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CENTER FOR WORKFORCE DEVELOPMENT

Version :: CUCWD 106 :: Rev 1 2013

This material is based upon work supported by the National Science Foundation under Grant Number DUE-1104181. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.

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Copyright © 2013 Clemson University Center for Workforce Development. All Rights Reserved.

* License information for illustrations and photographs can be found in the Attribution Table within the Open Text for each course module.

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CENTER FOR WORKFORCE DEVELOPMENT 6SAFETY

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6 Material Handling & Electrical Safety

» Define Material Handling Equipment and compare and contrast the types of Material HandlingEquipment.

» Outline the hazards associated with the various types of Material Handling Equipment and dis-cuss the safety practices that should be implemented when using and storing this equipment.

» Describe the classifications of Hazardous Materials and identify the chemical and physicalhazards associated with these materials.

» Discuss the safety measures for preventing accidents associated with hazardous materials anddefend the need for each safety measure.

» Analyze the causes of, and physical effects associated with, electrical shock and apply the ap-propriate NEC Hazard Prevention Guideline(s) to each cause and effect.

OBJECTIVES

What is Material Handling Equipment and how do the types of Material Handling Equipment differ from one another?

What hazards are associated with the various types of Material Handling Equipment and what safety practices that should be implemented when using and storing this equipment?

Can you describe the classifications of Hazardous Materials and identify the chemical and physical hazards associated with these materials?

What are the safety measures for preventing accidents associated with hazardous materials and why are these safety measures necessary and important?

Can you analyze the causes of and physical effects associated with electrical shock and apply the appropriate NEC Hazard Prevention Guideline(s) to each cause and effect?

The learner will be able to:

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INTRODUCTIONManufacturing facilities use various types of materials and equipment that are transported throughout the facility during the manufacturing process of their products. Handling the movement of these materials involves lifting, which is one of the leading causes of injury in the workplace as it can lead to back injuries. Transporting manufacturing materials also involves the use of equipment such as industrial trucks, pry trucks, slings, conveyors, forklifts, and cranes. Improper handling and storage of these materials and this equipment can cause serious health and safety hazards, including fire-related accidents and physical injuries due to slipping, tripping, and falling.



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6.1.0 Safety in Material Handling and Material Storage

Electricity-related hazards are also common in manufacturing facilities. These hazards include electrical shock, ignition of explosive materials, uncontrolled activation of machinery, and overheating and equipment burns. Proper safety measures have to be employed in industries to protect workers from these hazards.

This module covers safety practices associated with material handling and equipment storage. Also discussed are the potential hazards involved in material handling and storage, and the safe practices for avoiding these hazards.

Appropriate material handling and storage is important because hazards associated with these processes can result in fire or spill-related accidents and physical injuries due to slipping, tripping, and falling. Improper storage of materi-als such as unstable stacking of loads on pallets, exceeding safe limits for weight on storage racks, and stacking materi-als higher than the allowable limit can also be hazardous to workers. According to the National Safety Council (NSC), 20 to 25% of all worker injuries occur during material handling. Proper handling and storage of materials can be achieved only if the workers are aware of the potential hazards as-sociated with them as well as with the appropriate storage equipment and the safety practices associated with its use. Equipment used in industries needs to be properly operated to ensure that there are no safety or health hazards to the workers using it. The following section deals with material handling equipment and its potential hazards.

6.1.1 MATERIAL HANDLING EQUIPMENT

Material handling equipment includes any tools or machines that are used to lift or transport materials throughout a manu-facturing facility. This equipment simplifies the required mate-rial handling process and prevents the need for manual han-dling. Improper use of this equipment can result in safety and health hazards. The following sections focus on the types of material handling equipment including their potential hazards and the safety practices recommended for avoiding them.

6.1.2 INDUSTRIAL TRUCKS

Industrial trucks are used for moving heavy materials during a manufacturing process. Examples of industrial trucks include forklift trucks, tractors, motorized hand trucks, platform lift trucks, and trucks for specific industrial applications. Most of these industrial trucks are operated by electricity or propane and are referred to as powered industrial trucks. These trucks are



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charged in a designated area in the plant. Smoking near charging trucks can be very hazard-ous as these trucks have the potential to leak flammable liquids.

6.1.2.1 Pry Trucks

A pry truck (Figure 1), referred to as pry lever bar, is operated manually as workers use the L-shaped frame and wheels to push heavy materials. Overloading the pry truck could cause the materials to fall or spill. Workers should avoid this hazard by placing heavier materials at the bottom of the pile and by securing larger loads with straps.

6.1.2.2 Conveyors

Conveyors are used for moving materials from one part of the plant to an-other. The types of conveyors used in industry include belt conveyors, over-head conveyors, and screw conveyors. Conveyors can be very hazardous as evidenced by situations where workers have been killed, dismembered, or pulverized as a result of getting caught.

Belt conveyors have in-running nip points (Figure 2) and pulleys to control the belt movement. If thesein-running nip points get ahold of a body part such asan arm or a hand, there is the possibility of a worker’sbody being drawn into the machine. Loose clothing orlong hair can also get caught in the conveyor, causingserious injury to the worker. Serious injury can be pre-vented by installing guards on the in-running nip points,which act as protection devices or shields without inter-fering with the operation of the conveyor.

Overhead conveyors are used for transporting large loads. Hooks attached to a moving chain support the items on the belts. Like belt conveyors, overhead con-veyors also have in-running nip points. Fewer hazards are caused by overhead conveyors than by belt convey-ors because overhead conveyors do not have as many in-running nip points and the moving parts are located farther from the worker. Figure 3 shows an overhead conveyor and you can see that it is located well above from where a worker stands. Hazards associated with overhead conveyors include the possibility of dropping loads from the conveyor onto the plant floor or onto workstations. A safety measure preventing this hazard involves positioning screens or guards underneath the moving conveyor.

Figure 1. Pry truck

Figure 2. In-running nip points

Nip point

Figure 3. Overhead conveyor



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Screw conveyors are potentially dangerous because of their in-going nip point at the intake, which must be se-cured tightly to the material being transported in order to work properly. Since many employees work in close proximity to the conveyor, safety measures must be taken. For example, a screen can be installed to enclose the intake area and a small opening can be provided for the transportation of materials.

6.1.3 LIFTING EQUIPMENT

Lifting equipment used in industrial settings includes forklift trucks, platform lift trucks and cranes.

6.1.3.1 Forklift Trucks

Forklift trucks, powered industrial trucks used for trans-porting materials, are the most commonly used lifting equipment in industries. OSHA estimates that approxi-mately 1 million forklift trucks are used in industry. Most forklift accidents occur when workers attempt to inappropriately ride on the lift trucks. Forklift trucks are designed to lift materials, not people. If they are to be used for lifting persons, proper safety measures should be taken. These safety measures include securing a safety platform to the lifting fork, allowing the person on the platform to shut off the power to the truck, providing protection from falling objects, and ensuring passengers do not distract the driver.

A second potential hazard occurs if the fork on the forklift hits an obstruction and objects fall on personnel directing the truck driver. This situation can be avoided if workers do not stand beneath the elevated fork or in a position between a fixed object and an approaching truck.

Figure 4. Screw conveyor

Figure 5. Forklift

1. Use seat belts if available2. Keep arms and legs inside the

truck3. Never jump from a moving

truck4. Never operate a truck with an

internal combustion enginewithout adequate ventilation

5. Do not carry passengers6. Keep at least 3 vehicle lengths

between trucks7. Observe all traffic signals

8. Maintain at least a 10 footclearance from overheadpower lines

9. Keep forks raised 4 to 6inches while driving

10. Use wall mount mirrors to seearound corners when driving

11. When carrying a load on aramp, the forks should alwayspoint up ramp

12. When traveling on a rampwithout a load, the forks shouldalways point down ramp

13. Tilt loads backwards beforetraveling

14. When carrying a load, placethe forks as wide as possibleand never exceed the trucksload rating

15. Tie down unstable loads anddrive in reverse if the loadobscured your forward vision.

16. Sound the horn atintersections

17. Tilt the load back before lifting

17 OPERATOR SAFETY RULES

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6.1.3.2 Cranes and Slings

Cranes and slings are used for handling materials that cannot be handled by industrial trucks because of their size and weight. Slings consist of a line with a strap, chain or rope that is used to lift or pull a load. Cranes use a track or an overhead rail structure for moving through the manufacturing plant. Figure 6 shows an overhead traveling crane, also called an overhead bridge crane. The safety issues related to cranes involve their numer-ous moving parts and the accidents it can cause to the workers such as falling objects. The moving parts of the cranes need to be inspected thoroughly by a qualified inspector to ensure that they do not present a hazard.

Each crane has specified load limits. Cranes capable of lifting medium to heavy loads are typically used in manufacturing facilities. Overloading the cranes can result in severe accidents that can cause injuries to crane workers as well as workers on ground. Crane operators should undergo training and should be aware of the risks and consequences of overloading cranes beyond their acceptable limits. Drivers of the cranes that are meant for outdoor operations should be aware of the hazards that can occur due to wind. Certain cranes are equipped with an automatic rail clamp that locks the crane or make it immovable if wind speeds reach a certain velocity.

6.1.4 SAFETY PRACTICES

Material handling in industrial settings involves certain risks. For instance, back injuries can occur when workers continually lift heavy objects or if a worker is struck by an object. Additional injuries associated with material handling can result when workers are caught in pinch points or crushed by a machine. Workers can reduce the number of safety hazards in their workplace by identifying and correcting any material handling problems they observe. Following the safety guidelines of organi-zations like OSHA and EPA can also help to reduce the number of safety hazards. Specific safety practices that can be followed in material handling and storage are discussed below.

6.1.4.1 Safety practices for handling materials

» Carefully look over any object before lifting it, specifically checking for sharp edges that cancut your hand. If you find any, wear protective gloves. Greasy, wet, or slippery objects needto be cleaned before lifting to avoid slippage of objects.

» Follow the safe lifting practices prescribed by OSHA standards.» Avoid carrying objects that block your vision.» Avoid changing your grip while carrying an object.» Avoid awkward body positions while setting down objects.» Avoid pulling when using material handling equipment such as a hand truck or pry truck

since pushing gives you more control of the material than pulling does.» Suspended loads should not be left unattended.» Workers should use at least 2 straps placed equally from the center when lifting a long I-beam.

Figure 6. Overhead traveling crane



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6.1.4.2 Safety practices for storing materials

» Stack boxes and cartons by cross tying when the stack height is above your head.» Place bagged or stacked materials on platforms to avoid moisture absorption.» Store pipes and bar stock in racks or in piles. The layers can be separated by wood strips

and provided with end blocks.» When storing large machinery and equipment in designated areas, it is a good practice to

store them in rows and to leave walkway space between them.» When storing wire and cable, it is a good practice to block large reels to prevent rolling.» Store gas cylinders upright in racks.» Hazardous chemicals or substances should be stored in bulk in a well-ventilated and

temperature-controlled room.

Activity 6.1.1» Match the following material handling equipment to the appropriate descriptions.

1. Operated manually as workers use the L-shaped frame and wheels to push heavymaterials. Overloading is a potential hazard.

2. Involves the use of in-running nip points that can potentially draw limps, hair, orclothing into the machine.

3. Used for moving heavy materials during a manufacturing process and includes vehiclessuch as forklift trucks, tractors, and platform lift trucks.

4. Used for handling materials that are too large or heavy for to be handled by industrialtrucks.

Activity 6.1.4» Complete the following sentences.

1. Avoid when using material handling equipment such as a hand truck or pry truck since gives you more of the material than does.

2. chemicals or substances should be stored in in a and room.

3. Greasy, wet, or slippery objects need to be before to avoid of objects.

4. When storing machinery and equipment in designated areas, it is a good practice to store them in and to leave space between them.

a. Industrial Trucks b. Pry Trucks c. Conveyorsd. Overhead Conveyers e. Screw Conveyors f. Lifting Equipment

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Hazardous materials can be classified based on the guidelines of government agencies such as the Occupational Safety and Health Administration (OSHA), the Environmental Protection Agency (EPA), the Department of Transportation (DOT), and the National Fire Protection Association (NFPA). One way of classifying hazardous materials is by their state: mist, dust, fume, solid, liquid, va-por, and gas. Another classification scheme is based on whether the hazard is a result of their physi-cal or chemical form. Physical threats posed by hazardous materials can be due to the physical state (e.g. pressurized gas) or the physical properties (e.g. flammability) of the material. Chemical hazards result from the chemical reaction that occurs when a reactive material (materials that can cause irrita-tion to human skin) comes in contact with the human body. Chemical hazards include acute or seri-ous (e.g. toxic, highly toxic, skin hazard, eye hazard, corrosive, and irritant) and chronic or long-lasting hazards (e.g. carcinogen, liver toxin, kidney toxin, lung hazard, nervous system hazard, and blood toxin hazard). One example of a hazardous material is benzene. Benzene is flammable, can cause skin ir-ritation, and is a carcinogen. Figure 7 shows the signs that indicate flammable gases.

Most chemical accidents occur when the amount of the hazardous material that comes in contact with the human body or is inhaled or consumed by a worker exceeds certain limits. Below is a list of the hazardous materials and their classifications.

Chemical hazard Hazardous materials

Toxic Acrylonitrile, ammonia, aniline, boron, trifluoride, epichlorohydrin, and ethylene oxide

Highly toxic Aldrine, benzene, ethyleneimine, hydrogencyanide, and organomercurials

Skin hazard Acetone, chlorinated compounds, cryogenic compounds, cutting oils, fiberglass, and methyl ethyl ketone

Corrosive Glacial acetic acid, hydrochloric acid, caustic soda, hydrofluoric acid, phenol, and sulfuric acid

Irritant Ammonia, ethanol, nitric oxide, sodium hypochlorite, and stannic chloride

Carcinogen Acrylonitrile, asbestos, benzene, beryllium, formaldehyde, and carbon tetrachloride

Liver toxin Carbon tetrachloride, ethanol, chloroform, nitrosamines, trichloroethylene, and vinyl chloride

Kidney toxin Ethanol, halogenated hydrocarbons, and trichloroethylene

Lung hazard Asbestos, beryllium, coal dust, cotton dust, and silica

Nervous system hazard Carbon disulfide, ethanol, mercury, and tetraethyl lead

Blood toxin hazard Carbon monoxide, cyanides, metal carbonyls, nitrobenzene, hydroquinone, aniline, and arsine

6.2.0 Handling Hazardous MaterialsSubstances that can cause harm or damage to material, person-nel, and property is referred to as hazardous materials. Typically these hazardous materials and chemicals are used in the manu-facturing process or generated as by-products, and proper care should be taken in handling and storing them.

Figure 7. Flammable gas signs



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The physical dangers of hazardous materials include fire hazards, reactive hazards, and pressure hazards. Fire hazards occur due to combustible materials such as mineral spirits, methyl cellosolve (a hazardous organic compound used as a solvent in industries) and #1 fuel oils (oils obtained as by-products of petroleum distil-lation that are hazardous materials). Hazards associated with fire also result from flammable materials such as aerosol. Typically, combustible material accidents occur at higher temperatures while flammable material accidents occur at room temperature. Pres-sure hazards are caused by a sudden release of pressure (i.e. an explosion) by explosive materials such as TNT and nitroglycerine. Organic peroxides such as cyclohexene, cyclooctene, decalin, tetra-hydrofuran, and tetralin can cause reactive hazards since they are highly sensitive to shock and are highly flammable. Reactive hazards can also occur due to water reactive chemicals such as calcium carbide, metal hydrides, and metals like sodium and potas-sium. Water reactive chemical are those chemicals that reacts are when in contact with water which in turn can sometimes result in hazards like excessive heat.

Since hazardous materials can cause severe safety and health hazards, managers and workers in manufacturing companies should implement and practice safety measures while handling them. Isolating the hazardous materials by time, distance, and shielding can help reduce these hazards. Another safety measure is to provide proper ventilation, which helps prevent problems caused by airborne hazardous materials. Wearing respirators (devices to protect workers from inhaling harmful gases, fumes, and dusts) an also reduce worker exposure to airborne hazardous materials. Workers handling or working close to hazardous materials should always wear protec-tive clothing like gloves, aprons, coveralls (protective clothing that can be worn by workers to protect their body from industrial hazards), and protective suits.

Activity 6.2.0a» List the chemicals associated with the following hazards.

1. Toxic:

2. Corrosive:

3. Liver toxin:

4. Nervous System Hazard:

5. Reactive Hazard:

Activity 6.2.0b» Identify the classification of the following hazardous material characteristics as State or

Form.

1. Pressurized gas:

2. Gas:

3. Liquid:

4. Flammable Liquid:8



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Working with machines powered by electricity can be very danger-ous. According to OSHA statistics, several hundred deaths occur in work places due to electrical hazards, most being caused by elec-tric shock and static electricity. To reduce the number of electrical hazards in industry, safety measures should be implemented and followed by workers. The following sections discuss the basics of electricity, the different types of electrical hazards, and the safety measures and practices for avoiding electrical hazards.

6.3.1 ELECTRICITY

The physical phenomenon associated with the flow of electric charges through a conductor is termed electricity (see the glossary for an explanation of electric charges and conductors).Electricity can be quantified by measuring the voltage, current, and resistance associated with a conductor. To visualize the flow of electric charges through a conductor, consider the exam-ple of water flowing through a pipe. Voltage (measured in volts) is analogous to the pressure of the water in the pipe; current (measured in amperes) is analogous to the total amount of water flowing through a point in the pipe per unit time (volume of water flowing per sec), and resis-tance (measured in ohms) is analogous to the obstruction to the flow of the water.

The severity of a worker’s injury depends on the density or amperage of the current that flows through his/her body, with higher intensities or amperage of current causing more severe harm than lower ones. Exposure to a 100 milli-Ampere (mA) current at 60 Hertz (unit of frequency, Hz) can be fatal. The highest current density from which an individual can release himself or make himself free from electric shock is 16mA. Most of the electricity sources used in indus-tries are well above 16mA and, hence, the risk of potential electrical hazards is high in this work environment. Thus, safety measures preventing electrical hazards need to be observed and enforced in industries for worker safety.

The following injuries can result from electrical hazards:

» Internal burns causing damage to the tissues, muscle, and nerves

» Slow healing external burns

» Muscle contractions and spasms

» Disruption of normal heart rhythm

» Paralysis

The serious nature of electrical hazards requires that first aid and resuscitative measures should be started immediately after the injury. These measures should be continued until the person affected is revived or declared dead by authorized medical personnel.

6.3.0 Electrical Safety



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6.3.2 ELECTRICAL HAZARDS

Electrical hazards are hazards that can cause injury to persons or damage to property either directly or indirectly due to electric-ity. Most electrical injuries occur due to electric shock or static electricity. Figure 8 shows a warning sign indicating a high voltage electrical hazard.

6.3.2.1 Electric Shock

Electric shock results when electric current flows through a hu-man body that has become part of an electric circuit. It causes injuries if the voltage is sufficient to overcome the resistance that the body provides to the current flow. For example, a body with dry skin exhibits a resistance high enough to protect a person from a mild shock. If the person’s skin is wet, then the resistance of the body decreases and the severity of the person’s injury caused by the shock increases. Thus, the density or amperes of current flowing through the body determines the severity of the injury caused by the electric shock. Additionally, the intensity of the shock also depends on the current path, the frequency, (number of cycles per second), and the duration the current flows through an individual’s body.

The table below shows the effects of electric shock due to different current densities at 60-hertz:

Current Density Effects1 milliampere Involuntary reflex action

5-25 milliamperes Individuals lose control of their muscles25 - 75 milliamperes Individual collapses, becomes unconscious, or dies.

75 - 300 milliamperes Irregular heartbeat. Blood circulation stops, causing lack of oxygen to the brain and tissues, potentially resulting in death.

> 2.5 amperes This current stops the heart as it flows through an individual’s body, resulting in loss of consciousness, respiratory paralysis, and skin burns.

6.3.2.2 Causes of Electric Shock

The five primary causes of electric shock are equipment failure, failures in electrical insulation, contact with a bare energized conductor, static electricity discharge, and lightning strikes.

Electrical Equipment Failure

Equipment failures such as broken connections or internal wiring problems can cause the housing or outer cover of the equipment (particularly handheld electrical equipment) to be powered. The users of the equipment are shocked when their body comes in contact with the housing. If the equipment is not grounded properly to provide an alternate path for the flow of current due to broken connections, current can flow through the body of the user, causing an injury.

Figure 8. High voltage electrical hazard warning sign

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Figure 9. Overhead electrical lines

Failures in Electrical Insulation

Most of the conductors that carry electrical current are insulated. Insulation is a non-conductive protective covering, completely surrounding electrical conductors. The deterioration of, or damage to, the insulation can create an electrical hazard. These insulation failures can occur due to heat, moisture and humidity, oxidation, radiation, mechanical damage, high voltages, and biological factors such as organisms that eat insulation materials made from organic materials.

Contact with a Bare Conductor

Bare conductors are those which carry electric cur-rent but are not insulated. Fatal electrical injuries can occur if a worker comes into contact with a powered overhead electrical line or another type of bare con-ductor.

Static Electricity Discharge

Static electricity is created when electric charge accumulates on the surface of an object. When placed in contact with other materials, atoms from some substances release one or more electrons. This movement of electrons from one atom to the next is called electron flow and often results in electricity. This electricity can either flow as a current or be released in the form of static electricity, depending on the availability of an escape route for the electron flow. Static electricity is electric charge trapped on a surface, usually created by the friction of one surface highly resistant to electrical current, with another. For example, when a piece of glass is rubbed against silk, some of the electrons in the glass are transferred to the silk. As a result, the glass acquires a positive charge and the silk acquires a negative charge. Static electricity can also be created by several other means for instance, by applying mechanical stress to certain crystals or ceramics, through heat, or even by bringing an electronically charged object close to a neutral one.

Another example of static charge generation is the accumulation of charge on a per-son’s body when they walk across a wool or nylon carpet. When the person approaches a conductive surface that is grounded, a rapid discharge of the accumulated charge oc-curs as it provides a path for the electronic charge accumulated on the person’s body to flow, and the person is shocked. The intensity of the shock depends on the amount of charge that has accumulated on his/her body. Static electric hazards can be reduced or prevented by proper grounding, laying rubber matting on the floors, and wearing static control wristband.

Lightning Strike

Lightning is a natural static electricity discharge involving high voltages of and high cur-rent flow approximately 100 million volts and 30,000 amperes. Lightning occurs only under certain atmospheric conditions when the cloud above earth’s surface acquires higher amperes of electric charges. Lighting is unpredictable and is due to the electro-



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static discharge of the charges accumulated in the clouds to the earth. The current due to electrostatic discharge follows the path of least resistance from a cloud to the earth. Lightning becomes a hazard to humans when a person acts as a path of least resistance for the electrostatic discharge from cloud to the earth. One possibility for this is when he is standing in a deserted area with no buildings or trees near him. If a build-ing or a tree with a height higher than the person was present near him, then it can act as the path of least resistance for the discharge and can get damaged.

To protect humans and buildings from lightning hazards, light-ning rods (Figure 10) are constructed near the buildings and deserted areas. There are made of highly conductive materials and are grounded properly (connected to earth). Lightning rods are constructed in such a way that they are higher than the nearby buildings. When lightning occurs, lightning rods provide a least resistance path for the electrostatic discharge from the cloud to the earth.

6.3.3 SAFETY MEASURES FOR PREVENTING ELECTRICAL HAZARDS

The National Electrical Code (NEC) published by the National Fire Protection Association (NFPA) NEC Committee mandates specific guidelines that are to be followed in industrial set-tings to minimize the potential for electrical hazards. Engineers, electrical contractors, and inspectors need to follow the NEC to ensure worker safety. Specific safety measures that can be followed to prevent electrical hazards are given below:

» Electrical equipment shut down for maintenance or repair should be de-energized (removedfrom its power source) and locked out.

» A warning sign should be placed near the electrical equipment shut down for maintenance orrepair

» Electrical equipment parts that can come in contact with workers need to be insulated.

» Non-conductive mats such as ones made from rubber should be provided for workers tostand on when operating electrical equipment to protect them from electric shock.

» Warning devices should be connected to energized electrical equipment to indicate its status(e.g. on-off sign).

» Visible markings (warnings) should be placed near hazardous electrical equipment to warnworkers of potential hazards.

» Avoiding the use of materials that can generate static electricity is the simplest method forpreventing hazards due to static electricity discharges (e.g. wearing cotton clothes instead ofclothes made of nylon or wool).

» Humidification, or increasing the humidity, can cause static charges to disperse.

» A metal structure or a building protected from lightning should be used for shelter during alightning storm.

» If lightning occurs when a person is outside (e.g. in a field) and far away from elevatedpoints, the safest thing to do is lie down on the ground.

Figure 9. Lightning rod



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Activity 6.3.3» Match the following causes of electrical shock with the appropriate descriptions.

1. Rapid discharge of an accumulated charge.

2. Improperly grounded equipment does not provide an alternate path for the flow of cur-rent.

3. Power lines that are fatal if touched because they carry electric current but are notinsulated.

4. Injury results from the deterioration or damage of insulation caused by heat, moisture,oxidation, radiation, mechanical damage, and biological factors.

a. Equipment Failure b. Insulation Failure c. Static Electricityd. Bare Energized Conductor e. Lightning Strike

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NOTES



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Key Concepts

» Any tools or machines that are used to lift or transport materials throughout a manufac-turing facility are material handling equipment.

» Material Handling Equipment types and hazards:

– Industrial Trucks: potential to leak flammable liquids

– Pry Trucks: potential to overload

– Conveyors: potential for in-running nip points to draw limps, hair, or clothing into the machine

– Lifting Equipment: potential to be ridden inappropriately or drop materials on per-sonnel directing the driver

– Cranes and Slings: potential for operator error or malfunctioning moving parts

» Hazardous Materials can be classified based on their state (mist, dust, fume, solid, liquid, vapor, or gas) and their form (physical or chemical form).

» Potential hazards of hazardous materials include: toxic, skin hazard, corrosive, irritant, carcinogen, liver toxin, kidney toxin, lung hazard, nervous system hazard, blood toxin, fire hazard, pressure hazard, and reactive hazard.

» Safety practices for preventing hazardous material accidents include, isolating the hazard-ous materials by time, distance, and shielding, providing proper ventilation, wearing respi-rators, and wearing protective clothing like gloves, aprons, coveralls, and protective suits.

» Causes of electric shock: equipment failure, electrical insulation failure, contact with bare energized conductor, static electricity discharge, and lightning strikes.

» Physical effects of electric shock include: internal burns, slow healing external burns, muscle contractions and spasms, disruption of normal heart rhythm, and paralysis.

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Key Terms

Further Study

6.1 Hazards pg.1

Material handling equipment pg.2

In-running nip points pg.3

Forklift trucks pg.4

Cranes and slings pg.5

6.2 Hazardous material pg.7

Methyl cellosolve pg.8

#1 fuel oils pg.8

Explosive materials pg.8

Respirators pg.8

Coveralls pg.8

6.3 Electrical hazards pg.9

Electric charges pg.9

Conductor pg.9

Electricity pg.9

Voltage pg.9

Current pg.9

Resistance pg.9

Volts pg.9

Amperes pg.9

Ohms pg.9

Hertz pg.9

Spasms pg.9

Paralysis pg.9

Electron flow pg.11

Lightening rod pg.12

BOOKS

– “Industrial Safety and Health Management,” C. Ray Asfahl and David W. Rieske.

– “Occupational Safety Management and Engineering,” Willie Hammer and Dennis Price.



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This material is based upon work supported by the National Science Foundation under Grant Number DUE-1104181. Any opinions, findings, and conclusions or recommendations expressed in this material are those of the author(s) and do not necessarily reflect the views of the National Science Foundation.

Copyright © 2013 Clemson University Center for Workforce Development. All Rights Reserved. 15

» #1 fuel oils: Oils obtained as by-products of petroleum distillation that are hazardous materials » Ampere: The unit of current is called an ampere » Conductor: A material that is capable of carrying electric charges, e.g. copper and aluminum » Coveralls: Protective clothing that can be worn by workers to protect their body from industrial hazards

» Cranes and slings: Used for handling materials that cannot be handled by industrial trucks » Current: The flow of electric charges » Electron flow: The movement of electrons from one atom to the next; often results in electricity » Electric charge: Occurs when electrically charged matters experience some amount of force when they are near other electrically charged matters

» Electrical hazards: Hazards that can occur in industries caused by electricity » Electricity: The physical phenomenon associated with the flow of electric charges through a con-ductor

» Explosive materials: Highly reactive substances possessing large amounts of energy and can produce a large explosion

» Forklift trucks: Powered industrial trucks used for transporting materials throughout a manufac-turing facility

» Hazardous materials: Substances that can cause harm or damage to material, personnel, and property can be termed as hazardous materials

» Hazards: Conditions that can pose some level of threat to health, life, property, or environment. » Hertz: Unit of frequency of an electrical signal » In-running nip points: Generated when one machine art moves past a stationary object; exam-ples include gear rollers, pulleys, and belt drives

» Lightening rod: Devices that are used to protect equipment or buildings from lightning hazards; Also called lightning arresters

» Material-handling equipment: Equipment that can be used for storing, moving, controlling and protecting materials

» Methyl cellosolve: A hazardous organic compound used as a solvent in industries » Ohm: The unit of resistance is called an ohm » Paralysis: The human body state in which muscles do not do their intended functions » Resistance: The friction offered by a material to the flow of current » Respirators: Devices used to protect workers from inhaling harmful gases, fumes, and dusts » Spasm: The physical condition of the body resulting from involuntary contraction of muscles » Volt: The unit of voltage is called a volt » Voltage: The difference in potential energy between two points of an electrical circuit



6SAFETY

16

Attribution Tables

OPEN TEXT, ASSESSMENT GUIDE & POWERPOINT

Author(s) Title Source License

Sam 907Handling

materials in industry

http://commons.wikimedia.org/wiki/File:Flooring_in_a_material_handling_area_at_Pharmaceutical_company_Lilly,_France.jpg

Public Domain

NASA/Jack Pfailer

Airplane lifted by sling

http://commons.wikimedia.org/wiki/File:STS-129_Orbiter_Atlantis_Sling_2.jpg

Public Domain

StationNTmediaPry truck/pry

leverbar

http://commons.wikimedia.org/wiki/File:PryLeverBar.jpg CC-BY-SA-3.0

r@ge Belt conveyorhttp://commons.wikimedia.org/wiki/File:Green-belt-conveyor.jpg

CC-BY-SA-3.0

Robin StottOverhead conveyor

http://commons.wikimedia.org/wiki/File:Overhead_conveyor_to_clay_sheds_-_geograph.org.uk_-_1740292.jpg

CC-BY-SA-2.0

Luca MarzadroScrew convey-

orshttp://commons.wikimedia.org/wiki/File:Marzadro-Tramoggia_carico_vinacce.png

CC-BY-SA-3.0

Marketing Team (Sa’ad Jafar)

Forklift truckhttp://commons.wikimedia.org/wiki/File:Forklift.JPG

Public Domain

RvancoppPackage lifted

by cranehttp://commons.wikimedia.org/wiki/File:DCC38974rvancopp.jpg

CC-BY-SA-3.0

http://www.hy-drogen.energy.

gov

Signs to in-dicate flam-mable gases

http://commons.wikimedia.org/wiki/File:DOT_Hazardous_Material_Placard_liq-uid_hydrogen.jpg

Public Domain

BipinSankar

Warning sign for a high volt-age electrical

hazard

http://commons.wikimedia.org/wiki/File:DANGERBOARD01.png

Public Domain

WtshymanskiBare

conductor

http://commons.wikimedia.org/wiki/File:Miccable.jpg CC-BY-SA-3.0

Microsoft Cli-part

Close up on Fire

http://officeimg.vo.msecnd.net/en-us/im-ages/MH900438774.jpg

With permission from Microsoft

James Heil-man, MD

Lightning injury

http://commons.wikimedia.org/wiki/File:Lighteninginjury.JPG

CC-BY-SA-3.0

16

http://www.hydrogen.energy.gov





6SAFETY

17

Attribution Tables

Ivan Walsh Respirator http://www.flickr.com/photos/ivanw-alsh/3922610374/sizes/m/

CC-BY 2.0

Benjamin Ra-gheb

Electricity At-tacks

http://www.flickr.com/photos/benza-do/208764794/

CC-BY 2.0

Microsoft Cli-part

Chemical drum

http://officeimg.vo.msecnd.net/en-us/im-ages/MH900400414.jpg


Microsoft Cli-part

Power lineshttp://officeimg.vo.msecnd.net/en-us/im-ages/MH900386066.jpg


U.S. Navy photo by Mass Commu-nication Spe-

cialist 3rd Class Charles Oki

Coveralls

http://commons.wikimedia.org/wiki/File:US_Navy_100930-N-2013O-007_A_Sailor_dons_firefighting_cover-alls_during_a_mass_casualty_drill_in_the_hangar_bay_of_the_aircraft_carrier_USS_George_.jpg

Public domain

http://www.flickr.com/photos/ivanwalsh/3922610374/sizes/m/

http://www.flickr.com/photos/ivanwalsh/3922610374/sizes/m/

http://www.flickr.com/photos/benzado/208764794/

http://www.flickr.com/photos/benzado/208764794/

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