Tool Box

BY

LIYAQUATH ALI CHAPPANGA THOTTATHIL

PREVENTING WELDING FLASHBACK

Every year, hundreds of employees are injured or die as a result of improper use. Knowledge and precautions can prevent
fires and violent explosions.
There are several things you can do to help prevent flashbacks, fires and explosions:
Monitoring the level of hydrogen and shouldnt be low or empty.
Monitoring the partial pressure of oxygen not to be high compared to fuel gas pressure

If using acetylene, keep the pressure below 15 pounds.

Purge your hoses before lighting the torch.

Never light your torch with a mixture of fuel and oxygen. After purging the lines, light the torch with only the fuel gas
valve open.

Check valves should be installed on both torch inlets and operating properly.

Flashback arrestors must be installed on the outlets of both regulators, and/or torch inlets.
Take time to inspect the equipment before.

PROPER REPAIR OF ELECTRICAL CORDS

The first obvious step is often overlooked:
Unplug the cord and take control of both ends.
Cut back the connection only enough of the outer and inner insulation to make the repair.
Color-coded wires on one side need to be connected to the like-colored wires on the other.
Stagger the lengths of the inner wire so that conductors will not come in contact with each other in case of insulation failure.
Make good mechanical connections.

Twist the conductors together and solder, using electrical solder.

Insulate splices using shrink tubing.
Provide outer jacket in order to protects the inner wires from additional damage.
For Plugs Remove outer jacket only as much as is needed to make the repair.
Pay attention to the color coding.
Testing using a simple, inexpensive test light.

EQUIPMENT HAZARDS --REPORT UNSAFE EQUIPMENT

Get in the habit of reporting things that can lead to accidents.
Watch out for the loose or missing machine guard.

Monitor moving part with too much play.

Look for missing nut or bolt,the slipping belt,the loose or cracked shaft housing.
On the electrical side of the picture:
watch for the continually sparking motor,broken switch on a tool.

Locate the damaged extension cord,loose conductors,the burned switch, broken plugs and
receptacles.

Be with a pro-active preventive approach, as safety is everyone's business.

REPORTING AND INVESTIGATING AN ACCIDENT

A good accident investigation tries to answer these questions:

What happened?

When did it happen?

Where did it happen?

Who was involved?

Why did it happen?

How can it be prevented from happening again?

When these questions are answered for all accidents and near misses, patterns often emerge and preventable causes are
often discovered. But the patterns may not be true unless information acquired during the investigation is complete and
accurate. The observations of co-workers, as well as from employees that were directly involved, can be critical. It helps if
everyone will:

Make mental or written notes about the accident before the investigation starts.
Avoid talking to others before talking to the investigator, since this may confuse the facts.
Answer all questions about the incident as accurately as possible.
Take the investigation seriously--give it your best.

REPORTING AND INVESTIGATING AN ACCIDENT (Continued)

When an accident happens, is make sure the worker's injuries are treated.
Near misses should be reported as preventive measure.
Events must be immediately followed by a thorough investigation.
Employees should be constantly alert to potential causes of accidents.
PREVENTING ACCIDENTS IS EVERYONE'S RESPONSIBILITY!

GENERAL SAFETY - SAFE ATTITUDES

Positive attitudes towards safety is important in eliminating unsafe acts and accidents.

Negative attitudes toward safety lead to negative results.

Reminding people about family waiting at home.

Make awareness on adventage of remembering the emergency number.

Enforcing safety rules is part of your supervisor's job

Remind people about safety rules, they are made to protect you.

You are the primary beneficiary.

SAFE USE OF LIQUID PETROLEUM GAS

The primary dangers created by LPG are fire/explosion, carbon monoxide poisoning, asphyxiation, and extreme
cold.
Make sure that the cylinder and relief valves are not damaged in any way.
Damaged cylinders should never be used.
Store cylinders out of the direct sun and away from other heat sources.

A properly filled cylinder will not be full of liquid-some space should remain to accommodate gas.

Inspect your equipment for damages by impact, corrosion over a period of time.

Store LPG cylinders only in a vented areas and away from sources of ignition.

Extinguish all flames and cigarettes in the area on noticing LPG leaking.

Phone from a safe distance away.

Wear gloves to protect yourself when refilling or connecting an LPG cylinder.

Never use LPG appliances indoors without approved ventilation.

SEVEN COMMON ACCIDENT CAUSES

Consider this statistic: 80 out of every 100 accidents are the fault of the person involved in the incident. Unsafe Acts
cause four times as many accidents & injuries as unsafe conditions.

Taking Shortcuts to make the job faster and more efficient but dangerous.

Being Over Confident can lead to improper procedures, tools, or methods in your work leading to an injury.

Starting a Task with Incomplete Instructions.

Poor Housekeeping.

Ignoring Safety Procedures.

Mental Distractions from Work like family matters and interruptions of colleagues.

Failure to Pre-Plan the Work:

"It is better to be careful 100 times than to get killed once." (Mark Twain)

GENERAL SAFETY - SHIFT WORK

In Japan, a study of locomotive operators found that 82% of near accidents occurred between midnight
and 8 a.m.

Prepare and manage yourself for the shift timings.

Establish a bedtime routine.

Guarantee yourself a good seven hours of uninterrupted sleep.

Do not rely on pills..

Avoid caffeine and alcohol within five hours of bedtime.

Eat nutritious foods.

SUNGLASSES VS. SAFETY GLASSES

Use pair of approved safety glasses.
Safety glasses must be shields to reduce the risk of foreign objects from the sides, top or bottom.
Look for "Z87.1,ANSI designation identifying the glasses as approved safety eyewear.

Consider glasses providing IR and UV protection.

Look for glasses that are lightweight and adjustable.
Go for a comfortable one that will fit

THE TEN COMMANDMENTS OF GOOD SAFETY HABITS

Developing everyday safety habits can keep you injury free through the year. Here are ten safety habits to live by:

Set Your Own Standards and practices for safety.

Operate Equipment Only if Qualified..

Respect Machinery..

Use Your Own Initiative for Safety Protection.

Ask Questions. If you are uncertain, ask. Do not accept answers that contain, "I think, I assume, I guess." Be sure.

Use Care and Caution When Lifting.

Practice Good Housekeeping.

Wear Proper and Sensible Work Clothes..

Practice Good Personal Cleanliness.

Be a Positive Part of the Safety Team.