1
Arulmigu Meenakshi Amman college of Engineering
Vadamavandal-604410.
Prepared by,
V.Umapathy,
Prof./Mech.
Imortant Questions and Answers
CME388-INDUSTRIAL SAFETY
Syllabus
1. UNIT – I INDUSTRIAL SAFETY 9
Accident, causes, types, results and control, mechanical and electrical hazards, types, causes
and preventive steps/procedure, describe salient points of factories act 1948 for health and
safety, wash rooms, drinking water layouts, light, cleanliness, fire, guarding, pressure
vessels, etc, Safety color codes. Fire prevention and firefighting, equipment and methods.
2. UNIT – II MAINTENANCE ENGINEERING 9
Definition and aim of maintenance engineering, Primary and secondary functions and
responsibility of maintenance department, Types of maintenance, Types and applications of
tools used for maintenance, Maintenance cost & its relation with replacement economy,
Service life of equipment.
3. UNIT – III WEAR AND CORROSION AND THEIR PREVENTION 9
Wear- types, causes, effects, wear reduction methods, lubricants-types and applications,
Lubrication methods, general sketch, working and applications, i. Screw down grease cup, ii.
Pressure grease gun, iii. Splash lubrication, iv. Gravity lubrication, v. Wick feed lubrication
vi. Side feed lubrication, vii. Ring lubrication, Definition, principle and factors affecting the
corrosion. Types of corrosion, corrosion prevention methods.
4. UNIT – IV FAULT TRACING 9
Fault tracing-concept and importance, decision tree concept, need and applications, sequence
of fault finding activities, show as decision tree, draw decision tree for problems in machine
tools, hydraulic, pneumatic, automotive, thermal and electrical equipment’s like, i. Any one
machine tool, ii. Pump iii. Air compressor, iv. Internal combustion engine, v. Boiler,vi.
Electrical motors, Types of faults in machine tools and their general causes.
5. UNIT – V PERIODIC AND PREVENTIVE MAINTENANCE 9
Periodic inspection-concept and need, degreasing, cleaning and repairing schemes,
, 2
overhauling of mechanical components, overhauling of electrical motor, common troubles
and remedies of electric motor, repair complexities and its use, definition, need, steps and
advantages of preventive maintenance. Steps/procedure for periodic and preventive
maintenance of:i. Machine tools, ii. Pumps, iii. Air compressors, iv. Diesel generating (DG)
sets, Program and schedule of preventive maintenance of mechanical and electrical
equipment, Advantages of preventive maintenance. Repair cycle concept and importance.
S.No. Description
Unit-I
INDUSTRIAL SAFETY
Prepared by,
V.Umapathy,Prof./Mech.
Basic Concepts
Topic Basic Concepts / Key Points
An unplanned and undesired event causing injury, property damage or
Accident
production loss.
Causes of Unsafe acts (carelessness, improper operation) and unsafe conditions (poor
Accidents guarding, defective equipment, poor housekeeping).
Falls, slips, struck-by accidents, caught-in machinery, cuts, burns, electric shock
Types of Accidents
and explosions.
Results of Human: injury/death; Economic: medical cost, compensation, production loss;
Accidents Organizational: downtime and reduced productivity.
Identify hazards → assess risk → eliminate/control hazards → provide PPE →
Accident Control
training → supervision → accident investigation.
Mechanical Moving parts, rotating shafts, gears, belts, chains, cutting tools and presses can
Hazards cause crushing, cutting, shearing and entanglement.
Mechanical Machine guarding, interlocks, emergency stops, safe operating procedures,
Prevention regular maintenance and PPE.
Electric shock, burns, short circuit, arc flash and fire. Causes include damaged
Electrical Hazards
wires, overloading, poor earthing and unsafe handling.
Electrical Proper insulation and earthing, MCB/fuses, periodic inspection, lockout/tagout,
Prevention dry working conditions and trained personnel.
Factories Act, 1948 Provisions include cleanliness, ventilation, temperature control, prevention
– Health of dust/fumes, lighting, drinking water, latrines and washing facilities.
Covers machine guarding, work on/near machinery, hoists, lifting
Factories Act –
equipment, pressure plants, floors/stairs, fire precautions and hazardous
Safety
processes.
Washing & Adequate washrooms, latrines and urinals should be provided, maintained
Sanitation clean and suitably located.
, 3
Safe and wholesome drinking water must be provided at convenient and
Drinking Water
properly marked locations.
Lighting & Adequate natural/artificial lighting; floors, walls and work areas should be
Cleanliness clean, hygienic and free from obstructions.
Prevent ignition, control combustible materials, maintain electrical systems,
Fire Safety
provide fire exits, alarms, extinguishers and emergency training.
Fire Triangle Fuel + Heat + Oxygen = Fire. Removing any one element helps extinguish fire.
A: solids; B: flammable liquids; C: flammable gases; D: combustible metals;
Fire Classes
Electrical: energized equipment.
Firefighting Water, foam, dry chemical powder (DCP), CO₂ extinguishers, fire hydrants,
Equipment sprinklers, alarms and fire blankets.
Firefighting Cooling (remove heat), smothering (remove oxygen), starvation (remove fuel)
Methods and chain-reaction inhibition.
Must have safe design, inspection/testing, pressure relief devices, gauges, proper
Pressure Vessels
maintenance and protection against over-pressure.
Red: danger/fire equipment; Yellow: warning/caution; Green: safe
Safety Colour
condition/first aid; Blue: mandatory action; Black/White: general
Codes
identification/traffic markings.
Helmet, safety shoes, goggles, gloves, ear protection, respirators, safety
PPE
belt/harness and protective clothing according to the hazard.
Safety Hazard Identification → Risk Assessment → Control Measures → Training
Management → Monitoring → Emergency Preparedness → Review.
Two Marks QA
Prepared by,
V.Umapathy,Prof./Mech.
1. What is an industrial accident? Mention its two main causes.
Answer: An industrial accident is an unplanned event that causes injury, death, property damage or
production loss. Its two main causes are unsafe acts and unsafe conditions.
2. What are mechanical hazards? Give two examples.
Answer: Mechanical hazards arise from moving or rotating machine parts that may cause injury.
Examples are entanglement in rotating shafts and crushing between moving machine parts.
3. What are electrical hazards? Mention any two preventive measures.
Answer: Electrical hazards include electric shock, burns, short circuits and electrical fires.
Prevention includes proper earthing and insulation, use of protective devices, and maintenance by
trained personnel.
4. What is the purpose of machine guarding?
, 4
Answer: Machine guarding prevents workers from coming into contact with dangerous moving
parts such as gears, belts, shafts and cutting tools. It reduces the risk of cuts, crushing and
entanglement.
5. Mention any four health and safety provisions of the Factories Act, 1948.
Answer: Important provisions include cleanliness, ventilation, adequate lighting, safe drinking
water, washing facilities, sanitary facilities, fencing of machinery and fire safety arrangements.
6. What are the important requirements for drinking water and washing facilities in factories?
Answer: Factories should provide sufficient wholesome drinking water at convenient and suitably
marked locations. Adequate washing facilities and sanitary facilities should also be provided and
properly maintained.
7. What is meant by safety colour coding? Give four examples.
Answer: Safety colour coding uses standard colours to communicate hazards and safety information.
Red – fire/danger, Yellow – warning/caution, Green – safe condition/first aid, Blue – mandatory
action.
8. What is the fire triangle? How can fire be controlled?
Answer: The fire triangle consists of fuel, heat and oxygen. Fire can be controlled by removing any
one of these elements through cooling, smothering or starvation.
9. Name any four fire-fighting equipment and state their uses.
Answer: Water extinguisher – Class A fires; foam extinguisher – flammable-liquid fires; CO₂
extinguisher – electrical fires; DCP extinguisher – several classes of fire, depending on the agent
rating.
10. What are pressure vessels? Mention two safety precautions.
Answer: A pressure vessel is a container designed to hold gas or liquid at a pressure different from
atmospheric pressure. Safety precautions include periodic inspection/testing and provision of
pressure-relief devices, along with proper maintenance and operation.
13 and 15 Marks QA
Prepared by,
V.Umapathy,Prof./Mech.
1. Define accident. Explain causes, types, results and control measures of accidents. Discuss
mechanical and electrical hazards, their types, causes and preventive steps/procedures.
Arulmigu Meenakshi Amman college of Engineering
Vadamavandal-604410.
Prepared by,
V.Umapathy,
Prof./Mech.
Imortant Questions and Answers
CME388-INDUSTRIAL SAFETY
Syllabus
1. UNIT – I INDUSTRIAL SAFETY 9
Accident, causes, types, results and control, mechanical and electrical hazards, types, causes
and preventive steps/procedure, describe salient points of factories act 1948 for health and
safety, wash rooms, drinking water layouts, light, cleanliness, fire, guarding, pressure
vessels, etc, Safety color codes. Fire prevention and firefighting, equipment and methods.
2. UNIT – II MAINTENANCE ENGINEERING 9
Definition and aim of maintenance engineering, Primary and secondary functions and
responsibility of maintenance department, Types of maintenance, Types and applications of
tools used for maintenance, Maintenance cost & its relation with replacement economy,
Service life of equipment.
3. UNIT – III WEAR AND CORROSION AND THEIR PREVENTION 9
Wear- types, causes, effects, wear reduction methods, lubricants-types and applications,
Lubrication methods, general sketch, working and applications, i. Screw down grease cup, ii.
Pressure grease gun, iii. Splash lubrication, iv. Gravity lubrication, v. Wick feed lubrication
vi. Side feed lubrication, vii. Ring lubrication, Definition, principle and factors affecting the
corrosion. Types of corrosion, corrosion prevention methods.
4. UNIT – IV FAULT TRACING 9
Fault tracing-concept and importance, decision tree concept, need and applications, sequence
of fault finding activities, show as decision tree, draw decision tree for problems in machine
tools, hydraulic, pneumatic, automotive, thermal and electrical equipment’s like, i. Any one
machine tool, ii. Pump iii. Air compressor, iv. Internal combustion engine, v. Boiler,vi.
Electrical motors, Types of faults in machine tools and their general causes.
5. UNIT – V PERIODIC AND PREVENTIVE MAINTENANCE 9
Periodic inspection-concept and need, degreasing, cleaning and repairing schemes,
, 2
overhauling of mechanical components, overhauling of electrical motor, common troubles
and remedies of electric motor, repair complexities and its use, definition, need, steps and
advantages of preventive maintenance. Steps/procedure for periodic and preventive
maintenance of:i. Machine tools, ii. Pumps, iii. Air compressors, iv. Diesel generating (DG)
sets, Program and schedule of preventive maintenance of mechanical and electrical
equipment, Advantages of preventive maintenance. Repair cycle concept and importance.
S.No. Description
Unit-I
INDUSTRIAL SAFETY
Prepared by,
V.Umapathy,Prof./Mech.
Basic Concepts
Topic Basic Concepts / Key Points
An unplanned and undesired event causing injury, property damage or
Accident
production loss.
Causes of Unsafe acts (carelessness, improper operation) and unsafe conditions (poor
Accidents guarding, defective equipment, poor housekeeping).
Falls, slips, struck-by accidents, caught-in machinery, cuts, burns, electric shock
Types of Accidents
and explosions.
Results of Human: injury/death; Economic: medical cost, compensation, production loss;
Accidents Organizational: downtime and reduced productivity.
Identify hazards → assess risk → eliminate/control hazards → provide PPE →
Accident Control
training → supervision → accident investigation.
Mechanical Moving parts, rotating shafts, gears, belts, chains, cutting tools and presses can
Hazards cause crushing, cutting, shearing and entanglement.
Mechanical Machine guarding, interlocks, emergency stops, safe operating procedures,
Prevention regular maintenance and PPE.
Electric shock, burns, short circuit, arc flash and fire. Causes include damaged
Electrical Hazards
wires, overloading, poor earthing and unsafe handling.
Electrical Proper insulation and earthing, MCB/fuses, periodic inspection, lockout/tagout,
Prevention dry working conditions and trained personnel.
Factories Act, 1948 Provisions include cleanliness, ventilation, temperature control, prevention
– Health of dust/fumes, lighting, drinking water, latrines and washing facilities.
Covers machine guarding, work on/near machinery, hoists, lifting
Factories Act –
equipment, pressure plants, floors/stairs, fire precautions and hazardous
Safety
processes.
Washing & Adequate washrooms, latrines and urinals should be provided, maintained
Sanitation clean and suitably located.
, 3
Safe and wholesome drinking water must be provided at convenient and
Drinking Water
properly marked locations.
Lighting & Adequate natural/artificial lighting; floors, walls and work areas should be
Cleanliness clean, hygienic and free from obstructions.
Prevent ignition, control combustible materials, maintain electrical systems,
Fire Safety
provide fire exits, alarms, extinguishers and emergency training.
Fire Triangle Fuel + Heat + Oxygen = Fire. Removing any one element helps extinguish fire.
A: solids; B: flammable liquids; C: flammable gases; D: combustible metals;
Fire Classes
Electrical: energized equipment.
Firefighting Water, foam, dry chemical powder (DCP), CO₂ extinguishers, fire hydrants,
Equipment sprinklers, alarms and fire blankets.
Firefighting Cooling (remove heat), smothering (remove oxygen), starvation (remove fuel)
Methods and chain-reaction inhibition.
Must have safe design, inspection/testing, pressure relief devices, gauges, proper
Pressure Vessels
maintenance and protection against over-pressure.
Red: danger/fire equipment; Yellow: warning/caution; Green: safe
Safety Colour
condition/first aid; Blue: mandatory action; Black/White: general
Codes
identification/traffic markings.
Helmet, safety shoes, goggles, gloves, ear protection, respirators, safety
PPE
belt/harness and protective clothing according to the hazard.
Safety Hazard Identification → Risk Assessment → Control Measures → Training
Management → Monitoring → Emergency Preparedness → Review.
Two Marks QA
Prepared by,
V.Umapathy,Prof./Mech.
1. What is an industrial accident? Mention its two main causes.
Answer: An industrial accident is an unplanned event that causes injury, death, property damage or
production loss. Its two main causes are unsafe acts and unsafe conditions.
2. What are mechanical hazards? Give two examples.
Answer: Mechanical hazards arise from moving or rotating machine parts that may cause injury.
Examples are entanglement in rotating shafts and crushing between moving machine parts.
3. What are electrical hazards? Mention any two preventive measures.
Answer: Electrical hazards include electric shock, burns, short circuits and electrical fires.
Prevention includes proper earthing and insulation, use of protective devices, and maintenance by
trained personnel.
4. What is the purpose of machine guarding?
, 4
Answer: Machine guarding prevents workers from coming into contact with dangerous moving
parts such as gears, belts, shafts and cutting tools. It reduces the risk of cuts, crushing and
entanglement.
5. Mention any four health and safety provisions of the Factories Act, 1948.
Answer: Important provisions include cleanliness, ventilation, adequate lighting, safe drinking
water, washing facilities, sanitary facilities, fencing of machinery and fire safety arrangements.
6. What are the important requirements for drinking water and washing facilities in factories?
Answer: Factories should provide sufficient wholesome drinking water at convenient and suitably
marked locations. Adequate washing facilities and sanitary facilities should also be provided and
properly maintained.
7. What is meant by safety colour coding? Give four examples.
Answer: Safety colour coding uses standard colours to communicate hazards and safety information.
Red – fire/danger, Yellow – warning/caution, Green – safe condition/first aid, Blue – mandatory
action.
8. What is the fire triangle? How can fire be controlled?
Answer: The fire triangle consists of fuel, heat and oxygen. Fire can be controlled by removing any
one of these elements through cooling, smothering or starvation.
9. Name any four fire-fighting equipment and state their uses.
Answer: Water extinguisher – Class A fires; foam extinguisher – flammable-liquid fires; CO₂
extinguisher – electrical fires; DCP extinguisher – several classes of fire, depending on the agent
rating.
10. What are pressure vessels? Mention two safety precautions.
Answer: A pressure vessel is a container designed to hold gas or liquid at a pressure different from
atmospheric pressure. Safety precautions include periodic inspection/testing and provision of
pressure-relief devices, along with proper maintenance and operation.
13 and 15 Marks QA
Prepared by,
V.Umapathy,Prof./Mech.
1. Define accident. Explain causes, types, results and control measures of accidents. Discuss
mechanical and electrical hazards, their types, causes and preventive steps/procedures.
