TURORIAL:HAZARDS DURING MAINTANANCE JOBS AND ACCIDENT PREVENTION

TUTORIAL :HAZARDS DURING MAINTANANCE JOBS

AND ACCIDENT PREVENTION [A] INTRODUCTION: Maintenance activities are part and partial of an industrial organization maintenance whether it is predictive, preventive or breakdown can not be avoided in industries. In addition to these type of maintenance activities unlit. Crew will be asked to undertake emergency maintenance jobs. On plant e uipment fabrication installation jobs are also under taken for modification !lterations"additions action installation jobs are also undertaken for modification alterations"addition and e#pansion facilities. $uch activities passes various types of hazards in the chemical industries. %owever in this topic hazards during maintenance jobs are detailed and measures to prevent accidents are depraved. [B] MAINTENANCE ACTIVITIES:&efore undertaking any maintenance activity it's related hazards and prevent fire measures etc(should be identified. )he steps listed below should be followed. &efore maintenance *+, preparation of e uipment *-, Issue of work permit for maintenance job. . /uring Maintenance, *+, Carrying out the maintenance safety. *-, Change of intension during tenure of job should not be entertained. . !fter Maintenance *+, /ividing back the e uipment after maintenance ensuring about the completion of job in all respects. *-, )aking the e uipment back in line safety work permit is should be issued depending upon the job re uirement. )he prevailing upon the job re uirement. )he prevailing work permits are as below. *+, 0ermit to start work implant. *-, %ot work permit. *1, Continued space entry permit. *2, 3essel opening line breaking permit. HAZARDS ASSOCIATED WITH MAINTENANCE ACTIVITIES. Moving Machineries. Caught in between due to nip points rating parts. 4orking near moving machinery working loose clothing. 5se of hand gloves on turning machines. 4orking without prepare electrical isolation of relating machines. $hort out route to cross over the conveyer belts. $lippery floors on near moving machinery. 4orking above the moving machineries. 0ro#imate of any object near unbranded moving parts.

[C] . *a, *b, *c, *d, *e, *f, *g, *h, .

6lectrical shocks"fires"flash over. *a, 7on compliance of electrical isolation permit.

*b, *c, *d, *e, *f, . *a, 88 88 88 88 88

Inadvertent work on live pane, resulting into flashover. Improper identification mark on panel. Combustible material inconstant with live electrical systems. 5se of poorly maintained electrical hand tools. Overloading"over heating of electrical circuits. 0ower other than electricity like steam, air and Inert gas. %azard of splashing of steam"condensate due to 0oor condition of hose. Improper connection of hose. $udden opening of valve. 9oose and of hose not firmly holytide. 6#cessive pressure build up due to checking of process pipe.

*b, Obstruction due to improper laying of hose and entanglement of following hazard. *c, 0iercing hazard of thorough iron"metal particles in skin"eyes due to measure of air hose in clearing body"cloths. *d, In !dvantest use of inert gas instead of air. . *a, *b, *c, *d, :ull of materials tools etc(.from weight. 7on use of toe board and proper seas toads. 5se of improper work plot form having opening open space. Carrying tools in unsafe manner while ascending descending or lifting tools. 9eaving keeping tools of pipe rack and tuning of tools of pipe rack and tuning of tools or pipe rack and leaving of tools due to vibration or movement of others. :ull of materials tools etc(.from weight. 7on use of toe board and proper seas toads 5se of improper work platform having opening open space. Carrying tools in unsafe manner while ascending decoding or lifting tools. 9eaving keeping tools of pipe rack and facing of tools due to vibration or movement of others.

. *a, *b, *c, *d, .

:all of 0ersons;< Improper work platform having opening or without proper railing. 5nsafe means of access .i.e. non use of step ladder use of unsafe laden use of temporary access media like foam etc.. *c, 4orking on fragile rooting without taking due precautions. *d, $afety belt is re uired while deriding as unprotected height =following> points should be checked while using safety belt. 0roper condition of belt and its life line. 0roper length of lifeline etc.. i.e. less than the distance between ground and working place person should get hanged and should not tall trolley or struck on down below objects. !bstraction due to hose connection ground level pipelines. *a, *b,

$lippery floors.

$triking against seat folding members pipelines etc( Clear distance from ground level for first horizontal member of scaffolding should be more than fact. 0roducing end of scaffolding members. 7on use of safety helmet. *a, *b, *c, *d, *e, :ailure of heavy not handling devices. 9ack of proper inspection"testing of material handling e uipment. 9ack of component supervision. Overloading unbalancing of the load. Improper working methods. 0oor ground conditions. ?igging @obs;< Improper training to rigger. Confusing signals by rigger. More than one rigger to give signals. Improper size of sling Improper toeing, lifting and placement of heavy object. Overreaching the work place by change taking. $plashing of chemicals. &urn injury due to corrosive nature of chemicals. :ire out due to spillage of flammable li uids. )o#ic"poisonous effect of chemical. In ade uate flashing of pipelined. 7egligence to use safety applications. 0ower operated hand tools;< 6lectric shock due to leakage current. Cut and puncture would due or striking of power tools running condition. Improper fitting of accessories of hand tools such as grinding wheels, drill bit due to improper work method. :ailure of grinding wheel"drill B.C due to improper ward method. 0iercing of foreign particles in skin"eyes. welding"cutting operations;< :ire due to spattering spark. :ire due to non use of earthing cable. &lack fire in a effluence house due to poor condition of torch. 6#plosion in confined vessel due to leaky pipes of gas cutting set. $uffocation due to less o#ygen in continued space. $hock due to poor electrical cables. HAZARDS RELATED WITH HUMAN FACTORS/FAILURES.

. *+, *-, *1, *2, *A, *B, . *a, *b, *c, *d, *e, . +, -, 1, 2, A, . *a, *b, *c, *d, *e, *f, [D]

*a, *b, *c, *d, [E]

9ack of confidence"over confidence on the part of work man engaged of the job. 9ake of ade uate supervision and non fulfillment of safety re uirements. %asty actions in taking out e uipments for maintenance. 7on availability"non usage or knowledge to use fire fighting and other emergency safety protective appliances.

CODE OF PRACTICLE FOR SAFE MAINTANENCE:*+, Obtain durance signal safety permit pertaining to the job process department. *-, inspection of the site *by supervisor, analysis the job in minute detailed depending on job. *1, &riefing the job to the crawl person undertaking the job including the safety aspects maintained in permit. *2, Clarifying may doubt *it declared with sketch, and answering any specific. *A, 6#plain anticipated emergencies and corrective action during the job. *B, /isplaying identification trays of e uipments especially electrics process hazard points. *C, Detting the area lubricated opened due methanol's railing, guard etc( *E, Inspect by tools"tanks for any deflects if needed replacement facilities should be made ready. *F, Det ready with all the tools trackless and other arrangements like approaches scaffolding etc( *+G, If the job is felt ready hazardous confined space entire hot jobs near process area etc.. five assistance and be present at start up. Of job as well do periodic inspections. *++, &e vigilant about welding hazardous temporary electrical fillings gas leaks from cylinder etc.. *+-, 4hich for any abnormalities during the jobs and give proper instruction then and these. *+1, &e strict with compliance of using personals protective appliances indicated protective application indicate in permits. *+2, ?enew permits wherever the job is to be continued after the e#piry of originally indicated timings. *+A, 4henever jobs are handed over to outside"contractor agencies be e#tract vigilant and follow up for safe particles contractor should be instructed to cont by whenever a problem situation arises. *+B, )horoughly inspect the jobs before handling over the job especially for process perfect bo#ing up return of lags. ?eplacement of guards, safety valves such other safety devices. *+C, $ee that men and materials are back before allowing decommissioning of process jobs and leave the area cleaned of maintenance material + scraps. *+E, &e in content touch with the process department especially white engaged in jobs at distant located places"hazardous areas. *+F, %ave co<ordination with medical"fire department safety etc., for any emergency assistance.

%ope the above code it practiced by developing their due share of time if will go a long way to prevent up pleasant incidents.