Machinery Safety Part 3 (High Risk Machinery Part 2)

Machinery Safety Part 3

(High Risk Machinery Part 2)

Presented by: Eng. Luxman Graciyas Jansz

Legislation

High Risk Machinery is covered in Sri Lankan legislation under the Factories Ordinance in Part III, SAFETY (GENERAL PROVISIONS), from section 27 to 29 and 34 to 38.

Under the Factories Ordinance, there are eight (08) categories of high risk machineries shall be thoroughly examined and certified and test certificate entered in or attached to the general register available in the factory. In this article the following four (04) categories of high risk machineries are included with the relevant sections of the Factories Ordinance.

Steam receivers and steam containers – Section 35

Air receivers - Section 36

Gas receivers - Section 36A

Gasholders – Section 38

Steam receivers and steam containers

Section 35. (1) Every steam receiver not so constructed and maintained as to withstand with safety the maximum permissible working pressure of the boiler or the maximum pressure which can be obtained in the pipe connecting the receiver with any other source of supply, shall be fitted with –

(a) a suitable reducing valve or other suitable automatic appliance to prevent the safe working pressure being exceeded; and

(b) a suitable safety valve so adjusted as to permit the steam to escape as soon as the safe working pressure is exceeded, or a suitable appliance for cutting off automatically the supply of steam as soon as the safe working pressure is exceeded; and

(c) a correct steam pressure gauge, which must indicate the pressure of steam in the receiver in pounds per square inch; and

(d) a suitable stop valve; and

(e) except where only one steam receiver is in use, a plate bearing a distinctive number which shall be easily visible.

The safety valve and pressure gauge shall be fitted either on the steam receiver or on the supply pipe between the receiver and the reducing valve or other appliance to prevent the safe working pressure being exceeded.

(2) For the purpose of the provisions of the foregoing subsection, except paragraph (e), any set of receivers supplied with steam through a single pipe and forming part of a single machine may be treated as one receiver, and for the purpose of the said provisions, except paragraphs (d) and (e), any other set of receivers supplied with steam through a single pipe may be treated as one receiver:

Provided that this subsection shall not apply to any such set of receivers unless the reducing valve or other appliance to prevent the safe working pressure being exceeded is fitted on the said single pipe.

(3) Every part of every steam receiver shall be of good construction, sound material, adequate strength, and free from patent defect.

[§ 9, Law 12 of 1976.]

(4) Every steam receiver and its fittings shall be properly maintained and shall be thoroughly examined by a person who is the holder of a certificate issued in that behalf by the Commissioner, so far as the construction of the receiver permits, at least once in every period of twenty-four months.

[§ 9, Law 12 of 1976.]

(4A) If the person employed to make any such examination fails to make a thorough examination required by this section or makes a report which is false or deficient in any material particular or if the chief engineer of any steam receiver inspecting company or association permits any such report to be made, he shall be guilty of an offence and be liable to a fine not exceeding twenty-five thousand rupees.

[§ 4, Act 18 of 1998.]

(5) A report of the result of every such examination containing such particulars as may be prescribed (including particulars of the safe working pressure) shall be entered in or attached to the general register.

(6) Every steam container shall be so maintained as to secure that the outlet is at all times kept open and free from obstruction.

(7) In this section the following expressions have the meanings hereby respectively assigned to them, that is to say:-

“safe working pressure” means, in the case of a new steam receiver, that specified by the maker, and in the case of a steam receiver which has been examined in accordance with the provisions of this section, that specified in the report of the last examination;

“steam receiver” means any vessel or apparatus (other than a steam boiler, steam container, a steam pipe or coil, or a part of a prime mover) used for containing steam under pressure greater than atmospheric pressure;

“steam container” means any vessel (other than a steam pipe or coil) constructed with a permanent outlet into the atmosphere or into a space where the pressure does not exceed atmospheric pressure, and through which steam is passed at atmospheric pressure or at approximately that pressure for the purpose of heating, boiling, drying, evaporating or other similar purpose.

Air receivers

Section 36. (1) Every air receiver shall:-

(a) have marked upon it so as to be plainly visible the safe working pressure; and

(b) in the case of a receiver connected with an air compressing plant either be so constructed as to withstand with safety the maximum pressure which can be obtained in the compressor, or be fitted with a suitable reducing valve or other suitable appliance to prevent the safe working pressure of the receiver being exceeded; and

(c) be fitted with a suitable safety valve so adjusted as to permit the air to escape as soon as the safe working pressure is exceeded; and

(d) be fitted with a correct pressure gauge indicating the pressure in the receiver in pounds per square inch; and

(e) be fitted with a suitable appliance for draining the receiver; and

(f) be provided with a suitable manhole, handhole, or other means which will allow the interior to be thoroughly cleaned; and

(g) in a case where more than one receiver is in use in the factory, bear a distinguishing mark which shall be easily visible.

(2) For the purpose of the provisions of the foregoing subsection relating to safety valves and pressure gauges, any set of air receivers supplied with air through a single pipe may be treated as one receiver:

Provided that, in a case where a suitable reducing valve or other suitable appliance to prevent the safe working pressure being exceeded is required to be fitted, this subsection shall not apply unless the valve or appliance is fitted on the said single pipe.

(3) Every air receiver and its fittings shall be of sound construction and properly maintained.

[§ 10, Law 12 of 1976.]

(4) Every air receiver shall be thoroughly cleaned and examined at least once in every period of twenty-four months:

Provided that in the case of a receiver of solid drawn construction –

(a) the person making any such examination may specify in writing a period exceeding twenty-four months but not exceeding four years within which the next examination is to be made; and

(b) if it is so constructed that the internal surface cannot be thoroughly examined, a suitable hydraulic test of the receiver shall be carried out in lieu of internal examination.

Every such examination and test shall be carried out by a person who is the holder of a certificate issued in that behalf by the Commissioner and a report of the result of every such examination and test, containing such particulars as may be prescribed (including particulars of the safe working pressure) shall be entered in or attached to the general register.

[§ 10, Law 12 of 1976.]

[§ 5, Act 18 of 1998.]

(4A) If the person employed to make any such examination or test fails to make a thorough examination or test, as the case may be, required by this section or makes a report which is false or deficient in any material particular or if the chief engineer of any air-receiver inspecting company or association permits any such report to be made, he shall be guilty of an offence and be liable to a fine not exceeding twenty-five thousand rupees.

(5) In this section the expression “air receiver” means –

(a) any vessel (other than a pipe or coil, or an accessory, fitting or part of a compressor) for containing compressed air and connected with an air compressing plant;

(b) any fixed vessel for containing compressed air or compressed exhaust gases and used for the purpose of starting an internal combustion engine; or

(c) any fixed or portable vessel (not being part of a spraying pistol) used for the purpose of spraying by means of compressed air any paint, varnish, lacquer or similar material; or

[§ 7, Act 33 of 2000.]

(d) any vessel in which oil liquid or similar substance is stored and from which it is forced by compressed air or by any gas:

Provided that the provisions of paragraph (e) of subsection (1) of this section shall not apply to any such vessel as is mentioned in paragraph (c) or paragraph (d) of this subsection.

Gas receivers

[§ 11, Law 12 of 1976.]

Section 36A. (1) Every gas receiver shall –

(a) have marked upon it so as to be plainly visible the safe working pressure;

(b) in the case of a receiver connected with a compressing plant, either be so constructed as to withstand with safety the maximum pressure which can be obtained in the compressor, or be fitted with a suitable reducing valve or other suitable appliance to prevent the safe working pressure of the receiver being exceeded;

(c) be fitted with a suitable safety valve so adjusted as to permit the gas to escape as soon as the safe working pressure is exceeded;

(d) be fitted with a correct pressure gauge indicating the pressure in the receiver in pounds per square inch;

(e) be fitted with a suitable appliance for draining the receiver; and

(f) be provided with a suitable manhole, handhole, or other means which will allow the interior to be thoroughly cleaned.

(2) (a) In any case where, owing to the nature of the process or the action of the contents of any gas receiver, a pressure gauge or safety valve or both cannot be expected to work reliably, there may be installed, with the permission of the Chief Factory Inspecting Engineer and subject to compliance with paragraph (b) of this subsection, a tested and reliably working thermometer capable of recording a high degree of temperature on which there shall be clearly marked the maximum permissible temperature in the receiver.

(b) Where by reason of the technical processes in the receiver it is necessary to replace the safety valve by a thermometer, the receiver shall be equipped with a safety plug which will burst when the pressure rises by not more than twenty-five per centum above the authorized pressure. Where for any technical reason it is not possible to install such plug, there may be installed on one of the appliances (pressure gauge or thermometer) a suitable signalling device that will begin to function when the pressure or temperature rises above the safe limit. Such signalling device shall be so constructed as to avoid the possibility of an explosion in the factory premises due to sparking in an explosive atmosphere or other such causes.

(3) In any case where explosive or poisonous gases may be introduced into or may form in the receiver, the irruption of such gases into workplaces shall be reliably prevented such as by means of pipes leading to the outside of the factory premises from safety valves and plugs or other devices. Before poisonous gases are allowed to escape outside the factory premises they shall be rendered harmless by a suitable filter or other device.

(4) On every vessel which is capable of being opened there shall be a reliable working device by means of which the pressure in the vessel will be reduced to atmospheric pressure before the vessel is opened.

(5) The fittings of vessels installed outside any premises shall be protected against atmospheric influences.

(6) Every receiver containing a liquified gas under pressure or a poisonous gas shall be protected against foreign sources of heat.

(7) Where more than one receiver is in use in any factory, every receiver shall bear a distinguishing mark which shall be easily visible.

(8) For the purpose of the preceding provisions of this section relating to safety valves and pressure gauges, any set of gas receivers supplied with gas through a single pipe may be treated as one receiver:

Provided that, in a case where a suitable reducing valve or other suitable appliance to prevent the safe working pressure being exceeded is required to be fitted, the provisions of this subsection shall not apply unless the valve or appliance is fitted on the aforesaid single pipe.

(9) Every gas receiver and its fittings shall be of sound construction properly maintained.

(10) Every gas receiver and its fittings shall be thoroughly cleaned and examined at least once in every period of twelve months:

Provided that where, in the case of a receiver of solid drawn construction, the internal surface cannot be thoroughly examined, a suitable hydraulic test of the receiver shall be carried out in lieu of internal examination.

Every such examination shall be carried out by a person who is the holder of a certificate issued in that behalf by the Commissioner, and a report of the result of every such examination containing such particulars as may be prescribed (including particulars of the safe working pressure) shall be entered in or attached to the general register.

[§ 6, Act 18 of 1998.]

(11) If the person employed to make any such examination fails to make a thorough examination, required by this section or makes a report which is false or deficient in any material particular or if the chief engineer of any gas receiver inspecting company or association permits any such report to be made, he shall be guilty of an offence and liable to a fine not exceeding twenty-five thousand rupees.

(12) The Minister may by regulations provide for additional safety measures to be taken in respect of different gases.

(13) In this section the expression “gas receivers” means –

(a) any vessel (other than a pipe or coil, or an accessory, fitting or part of a compressor) for containing a compressed gas and connected with a compressing plant; or

(b) any vessel for containing compressed, liquified or dissolved gases.

[§ 12, Law 12 of 1976.]

Exceptions as to steam boilers, steam receivers and containers, air and gas reveivers

Section 37. The Chief Factory Inspecting Engineer may by certificate except from any of the provisions of the last four preceding sections any class or type of steam boiler, steam receiver, steam container, air receiver or gas receiver to which he is satisfied that such provision cannot reasonably be applied. Any such exception may be unqualified or may be subject to such conditions as may be contained in the certificate.

[§ 13, Law 12 of 1976.]

Precautions as respects water sealed gasholders

Section 38. (1) Every gasholder shall be of sound construction and shall be properly maintained.

(2) Every gasholder shall be thoroughly examined externally by a person who is the holder of a certificate issued in that behalf by the Commissioner at least once in every period of two years, and a record containing such particulars as may be prescribed of every such examination shall be entered in or attached to the general register.

(3) In the case of a gasholder of which any lift has been in use for more than twenty years, the internal state of the sheeting shall, within two years of the coming into operation of this section and thereafter at least once in every period of ten years, be examined by a person authorized by the Commissioner by cutting samples from the crown and sides of the holder or by other sufficient means, and all samples so cut and a report on every such examination signed by the person making it shall be kept available for inspection.

(4) A record signed by the occupier of the factory or by a responsible official authorized in that behalf showing the date of the construction, as nearly as it can be ascertained, of the oldest lift of every gasholder in the factory shall be kept available for inspection.

(5) Where there is more than one gasholder in the factory, every gasholder shall be marked in a conspicuous position with a distinguishing number or letter.

(6) No gasholder shall be repaired or demolished except under the direct supervision of a person who, by his training and experience and his knowledge of the necessary precautions against risks of explosion and of persons being overcome by gas, is competent to supervise such work.

[§ 13, Law 12 of 1976.]

(6A) The Chief Factory Inspecting Engineer may, after taking into consideration the design, construction and capacity of any gasholder or a class of gasholder and the purpose for which such gasholder or class of gasholder is used, by certificate grant in respect of such gasholder or class of gasholder, subject to such conditions as may be specified therein, exemption from compliance with the provisions of this section.

[§ 13, Law 12 of 1976.]

(7) In this section, the expression “gasholder” means a water sealed gasholder.

[§ 14, Law 12 of 1976.]

Regulations

38A. (1) The Minister may by regulations make provisions in respect of all matters relating to the issue of certificates referred to in sections 34, 35, 36, 36A and 38. (2) In particular and without prejudice to the generality of the powers conferred by subsection (1), such regulations may prescribe –

(a) for the issue of certificates and for their renewal annually;

(b) the form of application for certificates and the fees to be paid together with such applications;

(c) the qualifications or experience that an applicant should have;

(d) the conditions to be attached to certificates and the circumstances in which the Commissioner may cancel any certificate.

Reference: The Factories Ordinance No. 45 of 1942 and subsequent amendments.

Presented by: Eng. Luxman Graciyas Jansz

                       B. Sc. Eng, Chartered Engineer, FIE (Sri Lanka), MIIE (USA)

                       Visiting Lecturer – University of Moratuwa (Sri Lanka), CETRAC & NIOSH

                       Specialist Factory Inspecting Engineer,

                         97, Industrial Safety Division,

                         Department of Labour, Colommbo-05, Sri Lanka.

                       Tel: +94-714461670, +94-112507104

                             E-mail: lgjansz@yahoo.com, Web: www.schri.com/safetymeasures