©2015 National Safety CouncilACCIDENT PREVENTION MANUAL FOR BUSINESS & INDUSTRY Engineering & Technology 1

©2015 National Safety Council ACCIDENT PREVENTION MANUAL FOR BUSINESS & INDUSTRYEngineering & Technology

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Chapter 1Safety Through Design


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1-1. The Model for Safety Through Design


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1-2. Benefits of Safety Through Design

• Significant reductions in injuries, illnesses, and damage to the environment

• Improved productivity• Reduced operating costs• Avoidance of expensive retrofitting to correct design

shortcomings


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1-3. Hierarchy of Controls

Fourth Priority: Provide warning systems

Fifth Priority: Apply administrative controls

Sixth Priority:Use personal protective

equipment

To achieve the greatest effectiveness in hazard avoidance, elimination, or control, companies should apply the following priorities to all design and redesign processes:

First Priority: Eliminate or reduce risk in the design and redesign process

Second Priority: Reduce risks by substituting less hazardous methods or materials

Third Priority: Incorporate safety devices


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Chapter 2Buildings and Facility Layout


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2-1. Design for Safety

• Illumination • Noise and vibration control • Product flow • Ventilation • Control of temperature and

humidity • Employee work positions

and movements • Supervision and

communication • Support requirements

• Construction and procedures

• Visual displays, signs, labels

• Protective features and guards

• Controls and handles • Maintenance and service

needs • Accident prevention signs

General Design Considerations

Factors to Consider in the Design of Tools & Equipment


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2-2. Factors Affecting Site Selection

• Relationship of structure to climate and terrain • Space requirements • Type and size of buildings • Necessary disposal facilities • Transportation to and from facilities • Market • Labor supply • Hazards to the community


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2-3. Factors Affecting Size, Shape & Type of Structure

• Nature of the Business and Processes • Nature of the Production Materials • Maintenance • Heating, Ventilation, and Air-conditioning Equipment • Working Conditions • Shipping and Receiving Materials • Economic Considerations


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Chapter 3Construction of Facilities


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3-1. Elements of a Safety Plan

A successful plan must address:• Site-specific hazards• Safety expectations regarding safe work practices• Clearly defined safety roles and responsibilities


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3-2. Role of the Field Engineer

• Identify site-specific safety hazards to contractors• Establish that the contractors recognize hazards and

are prepared to deal with them• Coordinate the interfaces between contractors• Coordinate the interfaces between contractors and

operating facilities• Verify that the contractor is performing to agreed-upon

contract requirements


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Chapter 4Maintenance of Facilities


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4-1. Components of Facility Maintenance

• Proper long-term care of the buildings, grounds, and equipment

• Routine care to service and appearance• Repair work required to restore or improve service and

appearance


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4-2. Stairs and Exits

• appropriate exit signs • improper or inadequate

design, construction, or location

• lack of handrails • handrails placed too low or

rough handrails • improper lighting

(including emergency lighting)

• obstructions • locked doors

Note the following items, and repair or correct any defects found during a maintenance inspection:

• doors that open in the direction of an exit

• poor housekeeping • wet, slippery, or damaged

surfaces • faulty treads or mats on

stairs • lack of curbing on ramps • differentiation between

– the exit access – the exit – the exit discharge

4-3. Indoor Environmental Quality Elements

• Lighting• Ventilation• Chemical contaminants• Biological agents• Noise• Vibration• Air quality• Ergonomics• Temperature• Particulates• Relative humidity


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Chapter 5Fired Pressure Vessels (Boilers) and Unfired Pressure Vessels


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5-1. Common Causes of Explosions in Pressure Vessels

• errors in design, construction, and installation • improper operation, human failure, and improper

training of operators • corrosion or erosion of construction materials • Failure or intentional defeat of safety devices, and

failure or override of automatic control devices • failure to inspect thoroughly, properly, and frequently • improper application of equipment • overfiring• lack of planned preventive maintenance

Anticipate and avoid the following common causes of explosions in pressure vessels:


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5-2. Safety Devices for Pressure Vessels

• Safety valves—the spring-loaded type is commonly used on vessels containing air, steam, gases, and liquids

• Rupture disks—commonly used in chemical processing plants, these devices are designed to open and relieve pressure on a vessel or system of vessels

• Vacuum breakers—may be spring-loaded or weight-balanced, these are used on vessels working intermittently between pressure and vacuum

• Water seal—a U-pipe filled with water used on vessels that operate on low pressure or under slight vacuum, such as alcohol stills and gas holders

• Vents—relieves contents of a vessel before excess pressure builds

• Regulation (or reducing) valves—reduces high-pressure steam to the pressure required for a specific operation


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Chapter 6Safeguarding


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6-1. Characteristics of a Proper Guard

The characteristics of a proper guard include: • integrated as a part of the machine • well constructed, durable, and strong • able to accommodate workpiece feeding and ejection • protective • easy to inspect and maintain • relatively tamper-proof or foolproof

On the other hand, a guard should not: • create another hazard • interfere with production • cause work discomfort


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6-2. Safeguarding the Point of Operation of a Power Press


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Chapter 7Personal Protective Equipment


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7-1. Permissible Noise Exposures


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7-2. Suggested Outline for Selecting Respiratory Protection Devices

7-3. Protective Footwear Requirements


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Chapter 8Electrical Safety


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8-1. Path of Current


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8-2. Electrical Equipment Selection and Installation Checklist

• Selecting Electrical Equipment – follow recommendations of

established codes & standards – check state & local codes for

zoning requirements

• Installing Electrical Equipment – interlocks – barriers – warning signs – guarding

• Switches – knife switches – pendant switches

– push button or snap switches

– flush switches – surface switches

• Protective Devices – fuses, link fuses, plug

fuses, cartridge fuses – circuit breakers

• Ground-Fault Circuit Interrupters

• Control Equipment • Motors

– dust, oils, moisture – misalignment and vibration– overloads – friction and wear


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8-3. Electrical Equipment Selection and Installation Checklist (continued)

• Extension Cords – portable tools – heating devices – flexible cords – extension lamps

• Test Equipment – ammeter – voltmeter – megohmmeter – ground-fault indicators and

locators

– wattmeter – industrial analyzer – receptacle circuit tester – receptacle tension tester – voltage detector – recording instrument – specialized testing

instruments


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8-4. Electrical Detectors


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Chapter 9Fire Protection

9-1. Fire Risk Assessment Steps


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9-2. Objectives of a Fire Protection Program

1. Preventing fires2. Detecting and responding to fires

– early detection– initiating appropriate alarms– responding quickly to alarms

3. Controlling, suppressing, and extinguishing fires4. Recovering from fires

9-3. Example Risk Matrix


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9-4. Fire Extinguisher Classification and Symbols


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9-5. Common Types of Sprinklers andWater-Spray Systems

• Automatic Sprinklers—the most extensively used fixed fire extinguishing system, considered by most fire protection engineers as the most important fire-fighting tool

• Wet-Pipe Systems—accounts for the greatest percentage of sprinkler installation, this system works when heat fuses the fusible link on a sprinkler head, immediately releasing water over the area below

• Dry-Pipe Systems—a substitute for the wet-pipe system commonly used in areas where piping is exposed to freezing temperatures

• Pre-Action Systems—similar to dry-pipe systems, this sprinkler system works faster because a pre-action valve, actuated by a separate fire detection system, controls the water supply

• Deluge Systems—commonly designed for facilities that contain large quantities of flammable materials and where great quantities of water must be applied over large areas. These systems are recommended wherever quickly spreading fires (flash fires) are possible


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Chapter 10Flammable and Combustible Liquids


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10-1. Hazards of Flammable and Combustible Liquids

• The flash point of the liquid (lowest temperature at which liquid gives off enough vapor to create a flammable mixture near the surface of the liquid)

• The concentration of vapors in the air (whether the vapor-air mixture is within the flammable range)

• The availability of a source of ignition at sufficient temperature to enable ignition

• The degree to which ventilation prevents accumulation of vapors

The degree of potential hazard from flammable and combustible liquids depends on four elements:


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10-2. Potential Health Hazards Associated with Flammable Liquids

• Skin irritation• Intoxication or illness from inhaling vapors• Oxygen deficiency in closed containers used to store

these liquids


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Chapter 11Nanomaterials in the Workplace


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11-1. Steps for Clearing Use of Nanomaterials in the Workplace

1. Investigate and determine the physical and chemical properties (size, shape, solubility, etc.) that influence the potential toxicity of the nanoparticle

2. Evaluate short- and long-term effects nanomaterials may have on organ systems and tissue

3. Determine biological mechanisms for potential toxic effects

4. Create and integrate models to assist in assessing potential hazards

5. Determine if a measure, other than mass, is more appropriate for determining toxicity

11-2. Monitoring Results of Nanomaterials Use

After nanomaterials are put into use in the workplace, epidemiology and surveillance can be used to measure the consequences of this use. These monitoring steps include:•evaluating existing epidemiological studies of workplaces where nanomaterials are used•identifying knowledge gaps in which epidemiological studies could promote the understanding of nanomaterials and evaluating the likelihood of conducting such studies•integrating nanotechnology health and safety issues into existing hazard surveillance methods and determining whether additional screening methods are needed•using existing studies to share data and information about nanotechnology


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Chapter 12Materials Handling and Storage


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12-1. Rules for Lifting

• DO engineer manual lifting and lowering out of the task and workplace.

• DO be in good physical shape. • DO think before acting. • DO get a good grip on the load. • DO get the load close to the body. • DO NOT twist the back or bend sideways. • DO NOT lift or lower awkwardly. • DO NOT hesitate to get mechanical help or help from

another person. • DO NOT lift with the arms extended. • DO NOT continue lifting when the load is too heavy.


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12-2. Guidelines for Lifting

1. Maximum Permissible Limit (MPL) is defined to best meet four criteria:

• Musculoskeletal injury and severity rates increase significantly in populations where work is performed above MPL

• Biomechanical compression forces on the spinal discs are not tolerable over 1,430 lbs (650 kg) in most workers

• Metabolic rates exceed 5.0 Kcal/min for most individuals working above MPL

• About 25% of men and less than 1% of women have the muscle strength capable of performing above MPL

2. Action Limit (AL)—the large variability in capacities between individuals in the population indicates the need for administrative controls when conditions exceed this limit based on:

• Musculoskeletal injury incidence and severity rates increase moderately in populations exposed to lifting conditions described by the AL

• A 770-lb (350 kg) compression force on the spinal discs can be tolerated by most young, healthy workers

• Metabolic rates would exceed 3.5 for most individuals working above AL

• More than 75% of women and more than 99% of men could lift loads described by AL

Two limits are provided based on epidemiological, biomechanical, physiological, and psychophysical criteria:


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Chapter 13 Hoisting and Conveying Equipment


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13-1. Unsafe Conditions for Overhead Traveling Cranes

• Bearing: loose, worn • Brakes: shoe wear • Bridge: alignment out of true

(indicated by screeching or squealing wheels)

• Bumpers on bridge: loose, missing, improper placement of

• Collector shoes or bars: worn, pitted, loose, broken

• Controllers: faulty operation because of electrical or mechanical defects

• Couplings: loose, worn • Drum: rough edges on

cable grooves • End stops on trolley: loose,

missing, improper placement of

• Footwalk: condition • Gears: lack of lubrication or

foreign material in gear teeth (indicated by grinding or squealing)


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13-2. Unsafe Conditions for Overhead Traveling Cranes (Cont.)

• Guards: bent, broken, lost • Hoisting cable: broken

wires • Hook block: chipped sheave

wheels • Hooks: straightening • Lights (warning or signal):

burned out, broken • Limit switch: functioning

improperly • Lubrication: overflowing on

rails, dirty cups

• Mechanical parts (rivets, covers, etc.): Loose

• Overload relay: frequent tripping of power

• Rails (trolley or runway): broken, chipped, cracked

• Wheels: worn (indicated by bumpy riding)


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13-3. Hazards of Aerial Baskets

• not observing proper precautions against electrical hazards to personnel both in the basket and on the ground

• improper positioning of vehicle or outriggers, lack of sufficient blocking under outriggers, or overloading the boom, causing the apparatus to overturn or fall

• overreaching from basket or other improper work procedures • not using proper personal protective equipment, including

safety belts • moving the truck while the boom is raised, or moving where

there is inadequate clearance for the boom • structural or mechanical failure, or control jamming • swinging the boom or basket against overhead obstructions

or energized equipment • moving the boom into positions that interfere with traffic • inadequately training personnel

The most frequent causes of unintentional incidents while using mobile aerial baskets include the following:


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Chapter 14 Ropes, Chains, and Slings


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14-1. Factors to Consider When Choosing Rope


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14-2. Wire Rope Cross Section

• Wire rope is made from a number of individual wires grouped in strands, then laid together over a core member (fiber core, an independent wire core, or strand core).

• The number of wires per strand and the number of strands per core depend on the expected working conditions and the amount of flexibility required.

14-3. Chain Sling Inspections

Chain slings require three types of inspection:


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1. Initial inspections—Both new and repaired slings should be inspected before use to determine a) that each sling meets the requirements of the purchase

order;b) that it is the correct type and has the proper rated

capacity for the application;c) that it has not been damaged in shipment, unpacking,

or storage. 2. Frequent inspections— The sling should be inspected by

the person handling it each time it is used. 3. Periodic inspections—A semiannual or more frequent

inspection should be performed by a competent person who is experienced in the inspection of chain slings. The frequency of periodic inspections should be based on the following factors: frequency of use, severity of service conditions, and knowledge about the service life of slings used in present or similar conditions.


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Chapter 15Powered Industrial Trucks


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15-1. Typical Pallet-Loading Patterns


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15-2. Lift-Truck Maneuvers

A. turning a sharp corner B. turning across an aisle C. turning in an

exceptionally narrow aisle

D. turning around in a narrow passage

A B

C D


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15-3. Distribution of Load

• (Left diagram) With forks spread wide, the load is well distributed and tends to bind together.

• (Right diagram) With forks positioned too close together, the pallet tends to seesaw.


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Chapter 16Haulage and Off-Road Equipment

16-1. Safety Components

There are four basic safety components related to haulage and the operation of off-road equipment:•the working environment around the equipment or machine•the machine itself•the worker•the work process


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16-2. General Safety Requirements

Prevent accidents to heavy equipment by: • maintaining safety features on equipment • systematically maintaining equipment and making

repairs • training operators • training repair and maintenance personnel • training employees• planning work processes

16-3. Hand Signals for Flaggers


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Chapter 17Hand and Portable Power Tools


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17-1. Safety Practices

1. Provide proper protective equipment. – eye and face protection – hand and arm protection – respiratory protective equipment – hearing protection

2. Select the right tool for the job. 3. Know if a tool is in good condition and keep it in good

condition. 4. Properly ground power tools, using a ground-fault circuit

interrupter (GFCI) protected circuit. 5. Use tools correctly. 6. Keep tools in a safe place.

By observing the following six safety practices, most unintentional incidents with hand tools and portable power tools can be eliminated.


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17-2. Necessary Safety Program Activities

• Train employees to select the right tools. • Establish regular tool inspections. • Train and supervise employees to correctly use tools. • Establish a procedure to control company tools. • Provide proper storage areas. • Enforce the use of proper personal protective

equipment. • Plan each job well in advance.


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17-3. Inspection Checklist for Portable Electric Tools


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17-4. Types of Hammers

Types of Hammers • common nail hammers • nail hammers • ball peen hammers • sledgehammers • hand-drilling hammers • bricklayer’s hammers • riveting and setting

hammers

• other hammers – scaling – chipping – soft-face – nonferrous – magnetic – engineer’s – blacksmith’s – spalling hammers – woodchopper’s mauls

Hammers are made in different shapes and sizes, with different configurations and varying degrees of hardness. Each hammer has a specific purpose.


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17-5. Basic Rules for Selecting and Using Hammers

• Always wear eye protection • Always strike a hammer blow squarely-avoid glancing

blows, overstrikes, and understrikes. • When striking another tool, the striking face of the

hammer should have a diameter approximately 3/8-inch larger than the struck face of the tool.

• Always use a hammer of suitable size and weight for the job.

• Never use a hammer to strike another hammer. • Never use a hard-surface hammer to strike another

harder surface. • Never use a hammer with a loose or damaged handle. • Discard any hammer if it shows dents, cracks, chips,

mushrooming, or excessive wear.


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Chapter 18Woodworking Machinery


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18-1. Rules for Safe Operation of Woodworking Tools


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18-2. Rules for Safe Operation of Woodworking Tools (Cont.)


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18-3. Minimizing Hazards in Saw Operation

• All saws pose potential hazards for operators. Safety and health professionals can minimize these hazards by – providing training for operators– ensuring that all machinery is properly guarded– making sure that all ANSI, NFPA, and government

regulations are followed


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Chapter 19Welding and Cutting


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19-1. Pulmonary Irritants and Toxic Inhalants

• beryllium• cadmium• chromium• copper• fluoride• lead• magnesium

• manganese• mercury• molybdenum• nickel• titanium• vanadium• zinc


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19-2. Protective Clothing for Welders

• flame-resistant gauntlet gloves—leather or other suitable material (may be insulated for heat)

• aprons made of leather or other flame-resistant material to withstand radiated heat and sparks

• for heavy work, fire-resistant leggings, high boots, or similar protection

• safety shoes, whenever heavy objects are handled (because of spark hazard, avoid using low-cut shoes with unprotected tops)

• for overhead work, capes or shoulder covers of leather or other suitable material. Skull caps of leather or flame-resistant fabric may be worn under helmets to prevent head burns. Also, for overhead welding, ear protection is sometimes desirable.

• safety hats or other head protection against sharp or heavy falling objects


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Chapter 20Metalworking Machinery


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20-1. Rules for Safely Operating Machine Tools

• Never leave machine tools running unattended, unless the machine has been designed to do so.

• Never wear jewelry or loose-fitting clothing, especially loose sleeves, loose shirt or jacket cuffs, and neckties.

• Cover or tie long hair that could be caught by moving parts.

• Wear eye protection. This rule extends to others in the area, such as inspectors, stock handlers, and supervisors.

• Do not contaminate the metal removal fluid (e.g., discard refuse or spit into the tool’s coolant sump or reservoir). This action can create a chemical imbalance.

The following rules apply to safely operating any machine tool. Be sure that operators know and follow these rules:

• Do not manually adjust and gauge (caliper) work while the machine is running.

• Use brushes, vacuum equipment, or special tools for removing chips. Do not use hands.

• Understand the differences in machining ferrous and nonferrous metals, and know the health or fire hazards of working with these metals.

• Use the proper hand tools for each job.


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20-2. Grinder Checklist


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Chapter 21Working with Hot and Cold Metals


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21-1. Point of Operation Safeguarding Devices

• Fixed Die-Enclosure Guards—provide the most complete protection for the operator because the die is completely enclosed and the guard is a permanent part of it

• Fixed-Barrier Guards—should be attached to the frame of the press or to the bolster plate

• Interlocked Press-Barrier Guards—provide ready access to the die because they are designed with a pivoting, sliding, or removable section

• Adjustable-Barrier Guards—may be used when a die-enclosure guard or fixed-barrier guard is too time consuming to use, impractical, or both


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21-2. Procedure for Removing Dies

1. Make sure the work space is cleared of all stock, containers, tools, and other items.

2. Disconnect the power and lock out the switch.

3. Dismantle or disconnect the point-of-operation safety devices.

4. Clean off the bolster plate.5. If the die is to be operated

with an air pad, shut off the air supply and open release valve.

6. Remove bolts and clamps holding the die in place.

7. Ensure that the die is loose.8. Raise the arm slowly.9. Block the ram in its highest

position.10.Place the die truck close to

the press and ensure that the truck is stable.

11.Inspect, repair, and protect dies before storing them.


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21-3. Types of Power Press Brakes

• mechanical press brakes• hydraulic press brakes

General Purpose—operated by one individual with a single operating control station

Special Purpose—operated by one or more operators. Each operator should have a control station appropriate to the piece-part production system in use


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21-4. Maintenance Checklist for Steam Hammers


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21-5. Nondestructive Testing Methods

1. magnetic particle inspection 2. penetrant inspection 3. ultrasonic methods 4. triboelectric method 5. electromagnetic tests 6. radiography


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Chapter 22Automated Lines, Systems, or Processes


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22-1. Flowchart for Hazard and/or Risk Assessment


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22-2. 10 Rules for Safe Chemical Processing Operations


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Chapter 23The Computer as a Safety Information Tool


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23-1. Uses of Electronic Information by the SH&E Professional

1. As a reference tool—provides a less expensive and less time consuming way to keep track of rapidly changing regulations and technologies

2. As a networking tool—provides quick access to technical issues in specific fields, tips on how to approach specific problems, identifies prospective partners and/or consultants

3. As a safety culture tool—an organization’s website may provide for online training, a reference library, and a way to provide safety awareness

4. As an safety program management tool—enables data from specific environmental sampling instruments to be collected, organized, and managed effectively and efficiently

Chapter 24 Process Safety Management


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24-1. Basic PSM Programs

When developing a PSM program, management should consider:

• Incident-prevention objectives • existing employer and contractor PSM programs • use of internal resources versus outside consultants


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24-2. Four Types of Process Safety Compliance Inspections

1. Inspections Resulting from Responses to Accidents and Catastrophes

2. Unprogrammed Process Safety Management-Related Inspections

3. Programmed General Industry Inspections 4. Program Quality Verification Inspections

Chapter 25Aviation Safety


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25-1. The Federal Aviation Administration Responsibilities

FAA’s responsibilities include:•Register aircraft•Issue air-worthiness certifications•Approve aircraft designs and productions•Authority over airports in the form of regulating:

– safety– environmental programs– engineering design and construction– airport compliance– runway safety– fire fighting– safety management systems– wildlife strike prevention– administers air traffic control services through its operational arm – provide data and research to the public and the aviation industry


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25-2. Federal Aviation Administration Responsibilities (Cont.)

• Provide data and research to the public and the aviation industry

• Office of Accident Investigation and Prevention – provides preliminary accident and incident data for

the previous 10 working days accident and incident reports

• Aviation Safety Information Analysis and Sharing (ASIAS) system

• Oversee the certification types for airmen, aircraft, airlines, airports, and commercial outer space transportation

• Offer training and testing programs


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25.3. Elements Crucial to an Aviation Safety Management System (SMS)

• Safety and policy objectives—a formal safety policy signed by senior management and including top level commitments to implementing the SMS

• Safety risk management (SRM)—a five-stage process that identifies hazards and potential risks and encourages the design of risk mitigation strategies

• Safety assurance—policies that address auditing, oversight, and correction of discrepancies with input, review, and feedback from multiple sources

• Safety promotion—all aspects and levels of safety-related education and communication within an organization, which directs resources toward the goals of continuous improvement set forth by the formal safety policy


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Chapter 26Oil and Gas Safety


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26-1. Three Segments of the Oil Industry


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26-2. Four Elements of the Hazard Management Process


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26-3. Safety and Health Hazard Categories


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Chapter 27Waste and Recycling Safety


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27-1. Three Groups of Solid Waste Industry

1. Collection2. Treatment and disposal3. Other waste remediation services


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27-2. EPA Requirements for Landfill Design and Operation

• Location restrictions—ensure that landfills are built in suitable areas. • Composite liner requirements—include a flexible membrane overlaying

2 ft of compacted clay soil lining the bottom and sides of the landfill.• Leachate collection and removal systems—sit on top of the composite

liner and remove leachate from the landfill.• Operating practices—compact and cover waste frequently with several

inches of soil to help reduce odor; control litter, insects, and rodents.• Groundwater monitoring requirements—require testing groundwater

wells to determine whether waste materials have escaped from the landfill.

• Closure and postclosure care requirements—include covering landfills and providing long-term care of closed landfills.

• Corrective action provisions—control and clean up landfill releases and achieve groundwater protection standards.

• Financial assurance—provides funding for environmental protection during and after landfill closure (i.e., closure and postclosure care).


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27-3. Exposure to Potentially Hazardous Equipment

• Waste and recycling workers often complete tasks in close proximity to a variety of hazards, including heavy equipment and machinery with moving parts such as conveyor belts, push blades, balers, and compactors. To reduce hazards:– Facility operators should develop an employee equipment

orientation program and establish safety programs to minimize the risk of injury.

– Use lockout/tagout systems.– Implement and strictly enforce rules requiring that visiting

children and pets remain in the vehicle at all times. – Post signs and apply brightly colored paint or tape to

hazards alerting customers to potential dangers.


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©2015 National Safety CouncilACCIDENT PREVENTION MANUAL FOR BUSINESS & INDUSTRY Engineering & Technology 1