A.MAHANTI
Rule- 53. Work on or near machinery in motion.-(l) One or more adult male
workers shall be appointed for the purposes of under sub-section (1) of section
22. A list of such workers shall be maintained in a register as nearly as possible
in Form No. 7.
(2) No worker shall be appointed unless he has been suitably trained for such
examination or operation and is acquainted with the dangers from moving
machinery arising in connection with such work.
(3) A worker required to wear tight fitting clothing under sub-section (1) of section
22 shall be provided by the occupier with such clothing which shall consist of at
least a pair of closely fitting shorts and a closely fitting half-sleeve shirt or vest.
Such clothing shall be returned to the occupier on termination of service or when
new clothing is provided.
Guillotine machines
Circular saws;
2.0 OBJECT: To prevent contact of any part of the body with the dangerous parts
of the machinery and thus to avoid accidental injury to the workers and to protect
them from operational, mechanical or electrical failure of plant and equipment.
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PARTS EXAMPLES
ROTATING PARTS SHAFT,PULLEY, COUPLING, FLY
WHEEL
CUTTING/SHEARING PARTS MILLING, DRILLING, BAND SAW,
SHEARING MACHINE
IN-RUNNING NIP POINTS BELT DRIVERS, ROLLERS,PINIONS
SCREW MECHANISM SCREW CONVEYOR, LATHE
FORMING AND BENDING PRESS BRAKE
Depending upon the type of equipment, one must consider the following sources
of energy during maintenance work:
Electrical;
Hydraulic fluid under pressure;
Compressed air
Potential energy from suspended object;
: Potential energy stored in spring
Once any/all the above mentioned energies are neutralized, the machine is in a
state called Zero Mechanical State)
It affords maximum protection against unexpected movement. The concept
includes not only locking out the energy(electrical) but also requires that all
kinetic and potential are isolated, blocked, supported, retained or controlled to
the extent that such energies will not be released unexpectedly. This state
minimizes the number of accidents while doing maintenance job on machines.
FIXED
INTERLOCKING
AUTOMATIC
DISTANCE/POSITIONAL-INCLUDING BARRIER WITHADEQUATE
HEIGHT
BUILT IN-SAFETY BY CONSTRUCTION
SAFETY BY POSITION OF THE MACHINERY
TRIP DEVICES-INCLUDING SENSITIVE SCREEN/PHOTO ELECTRIC
DEVICE
Where access to danger area is not required during normal operation, the
following type of guards may be considered:
a) Fixed guard
b) Distance guard including barrier of adequate height;
c) Trip device including a sensitive screen/photo electric
device.
Aluminium or other soft metals are also used where rust is a possible danger.
It normal practice, the opening should not be more than 3/8 inch.
Max. safe opening= + 1/8 th the distance of guard from danger zone.
( this formula, however, does not hold good where the distance from the guard
to the danger zone exceeds 12 inches.)
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SUITABILITY:
POWER PRESS, SHEET LEVELLING OR PLATTENING MACHINE, MILLING
MACHINE, GEAR TRAINS, DRILLING MACHINE AND GUILLOTINE CUTTER
ADVANTAGE:
Easy to install
Ideal for blanking Power press
Can be combined with automatic or semi automatic feed
Permits increased production
Both hands free
Complete enclosure
4.4.2 INTERLOCKING GUARD
If a fixed guard can not be used, an interlocking guard should be fitted as the first
alternative. The type may be mechanical, electrical, pneumatic or combination type.
This type of guards prevents operation of control that sets the machine in motion
until the guard is moved into position, so that operator can not reach the danger or
point of operation. When guard is open, permitting access to the dangerous part, the
starting mechanism is locked and a locking pin or other suitable safety device
prevents the main shaft from turning or other basic mechanism from operating.
When the machine is in motion, the guard can not be opened. It can be opened
when only when the machine has come to rest or has reached a fixed position in its
travel.
BASIC REQUIREMENT:
An effective interlocking guard must satisfy the following three requirents. It must:
Guard the dangerous part before the machine can be operated
Stay closed until the dangerous part is at rest
Prevent operation of the machine if the interlocking device fails
Mechanical interlocks may be used if fixed or interlocking guards are not practicable.
SUITABILITY:
SHORT STROKE HIGH SPEED POWER PRESS, HYDRAULIC PRESS, HYDRO
EXTRACTOR, CENTRIFUGES, MILLING MACHINE, ROTATING SCREW
CONVEYOR.
ADVANTAGE:
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Ample space in power press can be arranged for feeding the job into the
space between the dies
Wear and tear is inevitably present in the automatic guard
ADVANTAGE:
Generally increases production,
Operator can not place hands in danger zone.
SUITABILITY:
BAKING AND CANDY MACHINE, CIRCULAR SAW, POWER PRESS, TEXTILE
PICKERS, WOOD PLANNER, WOOD SHAPER
ADVANTAGE:
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SUITABILITY:
DOUGH MIXER, EMBOSSING PRESS, PAPER CUTTERS, PRESS
MACHINES.
SUITABILITY:
ENCLOSED SPEED GEAR BOXES OF LATHE(CAPSTAN AND TURRET);
MILLING MACHINE, RADIAL DRILL; TOTALLY ENCLOSED INDIVIDUALLY
DRIVEN MILLING MACHINE.
Some time safety of machine may be ensured by safe positioning of the machine
so that the dangerous part of the machine remains out of reach of the operator.
The machine remains unguarded. It is assumed that the operator need not
approach the machine and it can be operated from distance. But it can not be
ruled out that accident may occur due to careless ness or thoughtlessness of the
operator. So choice of this type of guarding is not preferred.in the safety point of
view.it is therefore preferable that fencing of the machine by efficient guard would
be safer and one should not rely on this type of guard.
SUITABILITY:
This type of guard is particularly suitable for large presses. The photo electric cell
or electric eye should be installed far enough from the point of operation area
that it will stop the ram before the operators hand can get under it and enough
light beams must be used to cover the open area with a curtain of light.
These devices, however, can not be used in positive clutch power press. Not
effective on punch press with positive clutch because once the operating cycle of
a power press starts, no device can prevent completion of the cycle.
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CIRCULAR SAWS:
HAZARDS:
Contact with saw blade-moving/stationary
Kickback.
(i) The edge of the knife nearer the saw shall form an arc of a circle having a
radius of the largest saw used and it shall extend upward from the bench to a
height not less than that, reached by the largest wood or timber sawn.
(ii) The knife shall be maintained as close as possible to the saw, having regard
to the nature of the work being done at the time, and at the level of the bench the
distance between the front edge of the knife and the teeth of the saw shall not
exceed half an inch.
(b) Hood or crown guard- The top of the saw shall be covered by a strong and
easily adjustable guard, with a flange at the side of the saw farthest from the
fence. The guard shall be kept so adjusted that the said flange shall extend
below the roots of the teeth of the saw. The guard shall extend from the top of
riving knife to a point as low as practicable at the cutting edge of the saw. The
hood is supported in position by an arm fixed suitably to a post fixed to the
bench. It is U or L shaped and be strong enough to protect the operator against
flying slivers or broken saw teeth.
(c) Apron guard- The part of the saw below the bench shall be protected by two
plates of metal or other suitable material one on each side of the saw; such
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plates shall not be more than six inches apart, and shall extend from the axis of
the saw outwards to a distance of not less than two inches beyond the teeth of
the saw . Metal plates, if not beaded, shall be of a thickness of at least 1/10 inch,
or if beaded be of a thickness of at least 1/20 inch.
(d) Anti kick back fingers(dogs)- they are fitted in addition to the spreaders
/riving knife to prevent accident due to kick back. They may be in the form of
seriated can allowing the wood to move forward but preventing it from being
thrown back.
(e)Push sticks.-A push stick or other suitable appliance shall be provided for use
at every circular saw and at every vertical spindle moulding machine to enable
the work to be done without unnecessary risk.
(2) Every planing machine used for overhand planing shall be provided with a
"bridge" guard capable of covering the full length and breadth of the cutting slot
in the bench, and so constructed as to be easily adjusted both in a vertical and
horizontal direction.
(3) The feed roller of every planing machine used for thicknessing except the
cornbined machine for overhand planing aid thicknessing, shall be provided with
an efficient guard.
(2) Safety-trip rods or tight wire cables on rubber mills shall extend across the
entire length of the face of the rolls and shall be located not more than fifty-nine
inches above the floor or working level.
(3) Safety-trip rods and tight wire cables on all rubber mills shall be examined
and tested daily in the presence of the Manager or other responsible person and
if any defect is disclosed by such examination and test the mill shall not be used
until such defect has been remedied.
C.POWER PRESSES:
(b) Each die shall be provided with a fixed guard surrounding its front and sides,
and extending to the back in the form of a tunnel through which the pressed
article falls to the rear of the press.
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(c) The design, construction and mutual position of the guards referred to in (a)
and (b) shall be such as to preclude the possibility of the worker's hand or fingers
reaching the danger zone.
(d) The machine shall be fed through a small aperture at the bottom of the die
guard, but a wider aperture may be permitted for second or subsequent
operations if feeding is done through a chute.
FIXED BARRIER GUARD- This type of interlocked fixed barrier guard is used on
automatic presses where the point of operation is occasionally be exposed to
clear the jam. As further safety measures, hand tools or picks are to be used to
relieve jam.
When more than one operator is required in a press operation a duplicate set of
controls should be provided for each operator and press should not be
operational until all controls are energized.
This type of device should be operated from a closed electric circuit so that
interruption of the current will automatically prevent the press from cycling.
Advantage: Absence of mechanism in front of operator.
It is particularly applicable on large presses. The photo electric cell should be
installed far enough from the point of operation area that it will stop the ram
before operators hand can get under it and enough light beam must be used to
cover the open area with curtain of light.
However these devices are not suitable on presses with positive clutches.
They can be used on presses having friction, air or other clutches which can be
held at any position of the cycle and with adequate brakes for stopping the press
at any point of ram travel.
These devices should be supplemented by hand tools or feeding and ejection
devices.
AUXILIARY DEVICES:
Foot control guard:- All presses operated by foot pressure should have guard
over the pedal or switch button. The guard may be equipped a spring-closed
shield so that when the operators foot is removed, the shield snaps shut
enclosing the switch button.
The clutch rod should be connected to the pedal lever so that the distance the
distance between clutch rod and rear pivot on the pedal will be 1/3 of the length.
The tripping pedal should travel about 3 inches, the travel of the connecting point
will be 1 inch.
The pedal lever should have no side play and the tension of the pedal should be
maintained as per manufacturers recommendation.
SWEEP DEVICES:
These devices sweep the operators hand out of the point of operation/danger
zone. However they have some disadvantages, they may be violent. They are
activated by press action.
Some sweep devices are interlocked so that the press can not be operated
unless the sweep is in the closed position.
This requirement is at par with other approved devices and may be allowed if
suitable to the operation and well maintained.
.
D. CENTRIFUGAL MACHINES:
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These machines develop centrifugal force to separate liquid from solid materials.
Most centrifugal machines comprise a revolving basket or cage surrounded by a
stationary casing.
DANGER:
Contact with the revolving element
Bursting out due to unbalanced loading of basket or cage
GUARDING:
Safe working peripheral speed of the basket shall not be exceeded.
Automatic tripping device shall be fitted so as to cut off power in the event
of either overloading or unbalanced loading in the basket.
Shall be provided with metal lids or adequate strength. The lids shall be
provided with interlocking devices which will ensure that:
a) The machine cannot be started until the lid is closed
b) The lid cannot be opened while basket is in motion
All the centrifugal machines shall have effective braking arrangements
which shall be regularly inspected,
GUARDS-
Fixed or interlocking guards for the length of the in-running nips
Efficient doctor blade and feeding shall be made to prevent operators
hands approach the nip during feeding
Mechanical devices should be used to replace manual straightening/
smoothing
Automatic lubricating devices are preferred to manual lubrication,
Push buttons, for engine-stop, pull cord connected directly to the prime
mover and control clutches should also be provided,
Press rollers should be fenced by plate guards,
Felt rollers should be fenced by covering the felt rollers,
Each set of calendar rolls with the nip points at the in-running side should
be equipped with adjustable barrier guard. In addition, efficient doctor
blade, air feeder, and feeder belts should be used
Calendar machine intake roll should be fenced by fixed round bar,
FINISHING MACHINES:
REELING &SLITTING MACHINE
CUTTING MACHINE
PAPER CUTTING GUILLOTINE
All intakes between the rolls of Reeling and Slitting machine should be
securely fenced by automatic adjustable guard,
Slitting knives should be enclosed with guards
CUTTING MACHINE
Cutting machine brake wheels should be covered by hinged guard
Side belts, pulleys and cutter cylinder should be securely fenced.
The cutters and all the intakes between the rolls should be securely
fenced..
PAPER CUTTING GUILLOTINE
Paper cutting guillotine should be provided with automatic or interlocking
guard.