R - Safety Manual

HARDROCK FABRICATION (P) LTD.
JAMSHEDPUR
SAFETY MANUAL
PHA SE VI, INDUSTRIAL AREA, GAMHARIA, JAMSHEDPUR
Doc. No.: HF / SM / EMR

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OUR SAFETY PLEDGE We, the members of HARDROCK family,
solemnly affirm and pledge that we will, at all times, in our every work of life, whether be at works, home, society or our nation, practice safety and always respect and follow rules, regulations and enactments made for safety so that we have accident-free environment through out our life.

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SAFETY POLICY
1. PREAMBLE It is our embedded care and firm belief that safety and healthy working conditions are most important to members of HF family so that production, quality, cost and other aspects of industrial and related activities completes its destined cycle to the satisfaction of our members and ultimately our customers. It calls for planning and well coordinated efforts of all our members at all level. Safety of our members, clean and green surrounding is important to all, i.e. to the HF members, their family and to the organization. 2. OBJECTIVE a. b. Increase safety consciousness amongst HF members at all levels. We shall strive to manufacture all products and handle and dispose off all materials in a responsible manner without creating unacceptable risks to healthy, safety and the environment. We shall comply with all rules, regulations and enactments, and issues connected with safety shall be treated with the same thoroughness and scientific approach as applied to manufacturing activities. Resources required for safety, health and environment protection shall receive top priority. All available information pertaining to safety and hazards shall be shared to the extent necessary and appropriate. IAL members shall receive training in safety and environment protections required for their task and encourage their participation and involvement so as to make work place safer. Ensure zero incident causing injury, permanent disability or fatality frequency rate and total loss control progressively 3
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Ensure safety decisions are taken while purchase, erecting, commissioning and running of plant, equipment, machinery and material as well as selecting and placement of personnel.
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RESPONSIBILITY, AUTHORITY & ACCOUNTABILITY a. Prevention of hazards to lives and limbs of all employees is attainable with proper planning, organizing, directing and controlling of activities through efforts by persons at all levels. Safety is essentially a line responsibility and a staff function. Safety is everybodys business, which will be, accepted as a basic responsibility by the entire staff and line management right upto the workmen on the shop floor. Safety and Health accident reduction activities will be planned and executed under the guidance and advice of Manager under the Factories Act. Manager under the Factories Act will be overall Incharge of Safety and Health activities. He will be assisted by all concerned personnel in different activities such as Accident Investigation, Safety Surveys, Compilation and Analysis of Accident Data and Feedback on relevant aspects thereof at all levels. Prevention of incidents and occupational diseases at the place of work shall be the responsibility of HODs of respective operations. Specific responsibilities will be assigned to the subordinate staff by respective HODs. The contractors, sub-contractors, transporters and any other agencies which enter the companys premises will be observe all safety precautions and will ensure safety of their persons. They would know the safety instructions applicable to them from the department which is contracting the work to them. SAFETY COMMITTEE : The Safety Committee which includes Workers Representatives should meet regularly and review matters pertaining to health and safety, investigation of accidents and give relevant suggestions on these matters.
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i. TRAINING : Appropriate education and training in various aspects of safety Doc. No.: HF / SM / EMR 4

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including fire fighting, first aid will be provided at each level. The departmental heads should encourage individuals to get appropriate training. j. MOTIVATION : The Management will endeavor to introduce suitable motivational activities like Safety Award Scheme, Contests, Display of Departmental Accident Record, Suggestion Scheme, etc, which will create and maintain a climate of safety consciousness throughout the plant. For maintaining this climate, the Management will not hesitate to enforce Safety discipline, if necessary. The Management intends to take into account health and safety performance at the individual levels while considering the career advancement. The Management will seek cooperation of all concerned in achieving the objectives and is of the view that the enforcement of safety discipline will be an exception. The Management will devise suitable accountability in due course.
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REIVEW OF POLICY The policy will be reviewed periodically so as to make it compatible with changes in technology, working conditions, processes, layouts, legislations, etc.
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CONCLUSION The Management sincerely believes that accidents and occupational diseases at work places can be prevented and the well-being of employees and the environment can be ensured. Apart from statutory and other measures taken by Management, it is the conscious approach of all concerned and belief in SAFETY that can make this organisation a safe to work in. () BASE TEAM CO-ORDINATOR & MANAGER UNDER THE FACTORIES ACT

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My dear colleagues, We are delighted to present you Safety Manual for our colleagues so that safety practices in working environment form a part of your routine life. A minor slip could cost anywhere between injury and ones life and it has been always our endeavor that our members work in a safe and healthy environment to have accident-free life ahead by adopting safety procedures and practices same in their every breath of life. Safety Manual is intended to acquaint out members with the safe practices, which are to be strictly followed, as they are tool for your protection. We would like to impress our members that your safety is a precious asset to your family members, whom we treasure as much as you are for us. In case any aspect are not covered is not clear in this Manual, please feel free to ask us and ensure that you are working always safely. Safety is everybodys business. The continued safety if yourselves must, therefore, rely to large extent on conscientious observance of safety instruments by one and all. Apart from statutory and other measures taken by Management to promote safety, it is your belied in safety that can make our Group a safe place to work in. Safety consciousness should become our habit and part of life with you. At the end, I would like to say that every IAL Group member shall live to enjoy the fruit of his duties; that his mother shall have the comfort of his arm in her old age; that his wife shall always have her life support; that his children shall always have a strong father to tender and care; and that happiness and joy of association with IAL Group endures for ever. With best wishes for YOUR safe life always,
Ravi Kant Pandey Manager - Safety

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1. GENERAL 1. Wear the proper dress and use all necessary protective equipment and devices recommended for the job. E.g. Safety shoes, hand gloves while material handling. 2. Obey all warning tags and signs. 3. Observe good personal hygiene. 4. Do not report for duty in an intoxicated condition. 5. Do not play practical jokes. 6. Report unsafe conditions to your superiors. 7. Report accidents minor or major injury or no injury to your superiors. Obtain proper medical aid in case of injury. 8. Keep your work place clean and tidy and leave it safe behind you when leave. 9. Obey all traffic rules while moving on public road. 10. Get yourself trained in Safety, Fire Fighting, First Aid, etc. 11. In case of any dangerous occurrence such as Fire, Leakage of Gas, fall of building etc, report to Security, Safety and Maintenance.

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MACHINERY
1. Never operate machine unless you are qualified, authorized and familiar with its operation. 2. Before starting a machine, make sure that the guards are in place and safety devices are in working condition. 3. Do not wear rings, chains, long sleeves or loose clothing when operating machinery. 4. Use eye protective equipment for jobs where flying particles are encountered, e.g. grinding, drilling, etc. 5. Use the machine for the job for which it is intended. 6. Stop machinery before oiling, gauging or making adjustments. 7. Do not attempt to slow down moving machinery with your hand. 8. Use suitable brush, hook to remove chips, cuts from machine. Do not use hands or compressed air. 9. Before starting repairs on a machine, first isolate it from the source of power by removing fuse and place a tag on the switch. 10. Report any unusual sound or abnormal performance of a machine to your superiors. 11. Clear chips and turnings regularly from floor and put them in designated containers. 12. Clamp the jobs safely on the machines before attempting machining. 13. Do not use hand gloves while working on machines such as lathes, drilling machines, milling machines, etc.

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3. HAND TOOLS 1. 2. 3. 4. 5. 6. 7. 8. Use only tools, which are in good condition and of good quality. Do not use tools with mushroomed heads or without handles. When using the tool, do not place your hand where it can get injured if the tool slips. Use a tool only for the purpose for which it is designed and in a prescribed manner. Ensure that pliers, screwdrivers and other hand tools used in electrical work have adequate insulation. Keep tools clean. Always carry them in a toolbox or bag. Store all tools only in places meant for them. Do not leave them on the floor of the work place. Inspect all hand tools periodically. Repair and replace defective tools. Use right tool for the right job.

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4. PORTABLE POWER TOOLS (Electrical & Pneumatic) 1. All portable electric tools should be earthed, connect to power using a 3pin plug only. 2. Attend to wiring of portable electrical tools only if you are authorized. 3. Inspect extension cords for kinks, breaks in the insulation and exposed strands.
4. Keep guards of portable power tools in place while it is in use. 5. Use portable electrical tools working on low voltage to ensure safety. 6. Check the wheel for crack or damage before mounting. Make sure that wheel fits freely and easily on the spindle but loosely fitting. 7. Use only sound, strong hose with secure couplings and connections. Do not tie the joints with wires, threads, etc. 8. Do not leave with air power ON at near switch, but turn OFF at the mains. 9. When crossing passageways, either suspend cable, hose or guard with boards or runways.
10. Store all the tools in their designated place. Do not leave them on the floor of the work place. 11. Inspect all the tools periodically. Repair and replace defective tools. 12. Select nearest power point for electrical and tools to avoid insulation damage of cable while crossing passages, etc.
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5. MATERIAL STORAGE 1. Maintain neatness and orderliness in permanent and temporary storage areas. Do not pile up or throw around material in haphazard way
2. Do not exceed the limits of floor loadings while storing heavy materials. 3. Keep access to fire extinguishers, electrical switches, first aid boxes, free while storing material.
4. Keep aisles, exits clear. 5. Do not smoke in storage areas. 6. Before accepting any consignment of materials check the condition of the container. Do not accept leady containers for storage.
7. Store incompatible chemicals separately. 8. 9. Store bagged material in cross-tied manner with mouth towards inside of the pile. Remove bagged material from top of the pile and not half way up or from corner.
10. Stock glass panes on their edges with suitable supports. 11. Wear suitable personal protective equipment such as safety shoes, hand gloves, etc while handling material. 12. Keep paint varnishes, lacquers, thinners and other flammable materials in properly sealed or closed containers. Store these containers in a well ventilated area away from excessive heat, smoke, sparks or flame. 13. When barrels are piled on their ends , separate the layers by planks. Do not store barrels more than three high. 14. Store small diameter pipes (less than 7.5 cms) and bar stocks in racks. Do not keep the rack near to aisles or doors.
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15. Store large diameter pipes( more than 7.5 cms) and bark stocks separately on floor. Provide stops at ends to present rolling. 16. Store grinding wheels on their edges in racks and not on their slides. Do not drop them while handling. 17. Do not store glass wares, lamps on top shelves of racks. But store them in lower shelves as to avoid damage in case of fall. 18. Maintain good housekeeping. 19. Store full and empty containers separately. 20. Use proper racks for storage of material. 21. Use proper bins for storage of fasteners.
NO JOB IS SO URGENT AND NO SERVICE SO URGENT THAT IT CANNOT TAKE TIME TO PERFORM THE WORK SAFELY.
6. MATERIALL HANDLING (MANUAL & MECHANICAL) Doc. No.: HF / SM / EMR 1 2

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1. 2. 3. 4. 5. 6. 7. 8. 9.
Wear personal protective equipment recommended for the job, such as leather hand gloves, safety shoes, etc. Use the proper method of lifting to avoid back strain. When two or more persons are lifting together, coordinate the movement of the object. Secure the load properly. Do not over speed and overload material handling/lifting equipment. Do not operate forklift unless you are trained and authorized to do so. Use the correct size and type of sling for given load. Do not use V belts as a sling. Do not use a sling that is damaged or a hook that is spread. Do not exceed the safe working load. When handling unwieldy loads, attach a rope to control their movements. Avoid taking the loads over persons working below. Observe the prescribed limits of lifting load for manual lifting.
SAFETY ASSURANCE IS YOUR BEST INSURANCE
7. MATERIAL HANDLING (FORK LIFT OPERATION) 1. Observe all signals, instructions and traffic rules. 1 3

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2. 3. 4. 5. 6.
Drive only on roadways with sufficient capacity and are in good condition. Always slow down on curves. Brakes are for safety, apply them gently and carefully. Always apply hand brake when fork lift truck is not being used. Do not overload and over speed your fork lift truck. Keep at safe distance from other vehicles. Do not give rides to any person. Always look in the direction of travel and do not put your arms, hand or legs outside your fork lift truck. Always drive the fork lift truck with the elevated mast tilted backwards. When going down hill, put the fork lift truck in reverse gear and drive slowly backwards. Watch out for heights of doorways. Do not drive the fork lift truck with its forks in elevated position. The ground clearance of fork should be approx 15-20 cms. This is irrespective of whether they are loaded or empty. Do not pass underneath elevated forks. Do not put your arms or legs between the mast. While doing maintenance or repairs job, support it securely. Do not smoke while the battery is being charged. Be careful while raising, lowering or changing the position of forks. The battery weight of an electric fork lift or stacker can affect stability of the equipment. While replacing the battery, it should be of same weight and dimensions.
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18. 19. 20. 21. 22.
Place the forks flat on floor when the truck is parked. If you find any defect in your fork lift truck, report immediately to your superiors. Do not handle molten metal with forklift. Do not use the forklift for dragging the load. Follow the instructions regarding the load center while lifting the load.
MACHINES CANT THINK; ITS UPTO YOU TO PREVENT ACCIDENTS
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8. WELDING AND CUTTING 1. During the welding or cutting operation, protect your eyes with hoods, shields or goggles fitted with filter glasses of suitable shade numbers. Use leather gloves to prevent hand injuries. Ensure that no combustible/flammable materials are present in the immediate vicinity. Make sure that fire extinguisher is nearby and you know its operation. Keep partition screens around the welding area to protect others working nearby. Before doing hot work on vessels which contained flammable gases / liquids, get them certified as safe for the work. Keep oil, grease, etc. away from oxygen cylinder fittings since these react explosively with oxygen. Do not lubricate cylinder valves and other fittings. Before fitting the regulator on the cylinder valve, especially on oxygen cylinders, momentarily release the gas and close the valve (cracking) in order to dislodge any dirt lying inside. Use red hoses for flammable gases and black for oxygen. Replace defective and worn out hoses immediately. Do not hang welding torches on regulators or other fittings attached to cylinders. In electric arc welding do not allow the welding cables to get entangled with power cables. Ensure that cables are not damaged by material movement. Keep the welding area clean and dry. Do not use pipe lines containing flammable gases or liquids or conduits carrying electrical conductors or earthing strips of machines as part of ground return circuits. Use of approved and right type of regulator and torch recommended for the job. Do not weld the fuel tank when petrol resisting paint is wet.
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15. 16.
Do not weld under base or other material by keeping them on empty barrel of thinner, N.C. cleaner, paints, etc. Always keep acetylene cylinders in vertical position. ACETYLENE (C2H2) IN CYLINDERS
Important Properties Colour Odour have a : : Colourless Odourless when pure. Commercial grades
garlic-like odour. Physical Rate Boiling Point Explosive Limits Auto ignition temp: : : : Gas
-83 degree C 2.5% to 82% by volume in air Varies depending on factors like gas-air mixture composition, pressure, water vapor content and initial temperature. Mixtures containing 30% or more acetylene with air at atmospheric pressure can ignite around 305 deg C. 0.91 (air = 1)
Vapor density : Miscibility Toxicity mixture Chemical reactivity : :
Moderately miscible in water and many organic Liquids. Highly miscible in acetone. Non-toxic when pure. Mildly anesthetic in with oxygen.
Forms explosive compounds with copper, silver and Mercury; may explode violently when mixed with Chlorine or fluorine in the presence of sunlight.
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FIRE EASY TO START, HARD TO STOP

FIRE AND EXPLOSION HAZARDS Because of its wide explosive range, even a small leakage of acetylene on contact with a spark can lead to an explosion. Explosions of acetylene develop pressures higher than explosions of most other gases and are, therefore, more violent and damaging. Acetylene can also decompose violently (especially when under pressure) when subjected to heat or shock, even in the absence of air. With metals such as copper, silver and mercury, it reacts spontaneously to form explosive acetaldehydes. Its mixtures with chlorine and fluorine can explode violently in the presence of sunlight. HOW CAN ACETYLENE CYLINDER BURNS The manner in which an acetylene cylinder may burn depends upon the location, size of the leak and the pressure within the cylinder. Small leaks from gas escaping through packing glands on valves or around fuse plugs will burn if ignited but may not grow in size if the heat of the flame is insufficient to melt the fusible metal in the relief device. Larger leaks from cylinder valve or regulator connection, may become ignited and create sufficient heat to cause melting of the fusible metal in fuse plug. With fusion of metal in such a manner from the relief device, a rather loud noise may be heard when gas is released. Most bystanders tend to exaggerate the magnitude of this sound and often erroneously refer to it as an explosion. When fuse plug releases, a large volume of acetylene will rush out and may get ignited by a nearby source of ignition. PREVENTION OF FIRE AND EXPLOSION Cylinder, filter material and solvent (acetone) should conform to standard requirements. Never attempt to transfer acetylene from one cylinder to another or mix acetylene with other gases in a cylinder, or fill any other gas in an acetylene cylinder. When acetylene is used through torches or other devices equipped with shut-off valves on acetylene supply connections, the pressure of acetylene should be reduced through a suitable pressure regulator attached to the cylinder valve. Identify leaks in cylinders, rectify them by tightening glands, nuts, etc; if possible remove them to a place well away from any possible ignition and allow the gas to escape. Place warning signs in the area to preclude persons from Doc. No.: HF / SM / EMR 1 8

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approaching the site with a naked flame. Notify the supplier. Never point a burning acetylene torch towards an acetylene cylinder. Cylinders should be removed from the working areas and put in a store at the end of working period. Valve protection caps should always remain in place before and after the use of cylinders. Keep valves closed even for cylinders supposed to be empty. HANDLING LEAKS Identify leaks in cylinders and fittings by application of soap solution. Try to rectify leaks by tightening glandnuts. If leak persists, remove cylinder to an isolated place. FIRE FIGHTING When the fire brgade arrives, they should be informed of all cylinders. The following may be taken before the arrival of the brigade, if no undue risk is involved. 1. Cylinders which have not become heated, should be moved to a safe place as quickly as possible making sure that valves are shut. 2. Cylinders which have become hated should be cooled by spraying water from a safe position (A solid jet should not be applied). The area should lbe evacuated if cylinders cannot be cooled. 3. Burning gas from a leak should be extinguished only by shutting off the leak 4. A cylinder involved in a fire should not be used without consulting the suppliers. RECOMMENDED STORAGE AND HANDLING PRACTICE Cylinders should be stored and handled in upright position. Only cylinders meant for acetylene should be used to fill acetylene. Cylinders should be stored under cover to protect them against direct rays of the sun. The cylinders stores should be of suitable construction, preferably with explosion venting facility. Cylinders of chlorine and oxygen should not be stored with acetylene cyllnders. Empty cylinders should be marked and stored separately. Before the regulator is removed from a cylinder, the cylinder valve should be closed and all gas Doc. No.: HF / SM / EMR 1 9

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released from the regulator. Exits from stores should be easily accessible and free from any obstruction. Cylinders should not be allowed to come into violent contact with one another or with any hard object. If cylinders are lifted by cranes, rope slings should be used to lift a platform, cage or cradle with the cylinder housed and secured in vertical position. Cylinders with damaged valves or threads should immediately be labelled appropriately and returned to the supplier. Cylinders invariably should be kept away from acids and other corrosive substances. For movement in a brand trolley, secure the cylinder in a relatively upright position. PERSONNEL PROTECTION When entering confined spaces suspected to have acetylene gas, persons should use suitable breathing equipment. For very high concentrations, every effort should be made to provide sufficient ventilation to dilute the gas before entering the space. Persons entering such spaces should not use shoes with exposed iron nails or similar items, which may cause sparking. Persons affected by exposure to acetylene should be removed to fresh air and kept warm. If symptoms persist, first-aid/medical aid should be summoned.
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WORK PERMIT Sr. No.__________ International Auto Ltd., JAMSHEDPUR. Please allow Mr ____________________________ of M/s / Dept ____________________ ____________ to carry out welding/gas cutting in ________________ (specify area from operation to be carried out) for ________________________________ purpose. INCHARGE OPERATION --------------------------------------------------------------------------------------------------------------TO BE FILLED IN BY THE HOD Certified that the area specified above has been / cannot be cleared of all the combustible / damageable material and is made safe/not safe to carry out welding/gas cutting operations, with/without due additional safety precautions. HOD --------------------------------------------------------------------------------------------------------------TO BE FILLED BY P&A Satisfied that the necessary precautions have been taken. Hence, permission to carry out the welding / gas cutting is hereby granted. P&A --------------------------------------------------------------------------------------------------------------Date________________
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PRECAUTIONARY MEASURE 1. Security Guard Mr __________________________________________________ of M/s _______________________________________ posted from ___________ to _________ am / pm. _________________________________ Extinguishers kept. __________________________________________________________________
2. 3.
--------------------------------------------------------------------------------------------------------------AFTER COMPLETION OF THE WORK Welding/gas cutting work completed safely at ____________am/pm on _______________. OR The following happened when the work was in progress: 1. 2. __________________________ __________________________
HOD ---------------------------------------------------------------------------------------------------------------
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9. WORK AT HEIGHTS 1. 2. Obtain Work Permit for working at heights, or on roofs. Ensure that a scaffold used for working at heights is secure and safe means of access is available. Never climb on cross bracings.
3. Before stepping on a scaffold, make sure that planks are secure and will not tilt. 4. 5. 6. 7. 8. 9. 10. 11. 12. Ensure that guard rails and toe boards are provided at the open edge of the working platforms. Ensure that platforms and gangways are free from obstruction, projecting nails, slippery condition, etc. Use sturdy ladders of right type with non-slip shoes. Discard or repair defective ladders. Do not keep the base of the ladder away from the wall at a distance more than one fourth of its length. Do not use metal ladders around electrical lines. While using ladder, have somebody to hold the ladder at bottom or tie or lash it at the top. When climbing ladders, use both hands. Do not over-reach. Carry the tools in a bag or have them hauled up. Use helmets, safety belts, and safe ladders while reaching/working at height and where danger of free fall exists. Keep face towards the ladder while climbing up or down the ladder.
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FATE SAVES ONCE A TIME, SAFETY SAVES ALL THE TIME
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HARDROCK FABRICATION PVT. LTD. JAMSHEDPUR Dept: Date:________________
PERMIT TO WORK ON ROOF S No 1 2 3 4 is / are permitted to work on proof over _______________________________________ for the purpose of ________________________________________________________. He will go up at _____________hrs on ___________________ and finish / come down by ________hrs on __________. Name Employee No or Contractors Name
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10. ELECTRICITY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Do not work on electrical lines / equipment unless you are trained and properly equipped. Use three pin plug for tapping power. Use minimum length of cable and without joints. Ground all electrical equipment properly, preferably with double earthing. Do not work on electrical equipment if standing on wet floor or hands are wet. Obtain dry boards to stand on if necessary. Inspect the cables periodically. Replace/rectify the damage ones. Cables and wires should not be laid directly on the floor, but if it is required, it should be taken through GI/MS pipes etc. Do not use a fuse of higher rating than specified. Follow supervisors instructions for specialized work. Obtain work permit for carrying out work on major electrical installations. Ensure that hand lamps are provided with protective guards. Switch off power supply to machines and lighting fixtures, etc. when not in use or at the end of work.
11. Use tools with non-conducting handles and ladder of non-conducting material. 12. 13. 14. Use adequate insulated protective equipment such as shoes, gloves and safety belt for working at height. Use CO2 fire extinguishers on electrical fires. Do not use water. Discharge capacitors, HV bushings/terminals after switching them off. Do not work on them unless they are discharged.
ELECTRICITY BEFRIENDS NO ONE WHO VIOLATES ITS ORDNANCES
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11. LABORATORIES 1. 2. 3. 4. 5. food. 6. Know the hazards and properties of chemicals to be handled. While handling chemicals, wear suitable personal protective equipment such as gloves, face shields, etc. Store hazardous chemicals in a cool area away from source of heat. Do not store incompatible chemicals together. Wash your hands regularly after handling chemicals and before taking In case of spillage of chemicals on your body, wash thoroughly with copious amount of water.
7. Ensure that all chemicals are identified by suitable labels. Keep the quantities of chemicals to the bare minimum. 8. 9. 10. 11. 12. 13. 14. 15. Do not apply mouth suction for pipe ting. Use a pipette. Do not handle volatile solvents near an open flame or electrical mantle or hot plate. Use fume hood for all peat ions with toxic/flammable materials. Examine all glass wares before use. Reject damaged ones. Use a piece of cloth when inserting glass tubes or rods into rubber tubing or stopper. Do not leave heating operation unattended. While disposing of chemicals in the sink, dilute them with plenty of water. Switch off electricity and service lines before leaving the laboratory.
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HARD WORK OR LIGHT WORK, SAFETY MUST BE THE NETWORK 12. 1. 2. COMPRESSED GAS CYLINDERS
Know the properties of the gas before using it. Keep the gas cylinders in a cool, dry and well ventilated place away from sources of heat and not exposed to direct sun light or rain.
3. Keep the cylinders of acetylene and liquefied gases always in upright position. 4. 5. 6. 7. 8. 9. 10. 11. Keep gas cylinders in their stands secured with chain. Keep the valve caps in place while transporting cylinders. Drop cylinders only on soft pads such as tyres. Do not drag or roll cylinders. Use trolleys for moving them. Do not use the cylinders without a regulator attached to the valve. Use the standard key to operate the valve spindle. Do not use excessive force such as by hammering. Check the valve regularly for gas leakage using soap solution. Do not lubricate cylinder valves and fittings. Mark empty cylinders plainly as EMPTY. Keep full and empty cylinder separately.
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ONES OWN CARE IS THE BEST KNOWN SAFETY DEVICE

13. COMPRESSED AIR 1. Do not play practical jokes wit compressed air. It can be fatal.
2. Never use compressed air to clean clothing, hair or body, or chips from machine. 3. 4. 5. 6. Never point the hose at anyone and always see that nearby workers are out of the line of airflow. When not actually using the air, point the hose downwards and to the side of the feet. If the hose comes part and only then seize at some distance from business end, block by bending it, switch off and reconnect. When crossing passageways, either suspend the hose or guard it with boards or runways.
7. Do not leave with air ON at the near switch or valve but turn off at the main. 8. 9. 10. Use only sound, strong hose with secure couplings and connections. Wear suitable protective equipment goggles, face shields, etc. Remember normal work clothing is no protection against compressed air.
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NEGLECT IS FOREVER OF REGRET

14. PACKING AND DESPATCH 1. Take help while carrying long boards. Exercise care at corners and cross walks. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. shop 12. Use safe and sturdy ladders while reaching upper wooden cases for moving them. Do not overreach. Avoid carrying loads over persons working below. Do not allow nails to protrude out of board of wooden case. Keep aisles, passages clear while stacking material. Do not sack wooden cases more than two high. Maintain sufficient gap between two stacks for movement of persons. Do not smoke in wood working area. Use suitable personal protective equipment such as safety shoes, hand gloves while working. Do not drag the load while loading / unloading. Do not allow reversing of the heavy vehicle without assistance in the factory premises. Do not allow movement of outside vehicles (rickshaws/tempo etc) in the floor for any purpose. Do not move the packed cases by standing behind it. Clear view of the area in front should be available.
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HURRY NEVER GIVES MORE, TAKES MORE

15. PESTICIDES 1. Pesticides are generally poisonous substances.
2. Do not chew, eat or smoke at the place where pesticides are handled and used. 3. 4. Keep food and drink away from pesticides. Use personal protective equipment, e.g. gloves, aprons, safety shoes, etc. while handling pesticides.
5. Clean yourself with soap and water before taking food or leaving the factory. 6. 7. 8. 9. 10. Do not use any container that has contained a pesticide as a pot for food or drink. Do not handle any pesticide with bare hands. Use a handled scoop. Avoid spilling pesticide on body, floor or table. Maintain scrupulous cleanliness of body and clothing and of your surroundings. Do not store large quantities of pesticides at the place of work. Keep only required quantities at work place.
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THERE ARE HAZARDS IN EVERY TRADE, THAT IS WHY SAFETY RULES ARE MADE.
16. 1. HEAT TREATMENT OPERATION
Use hand gloves while handling heat-treated components.
2. Carry out the heat treatment and quenching operation in a wellventilated area. 3. Maintain oil level in quenching tank.
4. Stir the oil/water continuously to avoid local overheating during quenching. 5. 6. 7. 8. 9. Provide the drip trays for components while cooling. Dispose off carefully liquid waste after heat treatment operation Follow the required procedure while disposing the waste. Use suitable respiratory protective equipment. Keep hot jobs in vertical position. Keep quenching bath very near to the furnace.
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CAUTION IS THE ELDEST CHILD OF WISDOM

17. FIRE FIGHTING 1. In case of fire, report immediately to your superiors & security department. 2. 3. I). 4. 5. 6. 7. 8. 9. 10. 11. 12. Sound the siren to alert all. Tackle the fire immediately using appliances of suitable type(refer Chart In the event of electrical fires, switch off the supply. Do not use water. Familiarize yourself with position and mode of operation of extinguisher local to your job. Do not obstruct fire extinguishers, electrical panels, and switch boards. Keep them easily accessible. Do not obstruct emergency exit doors, internally and externally. Keep oily rags, separate from other waste preferably in closed container. Do not smoke at a place of work. Dispose off cigarette butts safely. Keep containers of solvent always covered. Store only required quantity at place of work. Maintain good housekeeping. Ensure periodical inspection of fire fighting equipment.
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JAMSHEDPUR
SAFETY IS THE BEST SECURITY

CLASSIFICATION OF FIRES & EXTINGUISHMENT MEDIUM Sr. No Type of Fire Extinguishing Medium
Soda acid type extinguisher Water type extinguisher (gas pressure). Water type extinguisher (constant air
Description Fire that occur in ordinary combustible material like wood, rags, paper, textile etc where cooling effect of water is essential for extinguishing of fire. Fires that occur in flammable liquids like oils, solvents, petroleum products, varnishes, paints, etc. where blanketing effect is essential. Fires involving gaseous substances under pressure where it is necessary to dilute the burning gas at a very fast rate with an inert gas or powder Fire involving metals like magnesium, aluminum, zinc, potassium, sodium etc. where burning metal is reactive to water and which requires special extinguishing media or technique. Fires that occur in electrical equipment,
Reference s IS 934 IS 940 IS 6234
1.
CLASS (A)
pressure)
Foam type extinguisher Carbon dioxide type extinguisher Dry chemical powder type extinguisher
2.
CLASS (B)
IS 933 IS 2878 IS 2171 IS 4308
3.
CLASS (C)
Carbon dioxide type extinguisher Dry chemical powder type extinguisher
IS 2878 IS 2171 IS 4308
4.
CLASS (D)
Special dry powder type extinguisher
IS 2171 IS 4861
5.
CLASS (E)
Carbon dioxide type extinguisher. Dry chemical powder
IS2878
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JAMSHEDPUR
lines, switches, etc where the electrical nonconductivity of the extinguishing media is of first importance
type extinguisher. When electrical equipment is deenergised same as for classes A & B.
IS 2171 IS 4308
SAFETY INSTRUCTIONS
FIRST AID
1. 2. 3. 4. 5. 6. Know the location of first aid box and the person who is in charge of it. Give first aid in time. Arrange for quick transfer of the patient to the dispensary/ hospital. In case of bleeding, control it by direct pressure. Cover the wound with dry dressing only. In case of fracture, immobilize the injured part by splinting. If breathing falls or becomes feeble, start artificial respiration and continue till a doctor takes over. In case of thermal burns, immerse the part in cold water for upto 10 minutes and then cover with dry dressing.
7. In the event of chemical burns, wash the affected part with plenty of water. 8. 9. 10. 11. In case of chemicals splashing into eyes, wash thoroughly with water. Do not try to remove foreign body from eye by yourself. Do not rub the eyes. Get the help of doctor. In case of electric shock, switch off the line and release the victim from the circuit. Give artificial respiration and cardiac massage as required. If overcome by noxious gases, remove the victim to fresh air and give artificial respiration if breathing has stopped.
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JAMSHEDPUR
BE SAFE LIVE SAFE LIVE HAPPY
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HARDROCK FABRICATION (P) LTD.

PHA SE VI, INDUSTRIAL AREA, GAMHARIA, JAMSHEDPUR

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

OUR SAFETY PLEDGE We, the members of HARDROCK family,

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HARDROCK FABRICATION (P) LTD.

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

HARDROCK FABRICATION (P) LTD.

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

Ravi Kant Pandey Manager - Safety

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

6. MATERIALL HANDLING (MANUAL & MECHANICAL) Doc. No.: HF / SM / EMR 1 2

HARDROCK FABRICATION (P) LTD.

SAFETY ASSURANCE IS YOUR BEST INSURANCE

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HARDROCK FABRICATION (P) LTD.

7. 8. 9. 10. 11. 12.

13. 14. 15. 16. 17.

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HARDROCK FABRICATION (P) LTD.

18. 19. 20. 21. 22.

MACHINES CANT THINK; ITS UPTO YOU TO PREVENT ACCIDENTS

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

Vapor density : Miscibility Toxicity mixture Chemical reactivity : :

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

FIRE EASY TO START, HARD TO STOP

HARDROCK FABRICATION (P) LTD.

HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

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HARDROCK FABRICATION (P) LTD.

FATE SAVES ONCE A TIME, SAFETY SAVES ALL THE TIME

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HARDROCK FABRICATION (P) LTD.

HARDROCK FABRICATION PVT. LTD. JAMSHEDPUR Dept: Date:________________

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

ELECTRICITY BEFRIENDS NO ONE WHO VIOLATES ITS ORDNANCES

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HARDROCK FABRICATION (P) LTD.

Doc. No.: HF / SM / EMR

HARDROCK FABRICATION (P) LTD.

Doc. No.: HF / SM / EMR