A number of tools are associated with the incidence of Machine Vibration. White finger (Raynaud’s phenomenon of Occupational Origin). The initial symptoms of this injury are a slight tingling or numbness in the fingers and this may pass unnoticed. Later the tips of one or more fingers most exposed to vibration suffer attacks of blanching (whiteness), the attacks being more frequent in cold weather and early in the morning. Attacks of VWF typically last about one hour, ending with a sudden rush of blood to the affected fingers and frequently considerable pain. If prolonged exposure to vibration continues, the fingers may take on a permanent blue-black appearance and, very rarely gangrene of a finger may occur.
These tools include pneumatic hammers and drills, chains saws, pedestal and hand-held portable grinders, Chipping hammers and concrete vibro – thickeners. Machine Vibration exposures from such tools may be reduced by the wearing of gloves, padded at suitable points with absorbent materials.
Certain tools for example chain saws, are available in an anti-vibration form, and design modifications of tools to reduce Machine Vibration level to be the only satisfactory way to combat VWF.
Noise:
Excessive noise is a hazard in the use of many power tools, particularly pneumatic. Noise should be reduced as far as possible, at the source. Compressors should be of the quit type or at least have sound reducing covers, which should closed when running. Suitable silencers should be fitted to tools, e, g., exhaust mufflers to concrete breakers. OSHA standards on the sound power level of airborne noise should be used. Where persons are exposed to a noise level exceeding 85 decibels, hearing protection must be provided and worn. Compressed air is delivered at high pressure. If it enters the body, it can rupture internal organs and cause death. Any form of horseplay is expressly forbidden under all circumstances.
This Maintenance Tools procedure is applicable to SMI, subcontractors, vendors and all personnel performing work on the project.
Should be regularly checked and thoroughly examined before storage and, if worn or damaged, they should be properly repaired or discarded. When not in use, tools should be stored in boxes or cracked, cutting edges should be sheathed. Tools should be kept clear of walkways so as not to present a tripping hazard. iii
Selecting the Right Maintenance Tools:
Every Electric Maintenance Tools has its proper application. The correct type, size and weight of too should be selected for the job. To misuse a tool, or to use the wrong tool, is to invite personnel accident, damaged or injury.
Electrical Risks:
All metal tools are conductors of electricity. Where
work takes place on, or near, electrical apparatus, only properly insulated and
non-conductive tools should be used.
Insulation and, where appropriate, ground continuity,
should be tested at regular intervals by a competent electrician. Current
should be switched off if possible.
Sparking Risk:
For work near highly flammable materials or explosive gasses/dusts, special tools, made from non-ferrous metals, e, g,. Beryllium (copper alloy) is required, since a spark could cause fire or explosion. Spark-proof tools should be regularly inspected in case steel splinters have become embedded and need grinding out to ensure continuing safe usage.
Section Manager:
The Construction Manager is responsible for ensuring
that;
Monitoring and checking of the compliance of this procedure.
All the machine and hand tools used on the site have been inspected and are safe to use.
Manpower, equipment and funds are available to purchase and use and maintain the machine and hand Maintenance Tools .
HSE Manager:
The HSE Manager is responsible for ensuring that, all machines and power Maintenance Tools shall meet the international standard and personnel are fully trained and aware of the safe use.
Proper training is conducted.
Toolbox meeting is conducted.
JSA system is applied.
All identified necessary work and precautions are
properly executed.
POWER TOOLS- GENERAL:
Many jobs CAN be done faster, more efficiently, even
more accurately, and certainly more economically using power tools. Operative
fatigue is reduced. It is essential, however, that these tools are only used
for those jobs for which they were designed. It is the responsibility of
management to provide the proper tool for the job and to see that it is
properly used.
Manufacturers and/ or suppliers should always provide
information concerning the safe use of tools.
The efficient and safe use of all powered tools can
only come through proper training, proper maintenance and from adequate
supervision on site. Too many accidents have occurred through the use of these
tools by untrained unskilled labor. With the tore potentially dangerous
equipment, e.g., portable saws cartridge tools and portable grinders, even
qualified tradesmen should be given specific instruction
Power for this type of equipment can be supplied from:
Compressed Air.
Explosive Cartridge.
Electricity.
Internal Combustion
Engines.
There may be little to choose between the efficiency
of tools operated from any of these sources, but there are sometimes other
considerations to be taken into account, e, g., the electric breaker is quieter
in operation than its pneumatic counterpart because it has no exhaust noise.
Such tools are therefore more suitable for use in some confined spaces where
exhaust fumes and the noise level would otherwise become dangerously high.
These advantages must be weighed against the dangers of using electrical tools
in certain confined spaces, such as steel vessels.
The continuing efficiency of all portable powered
tools, like all other mechanical equipment, depends on regular care and
maintenance. Tools should be regularly checked on issue from, and return to
their tool store.
All Maintenance Tools, which have exposed cutters should be switched off and held until they have stopped moving before being set down.
All tools with interchangeable parts must be isolated from the power source (unplugged) before any changes are made.
SAFETY CHECKLIST
ENSURE THAT THE TOOL IS IN GOOD
DON’T USE A SUSPECT TOOL REPAIR
Ensure that
you know the misfire procedure.
Don’t load a
cartridge before you need it.
Hold the tool
against the work surface for 30 seconds.
Pull the
trigger again.
If the
cartridge still does not fire, wait another 30 seconds.
Eject the
cartridge (strictly in accordance with manufacturer’s instructions) and
return it to store for destruction by the manufacturer.
Ensure that
the tool is at right angles to the fixing surface.
Don’t point
the tool at any person
Use the
correct fixing/ piston cartridge combination.
Don’t fix less
than 75mm from the edge of concrete or brick.
Change pistons
when they are worn.
Don’t fix less
than two and a half times the fastener’s shank diameter from the edge of
steel.
Change stop
rings when they damaged.
Don’t fix
where another fixing has failed.
Wear the
safety goggles provided
Don’t strip
down the tool without checking.
Ensure that
the tool is cleaned and lubricated after use.
Don’t press a
tool against your hand.
Keep
cartridges not being used in the tool box or container.
Don’t leave
live cartridges lying about the job site.
Used ear protection,
especially when fixing to steel or working in a confined area.
Don’t insert a
cartridge until after the nail or stud is loaded.
.
Don’t attempt
to use nails, studs or cartridges that have not been approved by the
manufacturer.
perators should not wear any items of loose clothing, which could become caught in moving parts of power Maintenance Tools.
To avoid Milling Machine Safety swarf becoming wrapped around the work piece use only cutting tools with a chip breaker ground in to the tool. Stop the lathe or milling machine to remove swarf with a stiff brush or wooden handle. Dispose of swarf to a closed container.
Extreme caution must be observed when changing lathe
chucks or some milling machine attachments, since these are heavy. Obtain
assistance or use a lifting appliance to avoid back injuries.
As with all rotating Other Machine Safety , loose fitting clothing, gloves or jewelry such as bracelets and rings should not be worn as these can easily be caught on revolving machine parts which would cause serious injury by dragging a hand or arm into moving machinery.
Handle lathe and milling cutters carefully to avoid cuts.
The use of machine and hand tools, in inexperienced or
untrained hands, is a prime cause of accidents and occupational illnesses in
any industry. These accidents are preventable if the operators are properly
trained and equipped with the correct PE, and the safety guidelines are
followed. The following procedure will define these guidelines which must be
followed for work in DEC Project.
Only authorized and qualified machine
operators/maintenance personnel are permitted to work on machine tools. Never
operate service or adjust any machine without proper training and without first
reading the instructions in the owners or manufacturers machine manual.
Familiarize your self with the location of all emergency stop switches.
Check that all machine guards and safety devices are
fitted before operating any machine tools. Never tamper with or make any
adjustments to manufacturers guards or safety devices.
Report all defects of Milling Machine Safety tools to your supervisor immediately once they are discovered.
Never carry cut any cleaning maintenance work while
the machine is in motion. Disconnect or isolate (lockout/ tag- out) the power
source to ensure the machine can not start whilst carrying out these
operations.
Wait for machines to stop completely before taking measurements of Milling Machine Safety
This CNC Drilling Machine procedure defines requirements for the safe operation of machine and hand tools used in all SMI Project.
The work piece must be securely clamped or bolted to the drill table during drilling to avoid accidents if the drill jams, this would otherwise cause the work piece to suddenly rotate. iii
Don’t apply excessive pressure on the drill. Re- grind or replace blunt drill bits.
Only the correct chuck key must be used and this must not be left in the chuck. The adjustable guard must be designed and fitted so as to render the chuck and length of drill not entering into the work piece inaccessible to the operator when the drill is running.
Use a stiff brush to remove swarf (drill cuttings). Not your hands! Store all waste correctly for later disposal.
The wearing of safety shoes is mandatory.
Always wear approved eye protection while machining to protect the eyes against flying pieces of steel chips, abrasive grains or even broken pieces of cutting tools.
Passage ways and floor area around the work place shall be kept free of oil and grease. Raw materials and large work pieces are to be stacked in an area away from CNC Testing Machine.
Obtain assistance when mounting a heavy machine part or heavy work piece, or use a proper lifting device.
The Supervisors are responsible for safe operation of all machine and hand tools used by his crews. All crews have adequate training and experience to work with the hand and CNC Drilling Machine tools. The Project Manager is responsible for ensuring that the requirements of this procedure are adhered strictly to during execution of the project.
Gloves should only be worn when handling sheet metal, heat resistant steel foil and sharp edged pieces of raw materials.
Terms and Condition
a. All standard and special attachment and accessories for 5 axis machining operation must be mentioned and supplied along with the machine and also capable to manufacture parts as per three attach sample/drawings and mention related tools to
Complete the job (at the time of PSI & Training) and supplied along with the machine. b. All additional accessories, attachments supplied along with the machine and mentioned with price in the financial offer. c. List of spare parts with price required for ten (10) years operation to be submitted in the financial offer. Price of sensor of each type quantity one to be mentioned in the spare parts List. d. All optional items with price must be mentioned in the financial Offer which will be certified by the manufacturer of the machine not by local agent. e. Pre-shipment Inspection (PSI): PSI of the machine will be Carried out by 02 BOF persons for 04 working days (excluding journey period). All cost of the PSI to be borne by BOF. f. Foreign Training: Machine operation with maintenance training for 03 BOF persons for 05 working days (excluding journey period) to be provided at machine manufacturer site. Air ticket & Pocket money will be borne by BOF. Others costs like Tuition fee for training, food, accommodation, all internal Travel & medical (if needed) costs to be provided by supplier. g. Local Training: Duration of training should be at least 16 working days. Following information must be given as under cnc drilling machine :
h. Machine installation, trial run and operational with maintenance, training is to be provided by the certified engineers' of machine manufacturer at BOF site within 30 days after receiving Machine by BOF. Otherwise penalty will be
Imposed at the rate of 2% (Two) but not less than 1% (One) and will not exceed 10% (Ten) of the total LC value. j. 2 × operation/programming manual in English (Hard & Soft copy) must be supplied with the machine. 1 Set of all Documents must be loaded in CNC system for easy maintenance. k. 2 × maintenance/repair manual (Hard & Soft copy) with mechanical spare parts list along with circuit diagram and troubleshooting with remedy in English must be supplied with the machine. 1 Set of all documents must be loaded in CNC system for easy maintenance. l. All necessary software to handle & maintain the machine must be supplied along with the machine. Original Technical parameters of Servo motors and drives, sensors to be Provided. m. The machine must be capable of making tools by using software with the help of PC. n. Warranty for 01(one) year after acceptance should be provided by the manufacturer. o. Bidder should submit original Leaflet/Brochure with the offer. p. The service support with spares for minimum 05 years to be provided by the manufacturer. q. Any other points related to do the required job should be mentioned in the offer.
PURPOSE of Manufacturing Vessel Standard Maintenance Procedure
Manufacturing Vessel – The objective of this Standard Maintenance Procedure is to describe the procedure for maintenance of mfg. vessel under Production department. Provides for use Safety Valves set at lower than maximum working pressure of the vessel. Pressure Gauges with maximum operating pressure marked by Red. Drain valve for each pressure vessel isolation valves for each pressure vessels…
SCOPE
Frequency of tests of pressure vessels-external every six months, internal (where possible to see) once every year. ( Where not possible to see inside ) not fitted with continuous plant-hydraulic test every to years, pressure vessel fitted with continuous process plant to be hydraulic tested every 4 years. This procedure is applicable for maintenance of mfg. vessel under Production department of Limited
AREA OF OPERATION
Production floor of General Production building.
RESPONSIBILITY
Operators under engineering department are responsible for following
this SOP.Routine responsibility for ensuring that this procedure is
implemented as and where necessary rests with the Head of Engineering
department.Quality Assurance Department is responsible for SOP
compliance.
INVOLVED
All concern
Operators, Executives / Officers and Head of Engineering Department.
DEFINITION & ABBREVIATION
Definition: There is (are) no unique term(s) in this
document.Abbreviation: There is (are) no unique term(s) in this
document.
HEALTH & SAFETY CONSIDERATION
Wear sound & Eye protective devices during machine
operation.
SYSTEM / PROCESS OWNER
Engineering Department
DESCRIPTION & SPECIFICATION OF MACHINE
Inside mat polish & out side mirror, SS grade: 304,.Inner chamber 3.0mm thick AISI 316, Outlet chamber 3.0mm thick, AISI304. Size57’’x58’’, Capacity: 2400 Liters, Heating source: Steam@4Kg/cm2. Stirrer: Electric power, 400V, 5.5HP, Speed: 300,450,600 rpm. Main shaft: AISI316, Propeller: fan type.
Procedure
Red Mark on pressure gauge. Inspection for voltage fluctuation
Proper earthing condition of machine
Inspection the supply pressure must be 3-4 bar.
Check the any leakage of compressed air
No rusts on seams. Check all bolts & nuts of stirrer assembly
Check the alignment of stirrer
Check the physical condition of T/C clamp
Clean from deposit of chemically reactive matter. Check the physical condition of ‘O’ rings
Safety valve set marked and sealed. Checked the bearing & oil seal of motor
Drain cock operating not blocked. Check the leakage of cooling pot
Cleaning & water replacement of cooling pot
Check the leakage of mechanical seal
No rusts on plates or body. Check the over heat of mechanical seal
Visual inspection for proper working of spray ball
No Pitting. Clean and free of carbonized oil and other matter. Cleaning
Check the correct indication of pressure gauge for cooling pot
Cleaning & water replacement of pressure gauge for cooling pot.
Greased all greasing point (By grease)
Stop valve to isolate, operating
No external visible leaks
No visible defects
Lubricated all lubricating point (By oil)
After completion of maintenance record as per SOP EN/002
REVIEW / CHANGE HISTORY
The procedure must be re-prepared, checked and duly approved whenever any change in the system/ method/ process, or in any circumstance, indicates the need for the same.
The SOP must be reviewed every 3 (three) years from the date of issue, in the light of current practice, to determine whether any change or revision is necessary.
All copies of the SOP which will be superseded by any revision must be withdrawn from active use.
After recalling all the copies of the superseded SOPs, redistribute the reviewed one by keeping records in Log books.
Preserve a copy of the superseded SOP in document archive and destroy rest of the copies keeping records. The SOP is to be archived for 2 years from the date of expiry.
Check Point
Item Description
Check points
Main power supply
01. Inspection for
voltage fluctuation
02. Proper earthing
condition of machine
Pneumatic
connection
01. Inspection the
supply pressure must be 3-4 bar.
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