Mechanical Laboratories

Importance, Safety, and Laboratory

Management

Introduction

• 1776: Over 90% of American colonists were farmers; the balance were craftsmen and shopkeepers.

• Today: Less than 2% of Americans are full-time agricultural producers.

• But: 20% of Americans work in some phase of Agricultural Processing, Service, Transportation, etc.

• Mechanization is a major factor for the rise in production.

• The world is dependent upon mechanical technology to supply modern man with security.

• Due to mechanization, people in agriculture must possess mechanical knowledge and skill to be successful.

• Competence in agricultural mechanics is necessary.

Importance of Mechanical Knowledge & Skill

• Save the cost of labor & save time• Recognize quality work in agricultural

mechanics• Learn a new skill through work experience• Gain self-confidence in performing

mechanical operations• Estimate the cost of jobs & materials

needed• Help others with mechanical problems• Understand when it is best for a specialist

to do the job• Construct projects related to the

laboratory

Importance of Rules & Regulations

• Conforming to rules develops good work habits and a positive safety climate for everyone involved.

• Purposes of Rules & Regulations:– Protect the people, tools, equipment, & facilities– Create lifelong safety attitudes & skills– Develop appropriate behavior, housekeeping

practices, & workmanship skills during learning– Develop skills for proper use & maintenance of

tools and equipment– Develop skills by drawing plans, creating bills of

materials, budgeting time, buying building materials, & constructing projects

General Laboratory Safety

– Never run.– No “horseplay.”– Do not distract

someone operating a machine.

– Never use the lab without the supervision of the instructor.

– Wear appropriate Personal Protective Equipment (PPE) at all times in the lab.•Eye & Ear protection•Respirators

–Use tools and equipment properly at all times.–Wear ear protection when near or when using equipment that produces excessive noise levels.–Wear dusts masks or respirators when needed.–Do not wear loose fitting clothing.–Do not wear jewelry.–Report any hazards immediately.

Housekeeping Rules

• It is the responsibility of each student to clean up.– Store hoses, extension cords, etc.

properly.– Shut off all machines, fans, & lights.– Return all tools and equipment to their

proper locations keeping traffic areas open.

– Clean work area, floors, & tools.– Remove any fire hazards from the

laboratory area.– Lock all doors, windows, & tool cabinets.

Cleanup

Wheel-a fair way to distribute cleanup tasks

Record Keeping & Project Rules

• Record keeping is important with learning any skill.

• Types of records to keep:– Notes from class that apply to the lab– Project plans– Bills of Materials

• Project Rules:– Approval of teacher & parents needed– Job Safety Analysis Sheet– Building the required lab project before a

personal project– Purchasing additional materials from lab

supply if needed

Safety Policies & Regulations

• Must be able to locate sources of information regarding safety policies and regulations in the lab

• Facilities must comply with ALL MINIMUM state, local, county, and municipal codes.

• Electrical:– Should comply with National Electric Code

(NEC)– Motors that exceed ½ horsepower & welders

require 240 volts that must be on separate circuits.

– NEC requires ground fault circuit interrupter to be used to prevent shorts and electrocution.

• Ventilation:– Standards or guidelines for laboratory

ventilation available from the American National Standards Institute (ANSI) or the American Welding Society (AWS)

– Necessary to remove welding fumes, exhaust gases, wood dust, & other harmful vapors

– It is recommended the ventilation intake be placed at the work level & not above the operator’s face to prevent fumes from moving across the face of the worker.

– Artificial Methods:•Individual Ventilation System:

– Remove fumes & smoke at the source– Examples:

»Hoods»Tube exhausts

•General Mechanical Ventilation Systems:

– Provide enough air in the workplace to dilute any harmful fumes & smoke in the air

– Examples:»Exhaust fans»Roof vents»Floor fans

Example of an Individual Ventilation System

Safety Color Coding

• When used properly, color speaks a universal language in factories, laboratories, & agricultural industries as a visual aid to safety.

• Helps identify safety equipment & hazards

• Safety color applications are based on Occupational Safety and Health Administration (OSHA) codes.

• Safety Red– Danger & emergency

•Fire equipment

• Safety Orange– Warning

•Cutting edges

• Safety Yellow– Caution

•Hand rails

• Safety Yellow with Black Stripes or Checkers– Non-moving hazards

•Low beams & extensions in walk way

• Safety Blue– Information

•Warning or caution signs

• Safety Green– First aid

•Location of all first aid equipment

• Safety Black and Safety Yellow stripes– Radiation hazard

•Radiation from X-ray radiation types

• Safety Gray or Vista Green– To reduce eye strain

•Body of machines, tables, workbenches, and floors

• Ivory– To improve visibility

•Vertical edges of machines, tables & workbenches

• Aluminum with Orange Band– Waste container for flammable

materials•Waste container

• Aluminum with Black Band– Waste container for non-flammable

materials•Waste container

Importance of Safety Measures

• Safety is the responsibility of everyone.• Total injuries = 3,800,000• Total injuries in Ag. = 150,000• Ag. Fatalities/100,000 workers = 22.5• Injuries cost the employer, the employee, and the

customer.

• Ways to maintain good safety records:– Job Safety Analysis (JSA)– “3-strikes you’re out” policy– OSHA: established to develop

regulations, make safety inspections, issue citations, & impose fines on employers•Purpose: to reduce the number and

severity of accidents by using mandatory means to make equipment & procedures safer

Personal Protective Equipment (PPE)

• Most work in agricultural mechanics requires some type of body protection.

• The best protection is prevention.

• The face and eyes are the most critical parts of the body to be protected.

• Unprotected eyes could lead to:– Blindness– Facial disfigurement– Death

Eye & Face Protection

• Texas Eye Safety Law: requires industrial quality eye and face protection devices to be worn by all students, instructors, & visitors in Texas school labs

• It is essential that prescribed eye protection be available & utilized.

• All eye & face protection devices used in Texas schools must comply with the latest standards publicized by American National Standards Institute (ANSI).

• In the U.S., ANSI has standards for selecting filter lens shades for tinted safety goggles & welding helmets.

• Personal eyewear must be worn in conjunction with, not in place of, approved safety glasses.

• Contact lenses do not provide eye protection.

Eye and Face Protective Devices

• General Operations– Flying fragments, particles, objects, sand, dirt,

etc.•Spectacles with side shields•Goggles with direct ventilation•Face shields

• Lubricating, Spray painting, etc.– Hot Steam, mists, splashing liquids

•Goggles, cup or covered type (indirect ventilation or nonvented)

• Acid and/or chemical handling and degreasing– Splashing liquids, sparks, explosions, irritating

mists•Goggles, cup or covered type

– (indirect ventilation or nonvented)

Eye and Face Protective Devices

• Welding: Electric Arc– Infrared or radiant light burns, sparks,

sputtering, molten metal• Filter lens shades: 10-14• Protector: welding helmet

• Welding: Gas– Flying sparks, splashing of metals, harmful

rays• Filter lens shades: 4-8• Protector: welding goggles

• Cutting– Flying sparks, splashing of metals, harmful

rays• Filter lens shades: 3-6• Protector: welding goggles

Eye and Face Protective Devices

• Brazing– Flying sparks, splashing of metals,

harmful rays• Filter lens shades: 3-4• Protector: welding goggles

• Soldering– Flying sparks, splashing of metals,

harmful rays• Filter lens shades: 1.5-3• Protector: spectacles with side shields

Ear Protection• Use with equipment such as:

– Radial arm saw– Planer– Router– Chain saw

• OSHA Max Safe Limit = 85-decibel (dB) for an 8 hour period

• Wood planers & riveting machines = near 110dB (safe only for 30 minutes/day)

• OSHA studies show that people being exposed to 85dB for a continuous 8 hours experience a 10% hearing loss over time.

• Hearing loss is ACCUMULATIVE: once lost it can never be regained.

Breathing Protection

• Masks & Respirators: cover mouth & nose– Filter out harmful dust particles,

toxic vapors & gases, and hazardous fibers

– Inhaling such particles:•Irritates the nostrils & sinuses•Can lead to lung disease

– Wear when sanding, painting, welding, or using chemicals

Clothing

• When welding:– Clothing should be free of flammable

materials, pockets, & ragged ends– Sleeves & collar should be buttoned

• When in lab:– Leather boots and gloves recommended

• Strength, durability, & ability to breathe

– Gloves protect hands from abrasions, heat or hot liquids.

Preventing Back Injuries

• When possible, DO NOT lift, pull, push, roll, or slide heavy objects.

• Procedures to Prevent Injuries:– Estimate the load to be lifted & ask for help if

possible.•Do not attempt to lift a load of more than 1/3

(35%) of your body weight.

– Keep feet about 8 to 12 inches apart to maintain balance

– Bend knees & keep hips lower than shoulders– Lift heavy loads with the legs and NOT the

back.– When two or more workers are lifting a load, a

signal should be given to lift.

Safety Procedures When Using Equipment

• Safe Use of Hand Tools:– Increase life of hand tools & avoid

injuries by following these basic rules:•Use the correct tool for the job.•Use the tool correctly.•Keep tools in good condition.•Store the tool safely when not using.•Use guards & personal protective

equipment when required.

• Safe Use of Power Tools:– The types of power tools are determined by

their power source:•Electric•Pneumatic•Liquid fuel•Hydraulic

– Kickback: the ejection of the workpiece from the saw back towards the operator•Precautions to prevent kickback:

– Keep saw blades sharp and clean.– Make sure the blade has adequate set in the

teeth.– Never cut wet wood.– Keep safety guards and shields in place.

• Safe Use of Power Tools:– General Precautions:

•Read the operators manual.•Use power tools for their intended function only.•Keep guards and shields in good working

condition and in place and use correctly.•Use power tools in areas free of flammable

vapors and liquids.•Turn power off when tool is unattended or being

serviced.•Stand clear of rotating or turning parts.•Use three-wire cords with grounds and ground-

fault circuit interrupters (GFCI) to protect from shock.

•Do not use damaged extension cords and plugs. Repair or replace them.

•Keep power tools cleaned and lubricated.

• Safe Use of Jacks & Hoists:– Know the capacity of the jack or hoist

and do not overload.– Check hydraulic fluid in hydraulic

hoists and jacks and fill with the recommended oil.

– Inspect the mechanical devices and chains to insure they are in proper working condition.

– Replace parts that are damaged or worn.

– Never walk, stand, or work beneath jacks or hoists.

– When lifting with a jack or hoist, position your body so objects do not fall or roll on you.

• Safe Use of Jacks & Hoists:– Set brakes and place the transmission in gear or

park & block at least one wheel touching the ground before positioning jacks.

– Jacks should be positioned so that they lift straight up and down.

– Try to keep equipment level & stabilized.– Always recheck the position of the jack after

starting to lift.– Attach the chain of a hoist at the pull point to

prevent the chain from slipping.– Attach the hoist directly above the load to be

lifted.• Two most common causes of accidents

when using hoists:– Overloading– Failing to position chains properly

• Ladder Use:– Ladder safety depends upon how and

where the ladder is used.– Ladder selection should be based on

appropriateness for the specific job.– Do not use metal ladders in electrical

settings.– Ladder should be long enough to

safely accomplish the job.– Distance from the base of the ladder

to the wall should be about ¼ of the height of the ladder.

– The ladder should extend 3 feet above the upper surface when working at a higher surface.

Electrical Safety

• Fires resulting from overuse of electric circuits or misuse of extension cords are one of the most frequent types of fires.

• Know the location of the master and emergency shut-off controls in the lab.

• Blown fuses or tripped breakers are an indication of an overload or a short.– Only the teacher should replace fuses.– Can happen if equipment is not properly

grounded or if the wrong gauge extension cord is used

• Cords and duplex outlets should be equipped with grounding features.– Ground fault circuit interrupters

(GFCIs):•Protect against shock & electrical fires

by preventing short circuits•Compares the amount of current flowing

to the equipment with the amount returning to the grounded neutral

•Shuts off current if a difference is sensed

• Check all electrical tools and cords for any damage.

• Frayed cords can expose electrical wires that spark on contact with each other or anything that can ground the current.

• Disconnect equipment if it is sparking or smoking and report the condition.

• Pull the plug from the outlet when disconnecting electrical equipment. Do not pull or jerk the cord.

• Never use electric tools in areas that are damp, wet, or explosive.

• Rubber soled shoes are the safest when working with electricity.

• A safe electrician considers all wires hot.

Fire Safety

• The best method of fire safety is “prevention.”– Prevention begins with knowledge of the

components of a fire.•Fuel: any combustible material that will burn (As

long as in the presence of oxygen, they may ignite and burn)

•Heat•Oxygen

– Can be prevented, controlled, or stopped by removing one or more of the components needed

– Best place to prevent is at the fuel or ignition sources

• Ways to Prevent:– Store fuels in approved containers & away

from materials that easily burn.– Dispose of all flammable objects.– Check the location of flammable materials

before igniting oxy-fuel torch or turning on welder.

– NEVER expose oxygen & acetylene cylinders to oil or grease because spontaneous fires may result.

• Classes of Fires:– Class A: Ordinary Combustibles

(wood, paper, cloth, etc. but not liquid or presence of electricity)

– Class B: Flammable Liquids (greases, fuels, paints, etc. not in the presence of electricity)

– Class C: Electrical Equipment (motors, switches, etc.)

– Class D: Combustible Metals (magnesium, sodium, potassium, titanium, etc.)

Extinguishers• Marked according to the class or classes of fires they

extinguish• Labels contain symbols to help the individual react

quickly.– Red diagonal line drawn through the picture to indicate

what type of fire it is NOT FOR• Common types:

– Water---------------------------------------Class A– Carbon dioxide---------------------------Class B & C– Dry chemical------------------------------Class A, B & C– Dry powder special compound------Class D only– Fire blankets

• Should be located near potential fire areas in clean, dry locations that are easy to reach

• Must be periodically checked & recharged if necessary

Extinguishers

• To use:P—Pull the pinA—Aim at the base of the fireS—Squeeze the operating handleS—Sweep from side to side until the fire is out

First Aid in Laboratories

• Minor Injuries: cuts, bruises, scratches, burns, or punctures

• Major Injuries: severe shock, scalds & burns, cuts, & broken bones– Should be handled immediately by

qualified school personnel and a physician– Teachers & students should know which

personnel are trained in first aid in case emergency medical attention is needed.

Electrical Shock:1. Call school nurse or physician for emergency

assistance.2. Never touch a person who is in contact with

electrical current.3. Disconnect power source if the person is

undergoing electric shock.4. If victim is not breathing, apply mouth-to-

mouth resuscitation. If victim has no pulse, begin cardiopulmonary resuscitation (CPR). (Only trained individuals should perform these.)

5. Cover associated electric shock burns with a dry sterile dressing only.

6. Keep the victim from getting chilled by covering with a blanket.

• Eye Injuries:– Rinse affected eye(s) thoroughly for about 10

minutes with cold water.– Do not attempt to remove any foreign

materials from affected eye(s).– Dress affected eye(s) with sterile cloth or

pads.

• Severe Bleeding:– To stop:

• Apply a clean dressing to the wound with constant pressure.

• Elevating the injured body part, if possible, will help decrease the flow of blood to the injury.

– Cover and dress the wound as soon as possible and then send for assistance.

• ANSI Standard Z308.1 (recommended first aid supplies for workplace first aid kits)– Absorbent compress– Adhesive bandages– Adhesive tape– Antiseptic swabs– Burn treatment– Gloves (one pair)– Sterile pads– Triangular bandage

Acknowledgements

Kirk Edney, Curriculum Specialist, Instructional Materials Service, edited and reviewed this PowerPoint presentation.

Kristie Weller, Undergraduate Technician, Instructional Materials Service, organized and developed the information used in this PowerPoint presentation.

All Rights Reserved

Reproduction or redistribution of all, or part,

of this presentation without written permission is prohibited.

Instructional Materials Service

Texas A&M University

2588 TAMUS

College Station, Texas 77843-2588

http://www-ims.tamu.edu

2007