Student Handbook On Workshop Safety

Student Handbook
on Workshop Safety

Copyright 2014, Ahmed Alramadan, TTC

This handbook has been designed and written for the students of the TTC as a guide to
the Safety Regulations and Procedures to be followed in the workshops.


1
Always Remember!
That the person responsible for your safety in the
workshop is YOU.
Emergencies:
Report all accidents and emergencies immediately.
How do I report an emergency?
Inform your Lecturer or person responsible for the class.
If there is no Lecturer present then a lecturer form a
nearby workshop/classroom should be informed.
Call the TTC first aid person at 0112762731/0112762 666.
Useful numbers you may need to call in an emergency:

o General Emergency Number: 112
o Ambulance (Medical Emergencies): 997
o Police (Crimes / Robbery): 999
o Civil Defense (Fire / Recue): 998
o Electricity (Electricity Service): 933

What should I say when the telephone is answered:
Say, This is an emergency!.
Describe the incident location.
Describe the incident.
Report injuries, if any.
Give your name and your phone number.
Repeat the above information.
Stay on the line until further instructed.


2
Safe working practices and procedures:

This handbook has been written as a guide to the safe working
practices and procedures which EVERYONE entering a workshop
or classroom in the TTC is expected to follow and adhere to at all
times. They should be READ and UNDERSTOOD by all
lecturers, trainers, technicians and trainees and anyone entering a
workshop or classroom at the Technical Trainers College.
Additional safety precautions/procedures may requested by the
lecturer or trainer or the responsible person at the area.
There are many aspects of workshop and classroom safety many
more then can be addressed in this handbook.
You must report immediately ANY unsafe equipment, conditions
or behavior which you encounter in a classroom or workshop to a
responsible person e.g. your lecturer or trainer.

Do not delay making your report or expect someone else will
report it.
Delaying or not making your report could be the cause of
someone getting seriously injured or worse.
If you discover an unsafe practice or situation: IT IS YOUR
DUTY TO REPORT IT IMMEDIATELY.
Failure to report it immediately could lead to you or one of
your fellow students or lecturers being seriously injured.


3
Table of content
Introduction ...................................................................................... 5
All workshops, laboratories and classrooms are equipped with
safety related items designed to be used in emergencies. ............... 6
Incident Reporting: .......................................................................... 6
Section 1 ........................................................................................... 7
Basic safety requirements: ............................................................ 7
Section 2 ........................................................................................... 9
Personal protective equipment PPE .............................................. 9
Section 3 ......................................................................................... 10
I. Safety in Welding, Brazing and Cutting: .............................. 10
II. Safety in electric arc welding operation: ............................... 11
III. Safety in gas welding, cutting and brazing operation: ....... 11
Section 4 ......................................................................................... 13
I. Safety in Handling Welding Cylinders ................................. 13
II. Safety in Using cylinders ...................................................... 14
Section 5 ......................................................................................... 15
Safety in copper pipe bending in the workshop ......................... 15
Section 6 ......................................................................................... 16
Safety use of Ladder ................................................................... 16
Section 7 ......................................................................................... 18
Safety in chemical ....................................................................... 18
Section 8 ......................................................................................... 19
Safety in maintenance in the workshop ...................................... 19
Section 9 ......................................................................................... 21


4
Safety in refrigeration workshops ............................................... 21
I. Safety in refrigeration gas: .................................................... 21
II. Safety in freezer room: .......................................................... 22
III. Safety in hoses for refrigeration: ........................................ 23
Section 10 ....................................................................................... 24
Safety in Electrical workshop ..................................................... 24
I. General electrical safety: ....................................................... 24
II. Soldering Iron Safety ............................................................. 25
Section 11 ....................................................................................... 26
Safety signs. ................................................................................ 26
I. 'Danger warning' signs ........................................................... 27
II. Signs required by law ............................................................ 28
III. 'Not allowed' signs .............................................................. 29
Student Test. .................................................................................. 30


5
Introduction

Before entering any of the workshops, laboratories or classrooms
you must have read and understood the safety regulations and
procedures which apply to that location.
If you have not read and understood the safety regulations and
procedures: DO NOT ENTER THE LOCATION UNTIL YOU
HAVE DONE SO. Your personal safety and that of everyone else
in that location could be compromised.
This handbook is designed to protect you and others from injury
and illness and to protect the property(including all equipment)
from damage by misuse, fire and other causes which may arise.
This handbook contains concise safety related information related
to working in or entering all of the student spaces in the TTC. It
also contains detailed information regarding the operation and use
of the tools and equipment contained/installed in the workshops,
laboratories and classrooms at the TTC.
When you have read and understood the specific sections in this
handbook related to your specialism you should complete the
student test at the back of the book.
When you have completed this test, show it to your lecturer and he
will correct it and sign to say that you have passed the test. When
you have obtained the lecturers signature you will then be able to
enter and work in the areas on which you have completed the
associated tests.


6
All workshops, laboratories and classrooms are
equipped with safety related items designed to be used
in emergencies.
Before entering or starting work: You should familiarize yourself
with the following safety items, their location, condition and
method of operation.

o You should know the location of first aid box.
o You should know the nearest assembly point.
o You should know the location of fire extinguishers.
o You should know the location of fire hoses.
o You should know the location of emergency exit.
o You should know what to do in case of emergency.
o You should know the location of eye wash.
o You should know the different sound of emergency sirens.

Incident Reporting:

o Immediately report all injuries they
inform your teacher or responsible no
matter how minor, get first aid
treatment, if necessary.
o Immediately report all fires, spills, and
releases, no matter how small, to the instructor.
o Immediately report any unsafe conditions, practices, near
misses or incidents to the instructor.


7
Section 1
Basic safety requirements:

Applicable to all students irrespective of specialism:
This section of the safety handbook applies to all areas of the
college i.e. workshops, laboratories and classrooms.
To ensure your own safety and that of your lecturers and
colleagues, the following points must followed at all times:

o Select the right tools and equipment for the task
in hand.
o Do not wear loose clothing or jewelry in the
workshops or laboratories.
o Select the right type of gloves for any given task
and WEAR THEM.
o Select the right type of safety glasses for each
task and WEAR THEM.
o Keep your work bench and area clean.
o Dont be distracted while you are performing a task.
o Do not clean your clothes by using compressed air, (shown in
Figure 1).
o Observe No Smoking regulations.
o Shut down your machine before cleaning, repairing, or
leaving it.
o Do not block access to fire extinguishers.
Figure 1 compressed air


8
o Do not operate machines or equipment
until you have been properly instructed
in their use and permitted to do so by
your lecturer/instructor.
o When lifting, use your leg muscles, not
your back muscles. For heavier loads,
ask for help.
o Do not throw objects.
o Clean up spilled liquid, oil, or grease immediately.
o Place trash and paper in proper containers.
o Dont drain any flammable, toxic or greasy materials into
sanitary system.
o Always use the safest method to move heavy objects e.g.
hand trucks whenever possible as (shown in Figure 2).
o Dont climb, stand or sit on equipment or unstable surface.
o Dont run in the work place except in emergency.
o Do not engage in horseplay or fighting in the work area.
o Dont operate or use any equipment that been tagged as
dangerous or do not use.

When you have finished studying this section, you should turn to
page 30 in the handbook and complete the test questions numbered
1 5. Your lecturer will correct them and sign off on this section
of the handbook for you.

Figure 2. Hand truck


9
Section 2

Personal protective equipment PPE

This section of the handbook is for students in RAC, PT.
Personal protective equipment (PPE) is clothing, equipment or
substances designed to be worn by someone to protect them from
risks of injury or illness.
PPE can include:
Always wear safety eye protection
while working.
Always wear safety face masks while
working.
Always wear safety lab coat while
working.
Always wear safety gloves while
working.
Always wear safety helmets while working.
Always wear safety ear protection while working.
Always wear safety Feet and legs protection while working.


Figure 3.PPE


10
Section 3

I. Safety in Welding, Brazing and Cutting:

General safety:
Welding equipment must be in the
clear sight of the user at all times.
All welding equipment must be in
good condition, any defects found
must be repaired immediately or the
equipment must be replaced.
All areas used for welding and brazing operations must be
well ventilated.
All loose work pieces must be properly secured.
All welding equipment must be turned off when not in use.
A portable fire extinguisher (of the correct type) must be
available within 3m.
Flammable materials around the work area must be removed
or protected.
A qualified fire watch must be maintained during welding
operations and for 30 minutes afterwards.


11
II. Safety in electric arc welding operation:

Also see electrical safety section.
Electric welding machines must be
bonded and grounded.
Welding cables must be continuous
within 3m of the electrode holder.
All damaged welding cables must be
removed from service and replaced,
do not attempt to repair or use taped
joints.
Welding screens of the correct type must be used at all times.

III. Safety in gas welding, cutting and brazing
operation:

Students should also read the section on compressed gas cylinders.
Lighted torches must not be left
unattended.
Compression type fittings must
be used on all hose connections.
All connections and equipment
must be checked for leaks prior to
use.
Flashback arrestors must be fitted
to oxygen and acetylene
cylinder regulators as shown in figure 4.
Figure 4. Flashback arrestor position


12
Cylinder regulators must be turned off
and hoses left open, so gas can escape.
Hoses must be protected from fire and
damage during welding operations.
Strikers must be used to light the torch,
do not use matches or a cigarette lighter,
shown in figure 5.
When opening the fuel cylinder valve, open it slowly.
Stand to the side of a regulator, not in front of it when
opening cylinder valves.
While acetylene cylinders are in use they must have a handle
or valve wrench in place at all times.


Figure 5.Strikers


13
Section 4

I. Safety in Handling Welding Cylinders

Secure protective caps on all
cylinders not in use, shown in
figure 6.
Secure cylinders in an upright
position while moving.
Use a cylinder trolley when
moving cylinders
Do not use ropes for moving
cylinders.
All cylinders must be labeled.
Do not strike cylinders together.
Valves must be closed when the cylinders are empty.

cap
Figure 6.Cap


14
II. Safety in Using cylinders

Proper pressure - reducing regulators
must be used and a check valve must be
connected to the cylinder valve.
If a leak occurs, close the cylinder
valve before attempting to stop the leak.
Never use oil or grease as lubricant on
regulator, valve or joints.
Markings on fittings must match the
cylinder valve outlet markings.
Make sure that the cylinder is in a good condition before
using.
Never use gas cylinders as rollers to move heavy equipment.
Protect cylinders from direct flame, sunlight and other heat
sources.
Make sure that all gauges, regulators, hoses and cylinder are
undamaged.

When you have finished studying this section, you should turn
to page 33 in the handbook and complete the test questions
numbered 16 20. Your lecturer will correct them and sign off
on this section of the handbook for you.


15
Section 5

Safety in copper pipe bending in the workshop
General safety:
Before starting, make sure that your
working area is clean.
Do not breathe refrigerant gas
vapors.
Do not use a hacksaw to cut the pipe.
Always wear safety gloves while
working.
After cutting the tubing, do not touch
it with your hands.
Do not blow into or use compressed air for cleaning the
pipes.
Place all unwanted tubing in the waste container.
Make sure that you clean the area after finishing the work.
Always use the correct size pipe cutter , (shown in Figure 7).
Keep the refrigeration piping clean and dry prior to
installation.
If a leak occurs check all of the refrigeration pipe-line
connections.
Figure 7. cutter


16
Section 6

Safety use of Ladder

There are limits to the safe use of
ladders and they should not be used
for working at heights above 6
metres.
Portable ladders must be supported
at the base and positioned on a
stable surface.
Do not use the ladder in wet
conditions.
Metal ladders must be fitted with
rubber feet, or a similar non-slip
material and it should be nonconducting.
Beware of overhead power lines when putting a ladder into
position.
Place ladders away from areas where there are hazards such
as sharp objects, machinery or chemicals.
Place ladders away from doors that could hit the ladder when
opened, or lock or barricade the doors to avoid inadvertent
opening.
Use only lightweight hand tools on a ladder and use the tool
bag.


17
Damaged ladder must not be used, if discovered they should
be removed and destroyed
All ladders must be inspected regularly for faults, cracks,
loose rungs etc.
Ladders must never be painted.



18
Section 7

Safety in chemical

Read the label before use any
chemical.
Lock chemicals in a cabinet if not use
it.
Do not mix chemicals.
Follow the manufacturer's instructions
and handle with extreme caution.
Do not reuse empty containers or
repack product in different containers.
Ensure all the time use the ventilation.
Do not prepare more chemical than you need it.
Do not use tools that generate heat or sparks near flammable
items.
Do not use the chemical for jobs for which they are not
intended.
Be very careful about chemical can cause irritation to the
eyes, throat, and skin.



19
Section 8

Safety in maintenance in the workshop

General maintenance:
Always ensure that your work
area is well lit.
Do not operate compressor
while system is in a vacuum.
Do not try to stop rotating
machinery by hand.
Always wear safety gloves
before starting work.
Before starting, make sure that the working area is clean.
Select the correct tool/s for the task in hand and then arrange
them.
When arranging the tools, place them near to you, so they
will be easy to access.
Unplug the power source from the machine before working
on, adjusting or moving the machine.
Ensure that the work area is clean when you have finished the
task.
Ensure that frequently used hand tools are placed on a work
belt or close to you.
Make sure that you understand the forces and mechanical
movement involved when using large machines.


20
All tools must be maintained in a clean and efficient working
condition.
Accumulated swarf should be removed from the machine by
means of a brush and not with the hands.
Seek assistance from an experienced operator of the machine
if in doubt.
Ensure that all electrical connections on the machine are
secure after cleaning or maintenance operations.
Manufacturers guidelines and service manuals must be
followed when carrying out routine maintenance of
machinery.
You must exercise extreme care when carrying out
maintenance operations on any moving parts.



21
Section 9

Safety in refrigeration workshops
I. Safety in refrigeration gas:

When checking for leaks you
should initially fill the system
using nitrogen for the
pressure test as using
refrigerant could be damaging
to the environment and would
cause the waste of expensive refrigerant.
You must ensure that the ventilation fans are switched on in
the area where the filling/charging of the system/appliance
with refrigerant takes place and when the refrigerant is being
recovered from the system/appliance.
Carry out regular inspections of the oil level in any vacuum
pumps being used.
Do not use the refrigeration compressor as a vacuum pump.
Do not expose of refrigeration gases to the atmosphere as this
practice can cause severe damage to the earths ozone layer
and contribute significantly to global warming.


22
II. Safety in freezer room:

Remember the temperature
in the freezer room is below
0C.
Do not enter a freezer room
on your own without first
telling a colleague.
Check that the door can be
opened from the inside.
Extreme cold can be as dangerous as extreme heat.
Do not touch the frost accumulated on the evaporator coils.
Check the lock and door handle inside and outside the freezer
room is working before you enter and keep the key with you.
Never stay inside a freezer room on your own for more than a
few minutes.
Wear warm clothing, including gloves and boots when
working in low temperature freezers.


23
III. Safety in hoses for refrigeration:

You must use different coloured
charging hose, red, yellow and blue.
Hoses must be protected from damage
during operations.
Do not repair a damaged hose just
change it.
Use the right type of hoses that are
suitable for refrigeration.
Check all of the hoses and connections before use.



24
Section 10

Safety in Electrical workshop
I. General electrical safety:

Always switch off the power before
starting work.
Check all wiring connections before
starting-up of the condensing unit.
Never repair a fuse. Always replace it
with one of the correct rating.
Before removing a fuse, ensure that the
switch for the circuit is in the off
position.
Ensure that the electrical power supply
is switched off before inspecting,
servicing, or repairing any electrical
equipment.
Always use a lockout when possible , (shown in Figure 8).
Always ensure that power is OFF by using a multimeter.
Never wear silver or gold jewelry as these are excellent
conductors of electricity.

Figure 8 lockout


25
II. Soldering Iron Safety

Never touch the element or tip of the
soldering iron, as it is at a temperature
of about 400C.
Always keep the cleaning sponge wet
during soldering operations.
Always use a soldering iron stand when
the iron is not in use and never put it
down on your workbench.
Always wear the correct type of eye protection.
Do not touch your eyes or mouth with your hands while
soldering.
Always wash your hands with soap and water after soldering
operations.


26
Section 11

Safety signs.

You will find the following Workplace Safety Signs displayed at
appropriate locations throughout the Technical Trainers College,
their function is to advise students, lecturers and visitors of the
existence of hazardous situations and locations throughout the
campus so that accidents and injury may be avoided.
The following is a list of the signs and their meanings.

There are three types:
Danger warning signs.
Signs required by law.
Not allowed signs.


27
I. Danger warning signs


28
II. Signs required by law


29
III. Not allowed signs



30
Student Test.

Answer the following questions true or false :
Section 1 Basic safety requirements.
1- Select all the tools and equipment for the task in hand.
True ( ), False( ).
2- Do not clean your clothes by using compressed air.
True ( ), False( ).
3- Place trash and paper in containers.
True ( ), False( ).
4- Clean up spilled liquid, oil, or grease immediately.
True ( ), False( ).
5- Always use the safest method to move heavy objects.
True ( ), False( ).

The test is available at: testmoz.com/376746


31
Section 2 Personal protective equipment PPE
6-Wear safety eye protection while working.
True ( ), False( ).
7- Often wear safety face masks while working.
True ( ), False( ).
8- Always wear safety lab coat while working.
True ( ), False( ).
9- Often wear safety gloves while working.
True ( ), False( ).
10- Never wear safety helmets while working.
True ( ), False( ).



32
Section 3 Safety in Welding
11- When opening the fuel cylinder valve, open it fast.
True ( ), False( ).
12- All areas used for welding and brazing operations must
be ventilated.
True ( ), False( ).
13- All welding equipment must be turned on when not in
use.
True ( ), False( ).
14 All damaged welding cables must be removed from
service and replaced, do not attempt to repair or use taped
joints.
True ( ), False( ).
15- Strikers must be used to light the torch or use matches or
a cigarette lighter.
True ( ), False( ).



33
Section 4 Safety in cylinders.
16-Secure protective caps on all cylinders.
True ( ), False( ).
17- All cylinders must be labeled.
True ( ), False( ).
18- Do not strike cylinders together.
True ( ), False( ).
19- Use gas cylinders as rollers to move heavy equipment.
True ( ), False( ).
20- Protect cylinders from direct flame only.
True ( ), False( ).



34
Section 5 Safety in copper pipe bending in the workshop.
21- Always wear safety gloves while working.
True ( ), False( ).
22- After cutting the tubing, you can touch it with your
hands.
True ( ), False( ).
23- Always use the correct size pipe cutter.
True ( ), False( ).
24- You can use a hacksaw to cut the pipe.
True ( ), False( ).
25-You can use compressed air for cleaning the pipes.
True ( ), False( ).



35
Section 6 Safety use of Ladder.
26- There are no length limits to the safe use of ladders.
True ( ), False( ).
27- You can use the ladder in wet conditions.
True ( ), False( ).
28- Use only lightweight hand tools on a ladder and use the
tool bag.
True ( ), False( ).
29- Ladders must never be painted.
True ( ), False( ).
30- Damaged ladders must not be used.
True ( ), False( ).



36
Section 7 Safety in chemical.
31-Read the label before using any chemical.
True ( ), False( ).
32- Lock chemicals in a cabinet if not in use.
True ( ), False( ).
33- You can mix any chemicals.
True ( ), False( ).
34- Do not prepare more chemical than you need.
True ( ), False( ).
35- You can use the chemical for jobs for which they are not
intended.
True ( ), False( ).



37
Section 8 Safety in maintenance in the workshop.
36- You can operate a compressor while the system is in a
vacuum.
True ( ), False( ).
37- You can stop rotating machinery by hand.
True ( ), False( ).
38- Always wear safety gloves before starting work.
True ( ), False( ).
39- Ensure that frequently used hand tools are placed on a
work belt or close to you.
True ( ), False( ).
40- All tools must be maintained in a clean and efficient
working condition.
True ( ), False( ).



38
Section 9 Safety in refrigeration workshops.
41- You can use the refrigeration compressor as a vacuum
pump.
True ( ), False( ).
42- Check that the door can be opened from the inside.
True ( ), False( ).
43- You must ensure that the ventilation fans are switched
off, when you work.
True ( ), False( ).
44- You must be not use different colors for charging hose.
True ( ), False( ).
45- You can repair a damaged hose.
True ( ), False( ).



39
Section 10 Safety in Electrical workshop.
46- Always switch off the power before starting work.
True ( ), False( ).
47- You can repair a fuse.
True ( ), False( ).
48- Always use a lockout when possible.
True ( ), False( ).
49-You can wear any type of eye protection.
True ( ), False( ).
50-Always wash your hands (with water) after soldering
operations.
True ( ), False( ).



40
Section 11 Safety in Safety signs.

51- This sign, it means hand hazard.
True ( ), False( ).

52- This sign, it means welding not allowed.
True ( ), False( ).

53- This sign, it means wash your hands.
True ( ), False( ).

54- This sign, it means secure locking not
allowed the.
True ( ), False( ).

55- This sign, it means do not enter.
True ( ), False( ).


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