General safety in the workplace

Personal Protective Equipment - PPE

Protection for clothing

You normally wear overalls over your normal clothes to protect them from getting soiled with grease and dirt.

Make sure that your overalls fit propperly.  If it is too long you may trip over it and too loose may get caught in working machinery causing accidents.

Overalls should not have loose buttons or holes in the pockets.

Overalls should always be clean because chemicals and oil on overalls can cause a fire.

Other protective clothing includes spats and leather aprons.

Spats cover the front of your legs and fit over your safety boots while leather aprons protects your clothes from welding.

Protection for your head

If you visit a worksite or work on a worksite where falling bricks and other material can hit you on the head you must wear a hard hat to protect your head.

Protection for your ears

Some workplaces have very high noise levels because of running machines. It is therefore very important to protect your ears while working there.

There are diffirent types of ear protection available. 

      Soft ear plugs. (made of sponge) 

      Wax earplugs. (made of wax that form to fit your ears)

      Plastic earplugs (relatively soft and cheap)

      Ear muffs (they cover your whole ears like old fasion

        earphones)

Protection for your feet

To protect your feet you can wear rubber boots or boots with steel toecaps.

If you are working in water or chemicals PVC gumboots will protect your feet.

In an engineering workshop you must wear boots with steel toecaps to protect your feet from falling objects.

Protection for your hands

You can use diffirent types of gloves to do this.

 1.     flameproof gloves (Protects you hands and arms from arcs, sparks and hot metal) 

 2.     insulating gloves. (protects your hands while working with live wires)

 3.     rubber gloves (protect against dangerous liquids and chemicals)

 4.     Leather gloves (they protect against sharp objects, metal chips and heat)

Breathing protection:

A mask will prevent you from breathing in chemicals and fumes.

Staying safe at work

Using general tools safely.

Some typical general tools:

Hammers; Pliers; saws; knives; spanners; chisels and Rasps.

1.  Never use tools when you are in a hurry.

2.  Hold tools propperly and correctly

3.  Use tools for the purpose they were made for.

4.  Store tools correctly and neatly.

5.  Keep tools clean and in good working order

6.  Keep tools sharp

7.  handles must be tightly fitted.

Using Power tools and Machines safely.

Because they are powered by electricity or fuel, these tools are very dangerous and should always be handled with care. 

Never use power tools or machines while you are under the influance of alcohol or drugs.

Portable Tools

Hand held with a power cord. Used for tasks like cutting, drilling and grinding

Stationary Tools

Fixed to a workbench, a stand or the floor.

Types and uses of Power tools.

Impact wrench - Replace nuts quickly and to certain torque

Angle Grinder - Cut steel and remove sharp edges on steel

Arc Welder - Join metal for repair work and steel fabrication

Nibbler - cuts thin steel into different shapes

Lathe - Manufacture cylindrical parts

Compressor - store compressed air in a reservoir

Drilling machine - drill holes in wood, PVC, metal and other material

Power saw - cut through wood, PVC, soft metal and other material  

Working safely with Power tools.

1. Make sure the power tool is correctly wired insulated and earthed.

inspect the wires for cuts or damage.

2. Make sure machine is switched off and all fittings are secure before plugging it in to the mains.

3. Make sure the STOP button on the machine is clearly visible and within reach

4. Before you adjust or replace fittings or blades on machine switch it off and unplug from the mains.

5. Always be aware of where the electric cord is.

6. Do not operate in whet conditions to prevent electrical shock.

7. Wear rubber shoes while operating the tool to prevent electrical shock

8. wear PPE and eye protection while operating tool.

9. Make sure the work area is well lit and ventilated.

10. When not in use , turn off the power and unplug the tool

11. When working with power tools always be aware of your hands. Make sure you know where they are in relation to blades and other dangerous parts.

Safety while using POWER DRILLS

1.  Always wear appropriate safety glasses

2.  Ensure start/stop button is within reach

3.  Use a clamp or drill vice to secure work piece

4.  Make sure drill-bit or cutting tool is locked in the chuck

5.  Keep drill-bits sharp and clean

6.  Keep working area clean of scraps, tools and materials

7.  Shut off the power before removing the drill bit

8.  Do not use bent or damaged drill bits

9.  Remember to remove chuck key before starting drilling.

10. Always drill small pilot holes before drilling big holes

11. Do not lift or lower the drill by its power cord.

12. Do not use the drill in wet or muddy locations

13. Do not use excessive force on drill while drilling

Safety while using Grinding Machine

1.  Always wear appropriate PPE

2.  Ensure start/stop button is within reach

3.  Fasten grinders securely

4.  Keep grinding discs sharp and clean

5.  Stand to one side of the grinder until disc reach operating speed

6.  Make sure the disc does not exceed the operating speed marked on the side of the disc.

7.  Shut off the power before removing the grinding disc

8.  Do not use cracked or damaged grinding discs

9.  Do not exceed maximum cutting depth for the grinding wheel.

10. Use proper wheel guards on all grinding machines.

11. Do not use excessive force when tightening the nut, you might crack the wheel.

12. Do not use the grinder in wet or muddy locations

13. Do not use excessive force on grinder while grinding

14. Use the correct type of disc

15. Clamp the work piece if it cannot remain stationary

16. Hold the grinder with both hands

17. Allow the grinder to stop before laying it down.

Unsafe acts in the workplace

1.  Using machinery or vehicles at high speed

2.  Not wearing your PPE

3.  Wearing loose clothing while working with power tools

4.  Not using your safety equipment correctly or at all

5.  Doing work that you are not trained to do

6.  Working on faulty machines

7.  Working on machines with faulty safety devices

8.  Using the wrong equipment

9.  Using the right equipment in a wrong way

10. Leaving tools and equipment lying around

Unsafe conditions in workplace

Not enough ventilation in the workplace will affect concentration negatively

Not enough light in the workplace. You will not be able to read instructions or instruments propperly

Dangerous chemicals are stored incorrectly can cause accidents

Protective equipment is not available (hard hats and masks) you coulD be injured

Machine gaurds are not in place or defective. You can cut yourself or even lose your hand

Workshop is overcrowded leading to accidents

Slippery floors

Objects and materials not stacked or stored correctly.

Safety signs and demarcation signs can not be seen.

Exits are blocked or cluttered.

Wires, cables and other items on the floor

Using chemicals, solvents, gases and explosives in the workplace

We often use these elements in the workplace. All of them are dangerous and should be treated with respect.

They can be poisonous and harmful to your skin, eyes and lungs.

Chemicals can be swallowed or absorbed through your skin. You can also inhale the gasses from chemicals.

Chemicals, solvents, gases and explosives that are commonly found in workshops.

  Chemicals: acetic acid, sulphuric acid,  diffirent paints, petrol and diesel.

  Solvent:  paint strippers, turpentine and photographic solutions.

  gas:  hydrogen, methane, nitrogen.

General duties of employers regarding listed work

1) Subject to such arrangements as may be prescribed, every employer whose employees undertake listed work or are liable to be exposed to the hazards emanating from listed work, shall, after consultation with the health and safety committee established for that workplace -

a) identify the hazards and evaluate the risks associated with such work constituting a hazard to the health of such employees, and the steps that need to be taken to comply with the provisions of this Act;

b) as far as is reasonably practicable, prevent the exposure of such employees to the hazards concerned or, where prevention is not reasonably practicable, minimize such exposure; and

c) having regard to the nature of the risks associated with such work and the level of exposure of such employees to the hazards, carry out an occupational hygiene program and biological monitoring, and subject such employees to medical surveillance.

2) Every employer contemplated in subsection (1) shall keep the health and safety representatives designated for their workplaces or sections of the workplaces, informed of the actions taken under subsection (1) in their respective workplaces or sections thereof and of the results of such actions: Provided that individual results of biological monitoring and medical surveillance relating to the work of the employee, shall only with the written consent of such employee be made available to any person other than an inspector, the employer or the employee concerned.

General duties of employees at work

Every employee shall at work -

a) take reasonable care for the health and safety of himself and of other persons who may be affected by his acts or omissions;

b) as regards any duty or requirement imposed on his employer or any other person by this Act, co-operate with such employer or person to enable that duty or requirement to be performed or complied with;

c) carry out any lawful order given to him, and obey the health and safety rules and procedures laid down by his employer or by anyone authorized thereto by his employer, in the interest of health or safety;

d) if any situation which is unsafe or unhealthy comes to his attention, as soon as practicable report such situation to his employer, or to the health & safety representative for his workplace or section thereof, as the case may be, who should report it to the employer; and

e) if he is involved in any incident which may affect his health or which has caused an injury to himself, report such incident to his employer or to anyone authorized thereto by the employer, or to his health and safety representative,as soon as practicable but not later than the end of the particular shift during which the incident occurred, unless the circumstances were such that the reporting of the incident was not possible, in which case he shall report the incident as soon as practicable thereafter.

First Aid Prosedure

This is by no means written by an expert and only meant to be guidelines to the person who land up in a situation where basic first aid is required. The first and foremost task of a first aid assistant is to make the patient comfortable and calm. In order to do this the first aid assistant must stay calm and appear confident. If you panic it will make the patient panic which will increase his/her heart rate and cause anxiety.

 Dressings, bandages and slings

Dressings:

Dressing is a covering for a wound. The aim is to stop bleeding and to prevent infection. 

Dressing should be sterile and put directly over the wound.

Dressing should be absorbent so that it can absorb blood.

Dressing should not stick to the wound.

Do not use dirty dressing as this will introduce germs into the wound causing infection in the wound.

We use adhesive dressing for small wounds with light bleeding. For example, Elastoplast is an adhesive dressing. It has an outer edge which is adhesive, with a dressing pad in the middle.  It sticks to the skin around the wound so it does not need bandage.

We use pressure dressings to control severe bleeding.

We use gauze dressings, which are kept in place with a bandage.

Special gauze dressings are available for burn wounds. If these dressings are not available, cool the wound down with clean, cold water and get the patient to medical help as soon as possible. Under no circumstances should burn wounds be covered wit cotton wool or any other cloth. This will only introduce foreign substances into the wound wich will make the work of the medical staff very difficult because all the foreign matter must first be removed before they can start to treat the patient. The removal of these foreign substances will cause the patient a lot of discomfort as well.   

Bandages:

A bandage is any kind of material that holds a dressing in place. 

A bandage also keeps pressure on a wound to help stop bleeding.

A bandage can support a part of the body and keep a part of the body from moving.

You can make a useful bandage by cutting a square piece of cloth (1 meter by 1 meter) diagonally from corner to corner to form a triangle.

This bandage can be used to support an injured arm, to immobilise a part of the body or as a broad or narrow bandage.

An Arm Sling:

An arm sling give support and protection for an injured arm and keeps the arm elevated.

How to make an arm sling:

Support the arm across the injured person’s chest. 

Keep the wrist and hand slightly higher than the elbow. 

Keep the arm slightly away from the chest

Put the triangular bandage between the forearm and the chest.

Move the top end of the bandage over the person’s shoulder and around to the injured side.

Support the person’s injured arm. 

Bring the lower end of the bandage over the hand and forearm, and tie at the top.

Bring the point of the bandage in front of the elbow and fasten it with a safety pin.

Make sure the person’s fingertips stick out of the bandage so you can check for any signs of loss of circulation. Fingers turning blue is a good sign for loss of circulation

FIRST AID FOR MINOR WOUNDS

A minor wound is one that is small, shallow and has not caused shock. The following steps for treating a minor wound.

1.  Wash your hands and put on a pair of gloves.

2.  Help the person to be comfortable and clean any dirt from the wound.

3.  Wash the wound in clear water to which you have added some disinfectant.

3.  Dry the wound gently. (Press Dry, do not wipe the wound)

4.  Cover the wound with a sterile dressing, and keep it in place with a bandage. 

5.  Try to keep the wounded part of the body in a raised position. This will slow down bleeding.

FIRST AID FOR DEEP WOUNDS

A deep wound is deeper and larger than a minor wound. Follow these steps for a deep wound.

1.  Wash your hands and put on a pair of gloves. Remember to hurry because you must stop the bleeding as soon as possible.

2.  Stop the bleeding by putting pressure on the wound. Use your hands or dressing.

3.  If the dressing becomes full of blood, do not remove it. Just add another dressing on top.

4.  Raise the body part where the wound is.

5.  Arrange for the patient to be taken to hospital as soon as possible. 

FIRST AID FOR FRACTURES, DISLOCATIONS AND SPRAINS

FRACTURES:

The primary aim of first aid for fractures is to reduce the pain and prevent further injury.

Only apply  a splint if it will be a long time before the medical staff arrive because applying a splint can be very painful.

Unless the patient is in a dangerous position you should not move the patient who has fractured a bone. 

Send for medical assistance 

If there are open wounds involved, dress the wounds as you have learned.

Dislocations:

A dislocation is when two bones are forced apart at their joint. This is usually very painful. The injured person will be unable to move the joint and the joint will look deformed, swollen and discoloured.

It is better not to move the bones back to their normal position if you are not a medical person. Rather use cushions or blankets to support the injured arm or leg.
Check the circulation and apply an ice pack. Keep the ice pack on for 15 minutes and then remove it for 15 minutes. Do this at least twice and get the patient to a medical facility or doctor as soon as possible.

Preparing an ice pack:
An ice pack helps to relieve pain and swelling.
To make an ice pack, fill a plastic bag two thirds with crushed ice. Press the air out of the rest of the bag and close the bag to make it watertight. Wrap the bag in a towel. Do not put the ice pack directly on the injured persons skin as the cold can cause more damage to the skin.

A bag of frozen peas or corn kernels works very well as an ice pack because it can form around the leg or arm. To make such a n ice pack take the bag out of the freezer and wrap it in a towel.

Burns:

A burn is more serious if the person is older or sick or if the burn is close to internal organs.

Deep burns, when the outer layers of the skin has been destroyed.

Superficial burns, when only the outer layer of the skin has been damaged.

First aid for burns:

1.  Take the person away from the cause of the burn.

2.  Switch off any electrical current or brush away any chemical substances that can cause further burning. Remember to protect your hands from chemical substances.

3.  Put cold water or towels soaked in cold water on the burn. For chemical burn, keep on pouring cold water over the burned area for at least 15 minutes.

4.  Remove the persons clothes because of chemical substances that may still be on the clothes. This is no time to be modest rather be seen naked than burn further with chemicals.

5. Help the injured person to take a shower.

6.  You can also help by giving the person small sips of water.

7.  Make the person comfortable by removing tight clothing, jewellery, belts and shoes.

8.  If any piece of clothing sticks to the burn, do not pull it away. Leave it as is for the doctor to remove.

9.  Most important, get the person to a doctor as soon as possible.

Dressing for burns:

   Do not put creams or ointments on burns until a medical professional has looked at the burns. Creams and ointments can damage the skin and make the injury worse.

   Do not break blisters!  This will cause pain and lead to infection.

   Do not put cotton wool or fluffy stuff on the burn. This will stick to the wound and the skin will came away with the cotton wool or fluffy stuff.

   Lightly cover the area with sterile dressing to keep the burned area clean.

   Do not touch the area of the dressing that will touch the wound as this may transfer germs into the wound.

First aid for eye injuries:

Your eyes are the softest part of your body and must be protected at all times. Wear eye protection.

In case of an eye injury you must act quickly to prevent the person from losing his/her sight.

Particles in the eye.

Any small foreign object in the eye can make the eyeball inflamed. Usually tears from the injured person will wash away the particle but sometimes it can get stuck. If you can see the particle then you can remove it.

You must remove it by using the corner of a moist tissue or clean moist cloth.

If you can not see the object it might be stuck to the underside of the top eyelid.

To look there follow the following steps:

Person sits in chair facing the light. Stand slightly behind him and to the side.

Tilt the persons head back and ask him to look down.

Hold the lashes of the upper eyelid between your thumb and forefinger and lift the eyelid over a matchstick so you can inspect the inside of the eyelid. 

Objects in the eye.

If an bigger object get into the eye, especially a piece of glass, do not try to remove it. Ask the person to lie down and place dressing around the eye. Put the bottom of a paper cup over the eye to prevent any further pressure on the eye and take the person to a doctor.

Cuts on the eye.

 cuts on the eye are very painful and dangerous. Do not put any pressure on the cut eye. It will not stop the bleeding and probably injure the eye even more. Give the following first aid:

Help the injured person to lie down. He or she will not be able to see and must be kept very quiet.

Close the injured eyelid. Cover the eye and the areas around the eye with soft padding You can keep the padding in place with adhesive strips. This will stop movement and protect the eye.

Prevent movement of the head and spine as this will increase bleeding.

Keep the persons head as still as possible and take him to a doctor as soon as possible.

Chemical burns to the eye:

If someone has a chemical burn in the eye, you must first remove the chemicals. 

If it is dry chemicals brush it out of the eye with a soft brush protecting your hands at all times. 

If the chemicals are in liquid form rinse the eye under running water for at least 15 minutes. Keep the eye open with your fingers while you do this. Cover the eye and take person to a doctor as soon as possible.

Burns to the eye from intense bright light.

Bright sunlight, flash from a welding machine or infrared lights can permanently damage the eyesight. Sometimes pain is only felt 4 or 5 hours after the incident. If a person has been burned by bright light in the eyes, cover the eyes and get the person to a doctor as soon as possible.

First aid for breathing:

If someone has stopped breathing start CPR immediately. (Cardio Pulmonary Resuscitation) CPR means to breathe into someone’s mouth and press on his/her chest in order to make the person start breathing on his own again. Every first aid kit should have a plastic mouth piece to form a barrier between the mouth of the patient and the person giving CPR.

Follow these steps to do CPR:

1.  Using gloved hands put the mouth piece in the patient’s mouth. 

2.  Use one hand and put your thumb over the persons lower teeth, gums and tongue, with your fingers under his chin and open his mouth gently. 

3.  Use your other hand to place the bite block of the mouth piece between the person’s teeth.

4.  Place your gloved hands under the plastic, In contact with the skin: the palm of one hand on the forehead, and two fingers under his chin.

5.  Lift the head and tilt the chin by pushing down on the forehead and lifting the chin up, to open the  person’s air passages.

6.  Place your mouth over the patient’s mouth with the plastic in between.

7.  Close the patient’s nose under the plastic sheet with the hand on the forehead. This will prevent air escaping through his nose.

8.  Blow into his lungs until you see his chest rise. 

9.  Give two breaths each lasting for one second.

10. If the person does not breathe or start moving, chest compression must be started. This means pushing down on the chest, in the middle of where the nipples are supposed to be. Push with the palm of your hand, one hand on top of the other. For thirty pushes. About one second per push. 30 pushes should take 30 seconds.

11. Stop and check if the person has started to breath or moving yet. If not, start again at number 4.

12. Repeat this proses until the patient start to breath or move on his own or until paramedics or a doctor arrive.

Operating and Monitoring machines and component production

Glossary
Backlash: relative motion of mechanical parts caused by looseness
CAM: computer-aided manufacturing. a process of using computer controlled machines to perform repetitive tasks
Clutter: items that are not necessary for the task at hand lying around.
Die: type of tool used for shaping solid materials. usually employed in the press working of cold metals
Guards: coverings around moving parts to ensure safety
Lubricate: substance that reduce friction between moving components.
Pertaining: to be relevant to something

Press-working: Dies are used in pairs. a smaller die or punch fits into the larger die or matrix. a sheet of metal (called a blank) is placed over the matrix on the press bed. the punch is mounted on a press ram and forced down by hydraulic pressure to form the component.

Timeously: on time

Verbal: Spoken rather than written

Safety in the workplace:

Accidents are caused by people

Accidents are caused by: carelessness,  lack of attention,  anger,  haste,  thoughtlessness. 

No workshop will ever be 100% safe as long as it is used by people.

Safety precautions are not there to irritate you, they are there to safeguard you against yourself.

Some general and common-sense safety tips are:

1.  Follow the instructions for the use of the machine

2.  Know where the main switch are and the emergency stop procedures for the machine you are working on.

3.  Know where the fire extinguishers are and how to use them.

4.  Be aware of your surroundings and possible dangerous behavior or situations.

Prepare the Machine:

Step 1: Understand the instructions. This will include;

 o  how to operate the machine

 o  know the workshop procedure to follow if machine should brake down.

 o  Safety regulations while operating the machine

 o  What did the customer ordered. (job specifications)

Step 2: Read, understand and apply the drawing informations. Drawing information is necessary for the machinest to know exactly what is expected from him and will include the following information.

o  shape of the component

o  dimensions and tolerances

o  cutting edge clearances

o  where to drill holes, cut, bore or shape.

Prepare for a Service

Safety in the workplace is of the foremost importance.
Before you start to work make sure of the following:
1.  Clean the work area. A clean work area is a safe work area.
2.  Make sure that there are no oil or water spills on the floor.
3.  Store all unused tools so that they are not in the way.
4.  Dispose of used parts and packaging according to regulations.
5.  The working area should be free of waste and off-cuts.
6.  Check plugs and power cords for any damage.
7.  Make sure that work area is well ventilated and that the lighting is good.
8.  Make sure lifting equipment is available and in working order when     working with heavy materials.
9.  Make sure lockout devices are in place where necessary.
10.  Know the equipment and machines.
11.  Wear the appropriate PPE. (Personal Protective Equipment)
12.   Put up screens for welding.
13.   Store dangerous  chemicals in a safe place.
14.   Make sure warning and safety signs are in place.

Step 1: select the tools and equipment that you need to finish the service.
Step 2: Inspect the parts. (before you start or even before you leave the shop.
Step 3: Arrange the component of the machine you took appart.
Step 4: Clean all the components.
Step 5: Replace the faulty parts with new parts or repare the faulty parts.

Service and record results

1. Use the manufacturers service manuel:

  this manual contains a list of the parts used to built the machine.

  this manual contains graphical drawings of parts and how they fit together. 

  this manual give step by step instructions of how parts fit together.

  this manuel give you all specifications for the parts.

  this manual give you all the torque settings for the nuts and bolts.

2. install the replacement parts into the component:

3. Inspect the assembly:

 check the assembly for obstructions

 check that the component move or rotate freely

 Check that all the components is correctly aligned

4. Check torque settings:

We use a torque wrench to tighten nuts to the correct specified torque. Torque is the power that make something turn around a central point. Manufacturers provide torque specifications

the formula used is: T = F x S = NM where T = torque, F = force and             S = distance. NM = Newtons meter.

5. Manually check the component for operation:

 If you have replaced and reasembled parts and components, check them by hand to make sure they work propperly and smoothly.

 Rotate gears and belts by hand to make sure of their alignment.

 Test V-belt tension with a reliable belt tensioner

 Finally start the engine and make sure there are no abnormal noise or vibrations.

6. Record service information:

When finished with the service write a report that include the following:

1.  the date that service was completed

2.  the parts that were replaced

3.  information of the replaced parts (type, brand name, lubricants used etc.

4.  reason why machine broke down or parts replaced.

5.  when next service is due

6.  name and signature of artisan that performed the work.

7.  some firms has printed reports where you only tick off what you have done.

Example of a service report:

Date: 17 December 2016

Reason for breakdown:  Because of a worn fan belt the engine overheated and the battery did not charge fully.

Parts replaced:   Worn Fan belt and faulty pulley. We also replace the water in the radiator and top it up with antifreeze.

Next service: Your vehicle is due for a service at 120 000 kilometers but not later than 17 December 2018.

Name of technician: (your name and surname)

Dismantle and clean components:

Ensure that work area and conditions are free of obstacles:

1.  Remove obstacles and tools from workbench to ensure you have enough room to work.

2.  Pick up tools from floor and store them away.

3.  Close lubricants and fluids and store them in proper storage.

4.  Dispose of any waste materials (safely)

5.  Remove/dispose of all components from previous job. If these components must be returned to the suppliers they should be labeled and packed.

6.  Clean any fluid spills.

7.  Wipe the workbench  

You can control  the hazard circumstances in your workplace:

1.  Flammable and toxic materials and fluids must be kept sealed or closed.

2.  Report poor electrical cables and connections.

3.  Make sure the machine you are working on is stable and supported.

4.  Make sure your work piece is secured before you start .

5.  Work in well ventilated area.

6.  Wear appropriate PPE

7.  Make sure the lighting is sufficient.

8.  Control dust and dampness.

9.  Before you start working, check that the workplace, work area and machinery are clean, safe and in good working order.

Inspect your work piece/component before disassembly:

1. make sure that you know how the component fit together.

2. it will help to make a scetch of the component before you start.

3. while you are inspecting the component, make sure you know in wich order to take it appart.

4. Pre-clean the component:

5. cleaning the component make it easier to see how it fit together and to see any cracks or breakages 6. because it removes the dirt and crime that may cover the defects.

7. All cleaning agents may not suit all materials to be cleaned. Make sure you use the correct cleaning agents.

8. Consult the technical manual for correct cleaning agents.

Inspect and diagnose components:

When you dissasemble the components, you must look for signs of wear and tear, cracks or other damage.

Damage can take different forms:-

cracks

chips

change in shape

deterioration

change in size

loss of elasticity

rounding of corners.

While you are inspecting the parts, ask yourself the question if these parts are still good enough to function on the component. Will they last until the next service or will they cause untimely breakdowns. If so, replace them.

Do a final cleaning with cleaning equipment.

It is important to inspect components for defects. Defects are not always obvious. Keep the following in mind with your inspection:

a)  the function of the components.

b)  the conditions it must work in (hot, cold, humid, etc)

c)  sort of stress put onto the parts or components.

If the component can not function properly in these conditions, determine why not and repair/ replace them.

The following conditions can influence the components:

Wear: - Sometimes the wear that took place is obvious. However, make sure that you inspect all sides of the component for wear. Then decide if the wear is af such an extend that the part must be replaced.

Assemble and test components:

Before you start you must select the tools and equipment to use  for the assembly.

Some tips for assembly:

1.  do not use pliers to loosen nuts and bolts.

2.  do not use a hammer on a spanner or a screwdriver

3.  do not extend the length of a spanner by putting a length of pipe over it.

4.  do not throw tools or leave them lying around

5.  do not use power tools with faulty or damaged plugs or wiring

6.  use a deep penetrating solvent (Q20) to loosen tight nuts

7.  Use the correct size spanner

8.  Clean tools after use

9.  Check tools regularly for wear and tear or damage.

Fit the components in time:

You do not want to finish the assembly and find spareparts still lying on the workbench. 

Make sure that you work correct and fit everything correctly

Plan how you are going to finish the job before you start

Make drawings and know how the pieces fit together

Check the quality of your work as you proceed

Check assembly and record results:

Once the the equipment has been assembled test it by rotating it by hand.

start the machine to see if it perform as expected

While the machine is running, check for the following obvious signs:

1.  overheating

2.  vibrations

3.  noise levels

4.  component expectancy

5.  kilowatt ratings up to standard

6.  overall performance.

Quality of components EP Level 4

A.  Tag a replacement part. This provides information for future reference and form part of the service record. The tag can be an information plate or a label containing the following information:
1.  the date it was replaced
2.  operational tolerances
3.  material specifications
4.  lubrication details
5.  lubrication intervals
6.  service precautions

B.  Ensure that the replacement parts are suitable to do the job. Order parts direct from the suppliers.
The reasons for this are:
1.  You are sure of the quality
2.  The parts are gauranteed and you do not loose your warrenty
3.  you are sure that the parts are suitable for the job.
4.  you are sure that the parts fit.
5.  When you receive the new parts make sure they are suitable to work in all conditions:- hot, cold,         dry, wet, dusty etc.
6.  If the parts is not designed for all the conditions it will fail.
7.  Check the parts when you receive them to ensure that they are not damaged or defective.

Ensure that lubricants meet operational conditions:

Lubricants must be able to reduce friction and wear. It must dampen the shock, cool the parts and prevent corrosion.

Reduction of friction and wear. Lubrication prevent friction and wear by putting a layer of lubricant between the moving parts wich prevent metal to metal contact between the two surfaces.

Damping shock: The right lubricant dampen any shock between components. The effect of increase in pressure between two surfaces are dampened by the oil inbetween the surfaces.

Cooling: Cooling system (lubricant) control the heat generated by friction. Because friction is reduced, heat generated by friction is also reduced.

Reduction of corrosion: Corrosion is the chemical reaction between two dissimilar metals or a metal and a chemically active liquid like an accid or an alkali. Rust is the result of the chemical reaction between oxygen and a metal.

Types of lubricants and where they can be used:

1.  Solid lubricants : commonly used are graphite; white lead; talc; mica; zinc oxide. They are used because they are less affected by acids or heat and less prone to clogging by dirt particles. Used in slow moving parts.

2.  Semi-solid lubricants: Grease is a mixture of oil and soap and used in bearings because it protect against dirt.

3.  Liquid lubricants: Most commonly used is oil. 

4.  Animal oil: whales, pigs bears, etc. Tallow comes from the harder fats of animals it is used to make candles, soaps and grease.

5. Vegetable oil: castor oil,palm oil, olive oil and linseed oil.

6.  Miniral oil: Produced from crude petroleum sources and coal. these oils are refined and graded before use.

7.  Gas lubricants: Air, helium, nitrogen and hydrogen are used because their viscosity is not affected by temperature changes.

Storage

Correct storage is very important. Storage and packaging must take into account the range of materials, range of the conditions and the effect on the parts.

Here are some ways to avoid problems:

1.  Store in an area that is out of direct sunlight.

2.  store in controlled humidity. Not too dry or too damp.

3.  Wrap in protective coating such as static free bags  for electrical parts, greased paper for ferrous parts that may rust.

4.  Label all components and ship with delivery notes attached. delivery notes should contain the following information.

a)  full details of the item.

b)  Customers address.

c)  Name of responsible person

d)  Shipping and handling instructions.

Pumps Level 4

ERD - Level 4

Pumps: Notes

Safety precautions when installing, servicing or maintaining pumps.

When we work on pumps for any reason at all we should take the following precautions:

l Work in a clean dry environment. Parts of the pump, like the bearing, must be free of dust and contaminants when installed to prevent excessive wear and tear.

l Make sure a lock out device is in place. This will prevent accidental connection of the pump while you are working on the pump.

l Ensure that the pump is turned off and not operating when you start working on the pump.

l Wear the necessary PPE

l Use the correct tools for the correct job.

l Make sure that you have the correct spares to replace broken parts.

Plan and prepare for pump maintenance.

Mechanical Inspection:

· Check that mounting points are secure

· Check for excessive vibration and noise

· Inspect the mechanical seal and packing

· Inspect the pump flanges for leaks

· Inspect coupling and alignment.

Lubrication:

· Lubricate the motor and pump bearing per manufacturer’s guidelines.  Do not over lubricate! More bearing damage occurs as a result of over greasing than under greasing.  If the bearing has a vent cap, remove the cap and run pump for 30 minutes before reinstalling cap.  This allows excess grease to work its way out of the bearing.

Electrical/motor:

· Check that all terminations are tight

· Inspect motor vents and windings for dust/dirt build-up. Clean as necessary

· Inspect starter/contractor for arcing, overheating, etc.

· Put a megohmmeter on the windings to check for insulation failure

Following the outline above will ensure that your pump lives a long and productive life – hopefully without incident!

Dismantle and assemble pumps 

1. Ensure that the correct tools are available to dismantle and reassemble the pump.

2. Use the proper equipment to lift and move heavy objects

3. Make sure the lockout devise is in place

4. If pump is used to pump poisonous or hazardous liquids, make sure that the pump is rinsed out and clean with none of the hazardous liquids still present inside

5. Allow pump and components to cool down before dismantling it.

6. Disconnect all piping and tubing from the pump

7. Disconnect coupling

8. Drain oil and lubricants from pump

9. Clean and inspect all parts

10. Replace all broken parts

11. Reassemble the parts

12. Test the pump by turning it by hand

13. Inspect the pump for any leaks

14. Connect and align coupling

15. Run pumps for couple of minutes to listen for strange noises and to visually inspect for leaks

Types of pumps  

The positive displacement pump can be classified as:

· Reciprocating pumps - piston, plunger and diaphragm.

· Power pumps.

· Steam pumps.

· Rotary pumps - gear, lobe, screw, vane, regenerative (peripheral) and progressive cavity.

Dynamic Pumps

Positive Displacement Pumps

Dynamic pumps include all types of pumps using fluid velocity and the resulting momentum to pump and move the fluid through the piping system. Although dynamic pumps usually have lower efficiency than positive displacement pumps, they require lower maintenance. They are also capable of operating at high speeds and high fluid flow rates. Classification of Dynamic Pumps Dynamic pumps can be classified into the following sub-categories: · Rotary Pumps o Centrifugal Pumps o Axial Flow Pumps o Mixed Flow Pumps · Special Pumps o Jet Pumps o Electromagnetic Pumps for Liquids & Metals o Fluid Actuated/Gas Lift or Hydraulic Pumps

Positive displacement pumps operate by filling and displacing liquid from a cavity. Such pumps deliver a constant flow and volume of liquid without discharge pressure or head. Positive displacement pumps are ideal for a low flow–high pressure combination, and other application niches. Classification of Positive Displacement Pumps Positive displacement pumps can be classified into the following sub-categories: · Reciprocating Pumps o Piston / Plunger Pumps § Single Acting Piston Pumps § Double Acting Simplex Pumps § Double Acting Duplex Pumps o Diaphragm Pumps § Single Diaphragm § Double Diaphragm o Rotary Pumps § Single Rotor Pumps § Sliding Vane Pumps § Flexible Tube or Lining Pumps § Screw Pumps § Radial Pumps § Multiple Rotor Pumps § Gear Pumps § Double Lobe Pumps § Triple Lobe Pump

Compressors: Notes

FAILURE TO MAKE THESE RECOMMENDED CHECKS COULD RESULT IN SERIOUS INJURY, PROPERTY DAMAGE, AND MECHANICAL FAILURE.

1. Remove all loose pieces and tools around the compressor installation.

2. Check oil level in crankcase.

3. Check motor and compressor pulley for alignment and tightness on shaft

4. Be absolutely certain that all mounting bolts are tight.

5. Manually rotate compressor through enough revolutions to be certain there are no mechanical interference.

6. Check belt tension, it should be neither too loose nor too tight.

7. Check all pressure connections for tightness.

8. Check to make sure all safety relief valves are in place.

9. Check to be sure all guards are in place and securely mounted.

10. Check fuses, circuit breakers and thermal overloads for proper size.

11. Open all manual shutoff valves (block valves) at and beyond the compressor discharge.

After all of the above conditions have been satisfied, jog the starter switch button to check the rotational direction of the compressor, it should agree with the rotation arrow on the unit. Follow this procedure for start up of a new installation, after changes to an existing installation have been made, and after service or repairs have been performed.

1. Instructions in addition to those contained within this manual, supplied by manufacturer of support equipment, must also be read and understood before start-up.

2. Jog starter button and check compressor rotation.

3. Start compressor and watch for excessive vibration and noises. If either is present, stop compressor and correct.

4. Check air receiver pressure.

5. Manually blow safety relief valve(s).

6. Check operation of controls.

7. Observe general compressor operation closely for first hour and then frequently for next seven hours. If any abnormal conditions exist, stop compressor and correct the problem.

8. After two days of operation, check belt tension, air and oil piping for leaks and crankcase oil level.

compressor.

Fitting and Turning - Safety regulations for Grinders (Level2)

OHSA - Occupational health and Safety Act (85 of 1993) lay down the rules for Employers as well as employees as far as safety in the workplace are concerned. These rules are written in such a way that they cannot be misunderstood. I will attempt to put them into layman's terms so that it is easier to study.

Here are the important excerpts for Level 2

General Machinery Regulations 3:

Safeguarding of machinery

Every employer, employee or user of the machinery shall

1) make sure that all machinery used are suitable for the purpose which it is used.

2) make sure all exposed and dangerous parts within normal reach of  a person is safeguarded to prevent accidental injury.

3) make sure that all safety equipment is in good working order and used correctly and safely.

4) make sure that the material used in the construction of the machinery and the safeguards is suitable for it's intended use.

5) make sure that all machinery that endanger the safety of the persons around it is enclosed and that the entrances of the enclosures are close and locked.

6) make sure that no safety equipment is tampered with or removed from any machine still in operation.

General Machinery Regulations 4:

Operation of machinery

1)  Every employer, employee or user of the machinery every person operating the machine or equipment is fully aware of the dangers involved and safety measures is taken at all times.

2) Machinery that need constant supervision in order to prevent accidents should under no circumstances be left unattended.

Driven Machinery Regulation 2:

Revolving Machinery

The following components of moving or rotating machinery should be guarded or fenced at all times.

1) every shaft, pulley, wheel, gear, sprocket, coupling or similar object.

2) every set screw, key or bolt on revolving parts as named in no. 1.

3) every shaft or spindle end that projects for more than a quarter of it’s diameter

4) every driving belt, rope or chain

5) every underside of overhead driving belts, ropes or chains above passages or workplaces that can fall and injure people.

Driven Machinery Regulation 8:

Grinding machines

1) power driven grinding machines should be clearly marked to indicate the speed or spindle speed in revolutions per minute recommended by the manufacturer

2) no user shall allow a power driven grinding machine to be operated above the recommended spindle speed.

3) the user shall ensure that the grinding wheel is mounted properly with flanges big enough to prevent the grinding wheel from breaking up.

4) the user shall make sure that the grinding wheel is guarded with a substantial guard that will withstand the force of impact should the wheel break up.

5) the user shall ensure that sufficient support is provided for the work piece and that the gap between the rest and the wheel is no more than 3mm

6) every grinding machine shall be fitted with a strong transparent shield to protect the operator’s eyes. This shield may only be omitted if the operator is issued with suitable eye protection and forced to wear it.

7) a notice must be posted at the grinding machine to inform persons operating or watching operation of the machine to wear eye protection.

General safety rules to be obeyed by every person entering the workshop.

We regard safety as very important for the following reasons:

l Financial considerations. Downtime because of accidents result in loss of income

l Concern for worker’s and visitors welfare

Risk of injuries are greatly reduced if workers are sensitive to safety and follow the safety measures below.

u Concentrate on your work at all time

u Keep your eyes and focus on your work

u Do not distract others while they are working and do not allow others to distract you from your work.

u Do not use or operate tools or machinery that you are unfamiliar with. Ask help.

u Use tools and machines only for the purpose that they were intended for. Use the right tool for the right job.

u Keep the tools sharp.

u Never make adjustments while the machine are operating or still in motion. Switch off and wait for it to come to a complete halt.

u Make sure guards are in place and fitted correctly.

u Read and understand the manufacturers instructions on how to use the machine/tool properly.

u Always use a brush to clean dirty table surfaces.

u Make sure all electrical cord are in good condition and power tools are earthed.

u Report any strange noises in a machine.

u Never lift heavy objects by yourself. Ask for assistance.

u Be careful of slippery, greasy floors. Especially if you are carrying heavy loads.

u Keep walkways clean of clutter.

u Never run or fool around in the workshop.

u Wear proper protective equipment.

u Obey all safety signs.

u Report all injuries, no matter how small or minor they seem to be.

Good Housekeeping: A PLACE FOR EVERYTHING AND EVERYTHING IN IT’S PLACE.

ü Return Equipment and tools to their rightful place at the end of each day.

ü Stack equipment and materials neatly and safely.

ü Clean all tools after use

ü Clean your work area regularly.

ü Keep small items like nuts and bolts in storage bins.

ü Color coding on the floor - red floor = walkways, green floors = work areas. DO NOT store tools and equipment on walkways (red floors)

ü Do not store anything in front of fire extinguisher or fire hose.

Effects of good housekeeping:

ü It limits the time searching for tools and equipment.

ü Injuries are prevented

ü Fire hazards are reduced

ü A neat and orderly workshop improve working moral among workers.

ü Space is saved

ü Production is increased

ü Less accidents.

Safety precautions before, during and after grinding.

v Select the correct wheel for the job.

v If there is no label with speed and type markings on the wheel the wheel should not be used.

v Make sure the spindle speed does not exceed the wheel speed.

v Examine the wheel for defects before use.

v Do the ring test to determine if the wheel is not cracked.

v Check that the tool rest is properly fastened and the gap is less than 3mm.

v Make sure the floor is clean and dry.

v Check that safety guards are in place and in good condition.

v Before switching on the machine, turn the wheel by hand to ensure that it runs freely.

v Stand to one side, switch the machine on and wait for it to reach full speed.

v Never grind on the side of the wheel.

v Never adjust any part of the machine while it is in motion.

It is very important that all machines, tools and equipment is cleaned after being used. Failure to clean the machine, tools and equipment will lead to corrosion, built up of grease or oil. Moving parts will get stuck and the machine, tools and equipment will stop functioning properly. This lead to delays in production, more expenses and unsafe conditions.

Safety clothing to wear during grinding:

1. Safety glasses with side protection is required by law whenever you use a grinding machine.

2. Ear plugs or other hearing protection.

3. Face mask

4. SABS-certified overalls with sleeves rolled up and jacket buttoned or zipped up

5. Cap or hair net with hair tucked in securely

6. SABS-approved safety shoes with steel toe cap.

7. DO NOT wear gloves while grinding. Gloves can get caught in the machine leading to injuries.

Identify and remove all flammable materials before you commence with grinding.