Week 3 S2 2016

Module 3

MEC3204

Module 3 Industrial safety

Self-assessment and tutorial questions
(The following questions are extracted from the reference book Introduction to Basic Manufacturing
Processes and Workshop Technology, Chapter 3)

1. What is an accident? Describe briefly the common causes and sources of accidents.
The accidents are the mishaps leading injury to man, machines or tools and equipment and
may cause injury and result either death or temporary disablement or permanent
disablement of the industrial employees.
There are (a) human causes, for example (1) Working on unsafe or dangerous equipments
or machineries possessing rotating, reciprocating and moving parts; (2) Operating machines
without knowledge, without safety precautions, without authority, without safety devices; (3)
Operating or working at unsafe speed; (4) Working for long duration of work, shift duty etc; (5)
Use of improper tools; (6) Working with mental worries, ignorance, carelessness,
nervousness, dreaming etc; (7) Not using personal protective devices. (b) Environmental
causes, for example, (1) Working at improper temperature and humidity causes fatigue to
the workers so chances of accidents increases with workers having fatigue; (2) The
presence of dust fumes and smoke in the working area may causes accidents; (3) Poor
housekeeping, congestion, blocked exits, bad plant layout etc. may cause accidents; (4)
Inadequate illumination; (5) Improper ventilation in the plant. And (c) Mechanical causes, for
example, (1) Continued use of old, poor maintained or unsafe equipment; (2) Use of
unguarded or improper guarded machines or equipments; (3) Unsafe processes, unsafe
design and unsafe construction of building structure; (4) Improper material handling system
and improper plant layout; (5) Not using of safety devices such as helmets, goggles, gloves,
masks etc. on machine.
The sources may come from: Revolving parts, viz. pulley, flywheels, worms; Projecting
fasteners of revolving parts, like bolts, screws; Intermittent feed mechanisms, viz., tool feed
of planer; Revolving shafts, spindles, bars, mandrels; Rotating worms and spirals enclosed
in casings, like milling cutters, circular saw blade, saw band, circular shears and grinding
wheels, etc. In all, Revolving, Rotating, Reciprocating and Moving parts of machinery are the
major sources

2. Explain in brief the various methods of safety adopted in a production plant.

There are many methods that can be adopted and considered at a normal production plan,
for example, (1) Safety by construction or design; (2) Safety by position; (3) Safety by using
fixed guards; (4) Safety by using interlock guards; (5) Safety by using automatic guards; (6)
Safety by using trip guards; (7) Safety by using distance guards; (8) Safety by workplace
layout and proper working conditions; (9) Safety by proper material handling; (10) Safety by
using personal protective equipment (PPE).

Week 3 S2 2016

Module 3

MEC3204

3. What are the three factors of combustions? Explain fire type, and for each of the type,
what are the appropriate extinguishers?
The three factors are (1) O2, (2) combustible material and (3) temperature raising to ignition
point of the material.
There are different types of fire according to different combustible materials. The normal
three categories are
Type 1 Fires occurring due burning of ordinary combustible materials such as wood, cloth
and paper. Pouring water is the most effective way for extinguishing this kind of fire.
Type 2 Fires occurring due burning of flammable liquids such as oils, petrol, grease and fat.
For extinguishing, blanket or smother this kind of fire, thus excluding oxygen, water must
never be used.
Type 3 Fires in this category involve live electrical equipment. The extinguishing agent must
be non-conducting of electricity and water must not be used for extinguishing this kind of fire.
In Australia, fires are categorised into six classes:
1. Class A fires are those which involve carbonaceous solids. A carbonaceous solid
is one which contains the chemical element carbon as the basic fuel. This is probably
the most common type of fire encountered by firefighters.
2. Class B fires involve flammable and combustible liquids. Examples: Petrol,
kerosene, oil, tar, paint, wax.
3. Class C fires involve combustible gases. Examples: LPG liquefied petroleum
gas, butane, propane; LNG liquefied natural gas, acetylene.
4. Class D fires involve combustible metals. Examples: Sodium, potassium,
magnesium and aluminium shavings.
5. Class E Electrical Fires there is no official Class E fire. Electricity is not a fuel; it
does not burn like a fuel. However, it is a dangerous complication at a fire, because it
is a source of heat and potential electric shock.
6. Class F fires involve cooking oils and fats. Examples: Lard, vegetable oils

Figure 1. FIRE EXTINGUISHER SELECTION CHART (sourced from FIRE & SAFETY AUSTRALIA)

Week 3 S2 2016

Module 3

MEC3204

Note: Similar to class C flames, water cannot be used on fires that burn metal. Spraying
water on a class D fire will actually serve to energize the flames, potentially spreading the
fire and creating additional heat and damage.
The most effective way to fight class D fires is with dry powder extinguishing agents because
they absorb heat and smother the flames, cutting off oxygen. By removing these two
essential elements of the fire tetrahedron, the fire will be put out safely and rapidly.[1]
REF.
[1] http://www.fire-extinguisher101.com/class-d-fires.html