches to be covered withproper covers and regularly cleaned.

F All switches on phase wire and not on neutralwire.

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

DON'Ts

N Don't tamper with settings of Earth LeakageCircuit Breakers.

N Don't have any unsafe temporaryconnections, naked joints/wirings.

N Don't work wet, on electrical equipmentN Don't just operate any switch unless you know

the repercussions.N Don't overload an electrical point.N Don't use water for extinguishing electrical

fire; Use dry sand, CO2, or DCP extinguishers.N Don't take short-cuts in tapping electric

current.N Don't store any material near the electrical

mains/switch-boards.N Don't work on live circuits, even when the job

is very small.

Electricity cannot be seen, cannot be tasted; Useelectricity carefully to avoid accidents

Do not leaveElectrical equipmentWithin the reach ofChildren.

Leave electricalrepairs toauthorized

People.

Don't tamperwith the switchwhen you areon the job.

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TIPS ON INSTRUMENTATION SAFETY

K Ensure isolation valves are closed beforeremoving pressure & flow transmitters fromlines.

K Ensure that no leak of process fluid existsafter installing pressure, flow and temperaturesensors.

K Ensure power supply is put off to instrumentsbefore removing from panel.

K Ensure proper fuses are put for eachinstrument and solenoid valves.

K Don't use copper lead in place of fuse.K Ensure process line is isolated before

removing Rotameter.K Ensure tank is empty before removing and

bottom, mounted, diaphragm-type leveltransmitter.

K Never by-pass any interlocks withoutobtaining written permission from plant in-charge.

K Never allow a loose connection, as it mayspark off and create fire hazards.

ACCIDENTS DO NOT HAPPEN: THEY ARE CAUSED!

BURNS:K Burns are caused by electrical flashes if a

body part comes within flashing distance of a

ELECTRICAL INJURIES

Electric Shock

Flow of electric current through human body isthe cause of electric shock. Voltage, resistanceof the body to electricity, duration of current floware important.Alternating current(AC) is more dangerous thanDC; the former causes involuntary grip whichprolongs time of contact and therefore moredangerous.On receiving an electric shock;K The current flows through nerves, and

muscles causing disturbance in their normalfunctions. If the path is through the heart, theaccident can be fatal.

K A person may fall from height as he may loosehis balance on getting a shock.

K A person may be thrown away at the samelevel causing him bodily injury.

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high voltages current.K Burns may be caused due to short-circuit

also.K Short-circuit may lead to electrical fires

causing burns.In case of electric shock injury, give the victimartificial respiration and call for a doctorimmediately, don't crowd around the victim; heneeds fresh air.

HAND-TOOLSLarge number of injuries are caused from hand-tools. The main causes are use of unsuitable anddamaged tools.

DO'sl Use hand-tools for specific purpose for which

they are designed.l Inspect hand-tools before use.l Heads of hammers, chisels should be

dressed periodically to avoid mushroom-heads.

l Store hand-tools in cabinets or tool-boxes.l Use only quality tools.

DON'Tsl Do not use spanner as a hammer or use knife

as a screw-driver.l Never use over-size spanner with packing

between nut and spanner.l Don't leave hand-tools carelessly, while

working at heights, as it is a source of dangerto the persons working below.

l Do not leave hand-tools on floors, onmachines and on pathways.

l Do not misuse tools.

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 finesttools

In the worldprotect them

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SAFETY IS A HORIZONTAL MOVEMENTIN THE SHOP-FLOOR, NOT A VERTICAL

TALK IN THE BOARD ROOM.

FILE:F Though the file is a humble looking tool, some

precautions are to be taken to avoid injuries.F Do not use a file without a handle; the sharp

point can cause injury.F Never use a file as a hammer, as this will not

only injure but also break it.F Never use a file for a 'pry'; it is almost sure to

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

SCREW DRIVER:u Never strike the handle of the screw driver

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

u Never use a screw driver as a pry, as thisbends the blade, making it less efficient. Abent blade is likely to slip out of the screwslot and may injure the hands.

u Be sure the screw driver fits the slot so thatthe tip will not slip to cause injury.

u When using the screw driver, never hold withone hand the material in which the screw isto 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:F Keep the head of the chisel clean from oil &

grease.F Hold the chisel in the correct position, if the

chisel or hand is slippery, accidents are boundto occur.

F Keep the hammer head smooth, it cracks onprolonged use. Such a hammer, when used,will result in injury to nearby people.

F Never chip towards a person nearby. Use ametal sheet or a wooden board as a screento prevent the chips flying far and causinginjury.

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DRILLING MACHINE:u Use drill properly sharpened to cut the right

size and see that the drill is running true.u Small drills should revolve at high speeds,

and large drills at low speeds.u Reduce speed to about 50% when drilling

cast Iron.u Do not forget to use goggles while drilling.u Do not hold your work under drill by hand.

Always clamp the work to table.u Run drill only at specified speeds.u Change the belt for speed regulation only

when power is put off and the machine hascome to dead stop.

u If drill stops in work, shut off the motor andstart drilling by hand.

u File or scrape all burrs from drilled holes.u Do not reach around or to back of a revolving

drill.u Keep your head back and well away from any

moving part of the drilling machine.u Do not use LPG for any kind of maintenance

work.

KEEP ALERT, DON'T GET HURT!

DAY DREAMSCAN BECOMENIGHTMARES

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

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GAS-CUTTING AND WELDINGDO'su Wear protective like goggles/face-shields,

hand gloves, shoes.u Acetylene cylinders should always be in an

upright position; they should be strapped orchained.

u Gas cylinders shall be kept, maintained undershelter and in ventilated area.

u Use lighters for lighting the gas torches.u For moving the cylinders, use only cylinder-

trolleys.u Never drop the cylinders do not permit them

strike against each other.u Ensure gauges on the cylinders are

functional.u Handle the valve gently and smoothly.u Ensure no fire-catching materials are lying

near-by.u Keep fire extinguishers/ buckets filled with

sand, water near-by.u Do not use LPG in maintenance work.

Your eyesAre worth protecting

MATERIAL HANDLING (MANUAL)

K Bring the load close to your body for morepower and less effort.

K Grip firmly with your hand, not just by fingersalone.

K Make sure you can see where your are going,move slowly with small steps.

K Do not twist your body with the load.K To unload, face the spot you have chosen

and lower the load slowly.K Use safety shoes, hand gloves.

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OIL ON THE FLOOR, OPENS ACCIDENT DOOR!

to ensure safety of men and material

DO'sP Check the equipment and connected

accessories at the beginning of each shift.P Know the capacity of the lifting machine and

of the lifting chain/wire rope.P Secure the load properly and firmly.P Raise the load slowly.P Avoid sudden stopping or reversing except

in emergencies.P Ensure long travel & cross travel brakes are

working.P Ensure all limit switches are workingP Ensure power-indication lamps are working.P Follow the signals while carrying the load.P Ensure that all switches in the pendent box

of the pendent-operated crane are in goodcondition.

LIFTING MACHINESThere are different type of lifting machines suchas EOT cranes, HOT cranes, Chain Pulley blocks,Hoists etc. These are required to be used carefully

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Hydrant system with Monitor to be installed.P To maintain clean environment in the storage

area and to avoid Oil/Liquid spillage.P Authorized Operator with blue badge only to

handle Fork Lift trucks/ To follow instructionsas per Equipment manual

P No one is permitted to sit on the fork lift truckother than the truck operator. To Drive at safespeed with caution.

P Do not leave the Fork Lift Truck with engineon and do not load such that visibility isrestricted. Ensure proper Anchoring of theLoad on Vehicles.

P Avoid using Fork Lift truck where ever trolleycan be used.

P Use proper lifting tackles and associated toolsand equipment such as Hoist, Chain Pulleyblocks, Jacks etc., for handling heavy loads.

P Avoid swinging of Hoist chain with or withoutload and movement of personnel below theoverhead load being carried.

DON'TsN Do not carry load without properly balancing

it.N Don't carry load over persons and machines.

When you work above,Remember

The men below.P Ensure that all indications

of the switches are clearlyvisible.

P Lift the load only to therequired height.

P Ensure the hook-latchesare in place whilehanding the load.

P Ensure to get the lifting machine, lifting tackleis inspected and certified by a competentperson, once a year.

MATERIAL STORAGE AND HANDLINGP Stacking of materials must never be against

the wall and should be well with in 3 metersheight. At least 1.5 meters around thestacking must be kept clear for movementand inspection on regular basis.

P Yellow line discipline to be adhered whereever applicable.

P Ensure adequate fire fighting equipment areavailable in the area.

P Adequate Fire fighting equipment 's and water

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N Don't allow load to remain suspended.N Don't overload the equipment beyond its

capacity.N Don't allow more than one person to give

signals.N Don't use the equipment for pulling the load.N Don't create jerk while transferring the load.N Don't ride on the load.

Keep clear ofsuspended loads.

ACCIDENTS DO NOT HAPPEN; THEY ARE CAUSED!

SAFE WORKING WITH MACHINERYN All moving/rotating parts of the equipment'

must be properly guarded with provision ofemergency shut down.

N To carry out periodic inspection of all rotatingand moving equipment's to identify riskinvolved and corrective action taken.

N All necessary safety precautions to be takeninto consideration while ordering newmachinery and proper installation procedureto be followed as per the manufacturerguidelines.

PRESSURE VESSELSPressure vessel means any vessel which is usedto store, handle air, any gas, liquid or vapour underpressure greater than the atmospheric pressure.K Ensure that the safety gadgets provided to

the pressure vessels are in working condition.K Any deviations in the working conditions of

the pressure vessel to be informed to thesupervisor, immediately.

K Do not undertake repair without the instructionof the supervisor.

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MACHINE GUARDINGMachine guarding means providing adequate/secured guards around the dangerous/rotating/protruding parts.K Ensure that all the rotating parts of the

machine which are easily accessible, areadequately guarded.

K Do not remove the guard from its position.K Ensure that the guards refitted after

maintenance/repair.K Know the safe-working pressure of the

vessel.

K Do not exert heavy pressure on the wheel.K Ensure pre-tests on the grinding wheel before

being put to use.K Display the diameter& maximum speed of the

wheel.K The speed of the grinding machine has to be

lesser than that of the wheel.K Wheel to be stored in horizontal position, free

from moisture.

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

SAFETY IN GRINDINGK Wear safety goggles while grinding.K Ensure guard to the rotating grinding wheel.K Adjust the tool rest as close as possible to

the face of wheel, say 0.3 mm.K Never use the side of the wheel unless it is

so designed.

Keep fingers clear ofmoving machinery

Use guards as intended

PROTECT YOUR EYESFROM FLYINGFRAGMENTS.

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PEDESTAL GRINDERK Stand to one side of the wheel when starting

it up, especially if the wheel is new.K Make sure that the tool rest is only 1/8" from

the face of wheel, Check this distanceK Too much clearance may cause job to jam

the wheel and break it.K Do not set the tool rest while machine is in

motion.K Never use a grinding wheel that is loose on

the shaft or its peripheral speed is not safefor the number of R.P.M of spindle. Checkwith the instructor for this information.

K Stop wheel if it chatters or vibratesexcessively. This may be a danger signal thatthe wheel is not properly balanced or notattached securely to spindle.

K All wheel should be tested for soundness.K Hold the job against the wheel firmly so that

it will not slip out of hand and cause hand/fingers to come in contact with wheel.

K Use clamp or other suitable holding devicesfor grinding short pieces.

K Always use face shield or goggles even if thegrinder is provided with protective glassshields.

SURFACE GRINDER

K Test all wheels for crack or defects beforeinstalling them on? The spindle.

K When starting the machine with a new wheel,stand at a safe distance to one side until youare sure that the wheel is sound.

K Whenever there is any danger or injury whileloading, unloading or checking work on thechuck, stop the machine.

K Do not use an unguarded wheel at any timeif it has a diameter greater than 1.5".

K Wear safety goggles.K Use properly under-cut safety washer in

mounting a wheel.K Exhaust hoods are provided as a safe guard

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

FIRST-AID FOR SPECIFIC ACCIDENTOR ILLNESS

TREATMENT FOR SUNSTROKE

K Measure temperature with a clinicalthermometer.

K If the temperature is high put the naked victim

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into a tub of cold water or give full bath orapply wet sponge over his body.

K If there is a rise in temperature, apply ice bagor clothes dipped in cold water.

HEAT EXHAUSTIONSigns to look for: fatigue, irritability, headache,feeling of faintness, cold, clammy skin and a lotof perspiration.

What to do:F Person should be made to lie down in a cool,

shaded area or an air-conditioned room.Raise feet.

F Message legs towards heart.F Give cold salt water,(1/2 teaspoon to ½ glass

of water) or cool sweetened drinks, especiallyiced tea and coffee, every 15minutes untilperson recovers.

F DO NOT let person sit up, even after feelingrecovered. Person should rest for a littlelonger.

TREATMENT FOR FAINTINGK Place victim in lying down position with head

lower than the rest of the body.

K Loose clothing around neck.K Ensure plenty of cold air.K Sprinkle face and chest with cold water.K Put smelling salt or ammonia to nose.K Rub limbs towards body.K Give stimulants which victim can swallow.

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

F Never administer first-aid on your own, if youdo not know.

F Take the assistance of trained persons.F Fully trained Emergency rescue team to be

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

F The first aid is to be given to affected personby trained worker during office hours andimmediately to inform the concernedManager and HRD cell.

F Details of persons and telephone numbersto contact in case of emergency is notified.

FIREKILL FIRE BEFORE IT KILLS YOU

F In case of fire, no matter how small it is, try to

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control it by using extinguishing media.F Raise alarm when you notice a fire.F Immediately report to the concerned for

further action.F Use right type of extinguishing media for

specific type of fire.

F ind,

I nform,

R esort,

E xtinguish,By dismantling any one segment, the triangle isincomplete and so the fire will not occur.

Fire Safety instructions1. How is fire formed?

By the combination of 3 elements:Air (Oxygen)Fuels (Combustible & flammable)Heat (Heat Producing sources)

2. What are the causes of fires?Heat producing sources like:Welding, gas cutting, Electric Sparks,Hot Metal, Hot Flames, Smoking etc.,

3. What is the Principle of extinguishing fire?

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

4. What are the extinguishing elements?Water, Dry powder, Carbon dioxide Gas andSand.

5. What is the effect of Extinguishing Elements?Removal of air: Blanketing Effect,Removal of Heat: Cooling Effect,

6. How fire can be prevented?By keeping all combustible and flammablematerials away from heat sources.

ALL BECAUSE ONE GUY WASN'T CAREFUL

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Cigarettes are fire hazards

Carelessly discarded cigarette or "beedi" butts are major firestarters. They combine with the rubbish strewn about andcause 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 smokingwhere chemicals and combustible materials are stored.

FIRE FIGHTING FIRE PREVENTIONFire usually starts in a small way. The main principle is keep any source ofAlways be alert. If you happen to ignition well protected, controlled and awayDiscover a fire: from any inflammable substance.F Do not panic.F Inform your fellow workers/-

Superiors/security department,F Find out what is on fire and what is

the ignition source.F Use the extinguisher cylinder/water

as may be appropriate.

ACCIDENT PREVENTION TAGS

(1s:8095-1976)F Used as a temporary means of warning of

an existing hazards till positive means canbe adopted to eliminate the hazard.

F Not to be considered as complete warning

method.F Tags are to be printed in English and regional

language of State where tags are likely to beused.

SAFETY & PRODUCTIONGO HAND-IN HAND!

"DO NOT START" TAGSThese should be placed inconspicuous position or insuch a manner that theyeffectively block the startingmechanisms which couldcause hazardous conditionsshould the equipment beenergized.

"DANGER" TAGSThese shall be used onlywhere an immediate hazardexists. All employees shouldbe instructed that it indicatesdanger and that specialprecautions should be takenfor safety.

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OBEY THE RULES, RESPECT THEPROCEDURES TO ENSURE SAFETY.

BOILER SAFETY

DO'sü Check the water level in the gauge glass and

in the storage tank, before starting the boiler.ü Check the feed-water pump discharge valve

is in open position.ü Check the valve position of fuel system.ü Gauge glass tube should be drained in every

shift to avoid false reading and possiblefailure.

ü Mobery unit should be drained periodicallyand also check the low water level alarm isfunctioning.

ü Clean feed-water level alarm is functioning.ü Clean feed-water storage tank periodically.ü Use treated water as per the specifications

recommended.ü Check the quality of feed-water& blow-down

water regularly.ü Blow down the boiler water at low loads.ü Blow-down valve to be always kept in closed

position while in operation.ü Drain the main steam line before opening the

main steam stop-valveü Check steam traps are working property and

clean them if found malfunctioning.ü Check for the insulation of fuel and steam

lines for any damage.ü Check for any steam leakages and attend to

them as early as possible.ü Check boiler pressure gauges for proper

functioning and get it calibrated regularly.ü Test safety-valves regularly to ensure that

they are popping up at the set pressure.ü Check and replace fusible plug once in a year,

minimum.ü Ensure proper temperature & pressure of fuel.ü Ensure proper air-to-fuel ratio is maintained

such that the smoke from the top of the

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chimney will have a hazy-brown colour.ü Check for boiler fire box doors leak-tight.ü Check for cleanliness and proper functioning

of photo-cellü Check for cleanliness of peep-hole glass.ü Clean the smoke-side of the boiler-tubes at

least once in 8 weeks, to prevent from clinkeraccumulation and tube overheating.

ü Clean the burner nozzles regularly.ü Display firing procedure

THE MEANS JUSTIFY THE END WHEN WE SAYSAFETY FIRST, PRODUCTION MUST!

DON'Tsû Never leave the boiler unattended or allow

unauthorized persons to meddle.û Never start firing without reaching correct oil

temperature & correct oil pressure.û Never cut-in the boiler unless the pressure is

nearly same as the header pressure.û Never ignore any abnormal conditions like

hissing sound, excessive white smoke fromchimney; investigate the baffle crumbling,puncture etc.,

û Never use oversized burners and so causeloss in efficiency.

û Never allow formation of heavy clinker andfailure due to overheating etc.

û Limit excess air supply in such a way that tokeeps oxygen below 5% in the flue gas

û Never work the boiler below its rated workingpressure in preference to pressure reducingstation where steam at low pressure issought.

û Never rely on automates always, be alert thancomplacent.

û Never use the boiler without changing thefusible plug after annual inspection.

û Never hit the safety valves or the mountingon the boiler with hammer while it is inoperation.

LPG SAFETY AT HOMEIN CASE YOU SUSPECT LPG LEAKAGE:

F Close the burner knobs and the cylindervalves and refix the safety protection cap.

F Extinguish any open flame.F Don't light a match or bring in other ignited

material.

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F Do not touch electrical switches.F Open windows for free ventilation.F Do not tamper with installation.

PREVENTION OFDOMESTIC FIRES

N Do not wear syntheticinflammable clothes,when cooking.

N Do not lean over aburning fire.

N Do not keep combustiblematerial near a stove.

F After use, extinguishfires effectively.

F If you smell raw gas,open doors and windowsand inform your supplier.

Immediately contact your distributor and the firebrigade; keep their phone numbers handy.

Using LPG. SafetyLiquefied Petroleum Gas (LPG), stored as liquidunder pressure in cylinders, is widely used inhomes as cooking gas. The main hazardsassociated with LPG are fire or explosion in caseof even minor leakage. In case of major, leakagein confined spaces; asphyxiation due to deficiencyof oxygen may also result. LPG being colourlessand odourless, a distinctive foul odour is added toenable easy detection of a leak. As LPG vapouris lower levels and fire or explosion may result.

-Keep stoves on araised platformrather than onthe kitchen floor.

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Safety While Taking Door Delivery

K Check whether valve sealing tag is intact andsafety protection cap is in position.

K Check leakage from valve by applying soapsolution.

Safety While Changing Cylinders

K Put out all fires in the room.K Do not operate any electrical appliances/

points.K Check for leakage from the rubber tube

connections by applying soap solution.K Never light a match stick to check the

leakage.K Leave changing of new cylinder to trained

person.K Don't drag, roll or drop the cylinders.K Open windows for free ventilation.K Preserve safety protection cap.

Safe Usage

K Always keep cylinder in upright position, awayfrom any source of heat, in a well ventilatedplace, While moving cylinder, keep it upright.

K Don't tilt it to draw the last bit of gas. No extragas can be obtained by tilting or shaking.

K Position stove/burner above the level ofcylinder.

K To light the burner, open the cylinder valve,hold a lighted match stick(or gas lighter) overthe burner and only then turn the knob of theburner on.

Preventive measures for GAS HAZARDS

F No unauthorized person should go to a gashazardous area.

F No person should take rest near gas lines/hazardous areas.

F Even at the slightest indication as abnormalsmell, headache or giddiness felt by anyperson working in an area where there ispossibility of gas leakage, one shouldimmediately leave the place, go into fresh airand then report to the Supervisor/concernedpeople.

F Keep all types of flames, lighted cigarettesand spars etc. away from the area.

F Never enter a furnace, tank, gas holder, gasmains or other closed space where gas issuspected to be present, without checking forpresence of gas and without a gas mask orany such safety appliances.

F Even a man enters such a place with all safetyappliances, and observer must be stationedoutside in a gas free atmosphere and a safetybelt or life-line should be attached to the maninside, so that in case of distress, he can be

47 48

taken out immediately.F If gas leak is in open area, cordon off the area

and hang a notice so that nobody goes near.F Shut off the gas valve or isolate gas holder

from system.F While operating the bleeder, see that the gas

is not allowed to flow in areas where peopleare working. Evacuate them if necessary. Thewind direction must be considered whilebleeding or purging gas lines.

F It is quite possible, due to wind directions, theleakage at the top of one place may affectmen working on the top of other place.

Tips During emergency

K Be calm, don't get panicky.K Decide the direction of the wind.K Do not run, walk quickly to the side

perpendicular to the wind direction.K Cover your nose with wet cloth and breath

through it.K If possible, use any available vehicle to move

away.

EFFECTS OF CARBON MONOXIDE GAS ONHUMAN SYSTEM

CO Concentration in Effects on exposurePpm Air percentage

50 0.005% TLV(Threshold Limiting Value)100 0.01% Mild & frontal headache after

2-3 hours.200 0.02% Nausea and mild frontal

headache after 1-2 hours.400 0.04% Occipital headache after

2-3 hours.800 0.08% Headache, dizziness & nausea

after 3-4 hours.1600 0.16% i) All above symptoms in 20 mts.

ii) Collapse, Unconsciousness &probability of death in 2 hours.

3200 0.32% All above symptoms in 5-12 mts.Death in ½ hr.

6400 0.64% All above symptoms in 1-2mts.And death in 15mts.

12800 1.28% Instantaneous, death in 1-4mts.

CONDITIONS FOR EXPLOSIONi) the gas and air mixture must be within their

explosive range.ii) The heat must be enough to ignite the mixture of

gas & air.iii) BF gas explosive limits: Lower35% Upper 73.5%

in air by volume.

"BEWARE OF GAS".GENERAL SAFETY

49 50

WORKING AT HEIGHT

Working at height is a high risk job. Manyaccidents, mostly fatal, are occurring every yeardue to fall, while working at height without properprecautions. Use of safety belt, anchored to alifeline or a strong supporting structure is a mustwhile working at height. While working on fragileroof, use of crawling ladder is a must in additionto safety belt.

PERSONAL POINTSA CHANCE TAKER AN ACCIDENT MAKER!

u Do not take chance, carry out the instructions.u Do not risk and indulge in unsafe act.u If you do not know, Asku Report and rectify all unsafe conditions with

intimation to the superiors.u Use correct tools and equipment.u Help to keep the workplace clean & tidy.u Do not indulge in horseplay or distract others.u Use protection for your safety without the

guards in place.u Obey all safety signs and rules.

A short cutin your way,

may cut shortyour life.

51 52

YOUR SAFETY IS IN YOUR HANDS !K Remember, your supervisor will have many

other things to do including Office work, sohe may not be able to stand with you all thetime to check or observe your actions; Youhave to take the responsibility of your safety.

Remember oxygenand oil meanDanger.

Alert eyes and ears meangreater safety for you.Always look where you're going.Always watch for what is coming.

A spray of air is arisky comfort,

Avoid it, ratherthan be sorry later.

Mischief and horseplaywith compressedair or other gasescan endanger life.

53 54

CONTRACTORS ROLE IN THE PLANT

l To ensure ESI cards availability and declaringbelongings at the security before entering thepremises.

l Engineering and utility in charge shouldensure all equipment's of the contractors arein stable condition to use.

l All contractor/ worker to be issued with identitycards/passes by the security personnel.

l Departmental Heads/Section in charge toensure that the contractor and their peoplehave vacated the place in safe condition.

l Contractors are responsible for theiremployees safety while inside the plant withproper and regular supervision

l Contractor/ subcontractor representative tobe near the work spot to implant safetyprocedure to be ensured all the time.

GENERAL

u Do not use broken ladder.u Do not use ladders in wet and grease surface.u Always ensure that the adjusting screw on

the regulator fully released before openingany compressed gas cylinder and check the

Not a ghost!But your friendlyProtective wear

"Safety is an integral part of productionactivities; not a separate entity!"

55 56

condition of the regulator.u Do not allow any source of heat to reach

cylinder and keep the gas hose pipe clearwhen working.

u Secure gas cylinders firmly on trolley withchain while conveying as well as storing.

u Ensure that electrical supply cable should notget mixed up with welding cable and earthconnection.

u Avoid welding near flammable material.u Standard colour codes should be used to

identify pipes, machinery, cable routing withflow direction and others along with thepotential dangerous areas.

u Proper lighting to be provided in the plantand offices.

u Safety permits to be obtained before startingof any work pertaining to working at heights.Hot working area, Loading and Unloading offlammable liquids, Electrical installation andBoiler areas.

RED SLIPS FOR SAFETY VIOLATIONS

1. Wearing of helmets by all personnelincluding visitors, contract labour and regularemployees is compulsory. However due topractical difficulties, a few exception aremade to this rule as follows :a) Training Hall, b) Dining Hall, c) SecurityOffice, d) Toilets, e) Admin Block, f) Main Roadsleading to shop floors and operational areas,g) Vehicle parking areas, h) snouts section

2. Wearing of Safety belts while workingabove 2 meters height excepta. Loading and Un-loading of transport

vehicles.b. Working on Wet Machines in M1 and

M2.c. Working on Pulp Chest platforms in

M1, M2 & FBC Boiler Platform..

3. Wearing of company provided safetyshoes is compulsory in all operationalareas.

4. Usage of welding shields/cutting goggles (forgas welding), leather hand gloves andconnecting the welding equipment through

57 58

the portable distribution board (with ELMCB)are compulsory for arc welding work.

5. Usage of goggles for any type of grindingand metal cutting activities is compulsory.

6. No job / contract work is to be undertakenwithout a valid written job order dulyauthorized by the concerned manager.

7. Only authorized operators with dueidentification mark can operate forklifts.

8. All fire fighting equipment like fireextinguishers & fire buckets are to be inworking order. Fire buckets are not to beused for purpose other than fire fighting.

9. Yellow line discipline is to be followed onthe shop floors. Gangway to be left freeand all loose items to have designatedplaces with marking (like fans, pallets, pallettrucks, stools, dustbins, tools, dies, brokeetc.,)

10. All departmental heads are authorized toissue work permits. During night shifts,the shift supervisors are only authorizedto issue such permits.

Types of jobs for which work permits arerequired

a. Welding / Gas cutting.b. Working on steam lines and

compressed air lines.c. Cutting / Welding on Diesel / Furnace

Oil / LDO lines.d. Working at heights above 2 meters

except for the routine jobs on hydrapulper, chests and wet machines inM1 and M2.

e. Working on HT lines.f. Material handling heavy loads

exceeding 1000 Kgs.g. Loading / Unloading of containers.h. Un-loading fuel oil tankers.

59 60

SAFETY COMMITTEE & ITS ACTIVITIES

Safety committee shall be chaired by SafetyManager and members of the committee shallattend the meetings

Meeting shall he regularly held once in amonth to review the safety aspect of the Plantand minutes of the meeting to be recorded andcirculated to all members.

Safety Audit once in three months by internaland external party.

Celebration of Safety day on 4th March ofevery year.

FUNCTIONS OF THE COMMITTEE

q First and foremost thing is to promote safetyawareness among employees.

q To assess the effectiveness of safetyprogram.

q To receive suggestion and implement throughHOD's

q To study the accident trend and statistics inthe plant.

q Carry out regular safety audits of the plants.

q Displaying of safety publicity posters insideplants.

q To investigate and submit incident reports tomanagement about every accident.

q Motivate work force to participate voluntarilyin safety training and seminars.

q To assist in observing the violation of safetyrules in the campus.

q To monitor, minor, major,& near missaccidents to take suitable corrective actions.

OBLIGATION OF OCCUPIEROccupier of the factory:K Shall ensure, so far as reasonably practicable,

the health, safety and welfare of all theworkers while they are in the factory.

K Shell make provision for maintenance of plantand systems of work in the factory that aresafe and without risk to health.

K Shall make arrangements in the factory forensuring safety and absence of risks to healthin connection with, use, handling, storage andtransport of articles& substances.

K Shall make provision to provide information,instruction, training and supervision to ensure

61 62

health and safety of all workers.K Shall make provision for maintenance of

working environment which is safe andwithout risks to health.

OBLIGATION OF WORKMEN:F Shall willfully interfere with or misuse any

appliances, conveniences or other thingsprovided in the factory for the purpose ofsecuring the health, safety and welfare of theworkers therein;

F Shall will fully and without reasonable causedo anything likely to endanger himself orothers;

F Shall willfully neglect to make use of anyappliances or other things provided in thefactory for the purposes of securing the healthand safety of the workers therein.

63 64

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OCCUPATIONAL HEALTH & SAFETY POLICY

Raman Boards Limited, will strive to achieve the beststandards in safety and employee occupational healthcomparable with best-of-class practices internationally.

The company will comply with National and Localregulations on Occupational Health and Safety.

By introducing suitable technology in productionprocess and material handling areas, the company will preventunacceptable risk to human life, safety and environment.

The company firmly believes that all accidents arepreventable and use of cost effective engineering control, useof personal protective equipment and safe work practices andtotal employee involvement can contain risks to injury andhealth.

The company expects from its employees :a) To comply with safety rules and follow safe work

practices.

b) To report safety violations and dangerous occurrences.

c) To maintain good personal hygiene and health.