EE211-Engineering Workshop-1

Lab 01

Introduction to Workshop Hazards, Personal Protective Equipment (PPE) & Tools

Workshop Hazards & preventive measures related to different technical areas are as follows,
1) Contact Injuries (abrasions, cuts, Burns etc.)
a) Wherever practicable, a clean-bench policy
should be adopted, with all items returned
to their designated storage location on
completion of a task. This requires suitable
and sufficient shelves, cupboards, wall
hangings and space to be available.
b) Materials used for workshop activities
should be held at the work area in
appropriate quantities. Bulk storage at the
work area is generally unnecessary and
contributes to congestion.
c) Segregation in storage must be practiced for
incompatible
materials.
Flammable
substances in particular must be held within
a flammable store, which is suitably
constructed, marked and located.
d) Shelving must be secure and never
overloaded. Ensure that freestanding
shelves and cupboards are secured to walls.
e) Care must be taken while handing over
sharp tools to others.
f) One must clearly intimate others regarding
any Hot Material, he has been working on
in the Lab.
g) One must maintain proper working space
for assigned job & avoid congested
situations for work.
h) Proper way to handle the tools is very
important. Many injuries could be caused due to ill posture or bad ways of handling equipment.

2) Electrical equipment (electric shocks or burns from using faulty electrical equipment)
a) All portable electrical equipment must be tested for electrical safety at correct intervals and labelled
with the date of the test.
b) Electrical cables and plugs should be regularly visually inspected by the user for damage.
c) Any defective equipment should be reported to the technician-in-charge and faulty equipment
should be labelled.
d) Electrical equipment must always be operated in accordance with manufacturers' instructions.
e) Electrical wiring during any experiment should not be tangled & circuitry should be intact (without
loose connections).
f) Safety gloves should be worn by candidate performing task.

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3) Manual handling of heavy/bulky objects(back & feet injuries)

a) A risk assessment must be completed for lifting heavy and bulky loads that present a risk of injury.
b) Training in lifting techniques must be provided for workshop staff who undertake the lifting of
heavy loads.
c) Appropriate PPE for lifting operations must be worn.
d) Safety shoes must be worn in order to avoid any foot injury.
e) Materials must be stored in such a manner to avoid spillage, leakage, breakage or falls.

4) Fire
a)
b)
c)
d)
e)
f)

Equipment should be switched off when not in use for long periods.
Flammable substances must be kept away from flames and ignition sources.
Flammable substance must be kept in an appropriate fire resistant metal cabinet.
The fire alarm system should be installed, maintained and tested.
Workshop users must be acquainted with the Fire Routine Procedure for the building.
Fire extinguishers must be installed and students must have basic knowledge regarding its use.

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Important PPE
Personal Protective Equipment (PPE) is an essential purchase for any industry wherein employees have to
operate in a hazardous environment. Historically, not all workers have been provided with a level of
protection that is now considered suitable. Demand for PPE is set to rise in conjunction with the growing
global awareness of the need to provide safe working environment

Types of PPE
1.
2.
3.
4.
5.
6.
7.

Eye and Face protection

Hearing protection
Respiratory protection
Head protection
Arm and hand protection
Foot and leg protection
Torso protection

Eye and face protection

1. Protect from flying particles, molten, metal, liquid chemicals, acids, caustic liquids, light radiations
and chemical vapors or gases.
2. Use safety prescription lenses or eye protection worn over regular glasses or contacts

Respiratory Protection
Two basic types
1. Air purifying respirators
2. Atmosphere supplying respirators

Hearing protection
1. Required in high noise areas, depending on the worker exposure
2. Long term exposure can result in permanent hearing loss impairment
3. PPE- earplugs or earmuffs

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Torso protection
1. Hazards include heat, splashes from liquids, impacts, cuts and radiation
2. Injuries include heat burns, radiation burns, chemical burns and abrasions
3. Equipment includes vests, jackets, aprons coveralls and full body suits.

Head protection
1. Exposed electrical conductors
2. Helmets rated as types 1 or 2 and providing class A, B and C protection
A= General impact, 2200 volts protection
B= 22000 volts protection
C= Bump protection, no electrical protection

Arm and Hand protection

1.
2.
3.
4.
5.

Hazards from chemicals and other substances, sharp objects, temperature effects
Injuries include shock, cuts, burns, abrasions, amputations
Glove protection information to be obtained from the manufacturer
Protection Includes, gloves, sleeves, hand pads, wristlets, etc.
Rubber insulating equipment needed for electrical workers

Foot and Leg protection

1. Hazards from rolling or falling objects, objects piercing the sole, hot Surfaces
2. Shoes/boots may provide impact protection puncture protection, compression Protection
3. Leggings protect the lower legs and feet from molten metal and welding sparks

Electric Shock
This is so important! Electricity can shock, burn or kill
you! You never know when contact with electricity will be
fatal, but you can count on it hurting. It's not only power
lines that can kill or injure you if you come in contact with
them but you can also be killed by shock from an appliance
or power cord in your home if you don't know how to take
precautions!

Lab 01

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Lab 01

Avoid Electric Shock!

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

Never climb utility poles or play on fences around substations.

Keep electrical cords and wires away from heat and water.
If you are touching water, never touch electrical devices such as light switches, hair dryers, curling
irons, mixers, or toasters.
Don't pull on electric cords to unplug them.
If you see a fallen electrical wire, stay away!
Disconnect appliances before cleaning them.
Tell someone if you see a frayed cord.
Don't touch overhead wires when you're carrying a ladder, pool skimmer, or any other long object.
Don't climb a tree that has power lines running through or near it.
Don't use an electrical appliance when you're wet.
Don't touch anyone or anything that is touching a downed wire.

Electric Safety instructions

1. No machine is to be operated while the teacher is out of the room.
2. You are not required to operate any power driven machinery in the lab in order to earn your credit.
3. Before you will be given permission to operate any machine you must: pass a test on the general Safety
instructions, pass the test on the safe operation of that machine.
4. All students must be aware of the fire safety procedures.
5. All flammable liquids must be stored in approved safety cabinets.
6. Only use toxic chemicals in properly ventilated areas.
7. Put all used or oily rags in approved covered metal cans. Oily rags exposed to the air may catch fire.
8. Use of abrasive materials must be done with extreme caution.
9. You must report all accidents to the teacher at once.
10. Everyone must use approved eye protection whenever anyone is working in the shop.
11. You must have all loose clothing tightly fastened or removed before operating any machine. All Rings and
loose jewelry must also be removed and hair must be tied back.
12. Particle masks are provided for dusty or toxic atmospheric conditions, such as spray finishing, Sanding,
sawing, and lathe work.
13. Do not lift heavy objects beyond your strength. Ask the teacher for assistance.
14. Never put or carry nails, screws, or other objects in your mouth.
15. Running, scuffling, pushing another student, and horseplay in the lab are not allowed at any time.
16. You must never throw anything in the lab.
17. Any spills must be cleaned up immediately.
18. You must never leave any tools or materials of any kind lying on the floor.
19. Return all tools that you are not using to the proper storage area.
20. Carry tools so that the sharp edges are pointed downward and away from your body.
21. To remove a power cord from an outlet you should pull the plug, not the cord.
22. Make sure all plugs and power cords are not damaged and in proper working order before using any piece
of equipment or portable electric tools.
23. If you find a damaged tool, report it to the teacher. Never use it in that condition.

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Lab 01

Introduction to Workshop Tools

1. Screwdrivers
A screwdriver is a hand tool that is designed to turn screws. The shank
is made of steel set into a wooden or plastic handle. The blade is shaped
or flattened to fit recesses in heads of screws or bolts screwdrivers are
made in many size & types.

2. Wire stripper
A simple manual wire stripper is a pair of opposing blades which
makes it easier to cut the insulation without cutting the wire. This type
of wire stripper is used by rotating it around the insulation while
applying pressure in order to make a cut around the insulation. Since
the insulation is not bonded to the wire, it is pulled easily off at the
end. This is the most versatile type of wire stripper.
Another type of manual wire stripper is very similar to the simple
design previously mentioned, except this type has several notches of
varying size. This allows the user to match the notch size to the wire
size, thereby eliminating the need for twisting. Once the device is
clamped on, the remainder of the wire can simply be pulled out,
leaving the insulation behind.
Types and Shapes
1. Manual wire stripper.
2. Automatic wire stripper.

Automatic.

Manual.

Manual.

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3. Cutter
Cutting is used for cutting. A very sharp blade is affixed in the handle
for grip. Special care should be taken while handling it.

4. Knife
A knife is any cutting edge or blade, handheld or otherwise, with or without a handle. Knives were used
at least two-and-a-half million years ago, as evidenced by the Old wan tools. Originally made of rock,
flint, and obsidian; knives have evolved in construction as technology has with blades being made from
bronze, copper, iron, steel, ceramics, and titanium. Every culture has a unique version of the knife. A
knife may be either a fixed-blade or a folding version with blade patterns and styles as varied as their
makers and countries of origin. Due to its role as mankind's first tool, certain cultures have attached
spiritual and religious significance to the knife.

5. Wire Gauge
Wire gauge is a measurement of how large a wire is, either in diameter or cross sectional area. This determines
the amount of current a wire can safely carry as well as its electrical resistance and weight per unit length. It
consists of circular or oblong form having notches of different widths to receive wire and sheet metals of different
thicknesses. Increasing gauge nos. gives decreasing wire diameters.
Types
There are two types of wire gauge. AWG values
are also given in fig.

Empirical wire gauge (Geometrical wire

gauge)
AWG(American wire gauge)

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Lab 01

AWG (American Wire Gauge)

The American wire gauge (AWG) of a stranded wire is determined by the total cross sectional area of
conductors which determine its electric current carrying capacity and electrical resistance.

Uses

Applicable to both (electrical & non- electrical wires) being important to electrical wiring.
Used by steel industry to make steel wires and rods.
AWG is commonly used to specify body piercing jewelry sizes, especially smaller sizes.

Advantage
Advantage of this system includes the ability to readily calculate the physical dimensions or weight of wire, ability
to take account of non-circular wires and ease of calculation of electrical properties .

6. Phase Tester
Phase tester is an electrician tool used to detect the voltage & current in a
circuit. It consists of a light bulb which turns on in the presence of voltage.
Uses
Phase tester is used:
To detect the current passing through a circuit.
To find the voltage passage through any circuit.
To check the short circuits.

7. Pliers
Pliers are the tools used to hold an object.
Linemans pliers, also called combination pliers are
a type of pliers used by electricians and other
tradesmen to grip small objects, to cut and bend the
wire and cable. They have insulating handle grips
that reduce the risk of electric shock.
Types and Shapes There are different types and
shapes of pliers as shown in figures.

Linemans pliers.

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Uses
The typical uses of pliers are:

They are used to cut, bend and strip the insulation of wires and cables.
They are used to crack the spiral casing of the cables.
The most common example in gripping is to twist bare wires together, to form a common connection.

8. Hammers
A hammer is a tool meant to deliver an impact to an object. .The hammer is a very simple striking tool, being
just a weighted head and a handle to direct its course.
Shapes
There are different shapes of hammers as shown in figs .

Uses
The most common uses of hammers are:
1.
2.
3.
4.
5.

For driving nails.

Fitting parts.
Fogging metal.
Breaking up objects.
The straight-peen hammer is used for spreading or drawing out metal in line.

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6. The cross-peen hammer is used for the same operation at right angles with the handle.
7. The claw hammer is used for driving and pulling nails.

Straight peen

Ball Peen

Cross Peen

Parts of Hammer

9. Vernier caliper
This device measures the inner & outer length, diameter & depth of any object under observation in
LAB. Its least count is 0.01cm (0.1mm). There are two main parts of vernier caliper,
1. Main Scale (Fixed Scale): it is graded in cm scale & largest part as compared to other.
2. Vernier Scale: This part slides on main scale. Ten lines are engraved on in, which help us to
measure the exact length of object.
3. During measurement first of all find the reading on the main scale which is before the 0
marking on the vernier scale.
4. Then find the marking on vernier scale as compared to main scale, which is exactly in line.
5. At the end, add the measurements of main scale and vernier scale. (multiply vernier scale
reading by the least count).

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Lab 01

Importance
1.
2.
3.
4.

It used to measure the length, diameter and depth.

It commonly used in industry to provide a precision up to a hundredth of a millimeter.
Modern vernier calipers are two types: digital and analogue caliper.
Accuracy of measurement when using a caliper is highly dependent on the skill of the
operator.
Its parts are as shown in figure.

10. Screw gauge

The spindle of an ordinary metric
micrometer has 2 threads per
millimeter, and thus one complete
revolution moves the spindle through
a distance of 0.5 millimeter. The
longitudinal line on the frame is
graduated with 1 millimeter divisions
and 0.5 millimeter subdivisions. The
thimble has 50 graduations, each
being 0.01 millimeter (one-hundredth of a millimeter). Thus, the reading is given by the number of
millimeter divisions visible on the scale of the sleeve plus the particular division on the thimble which
coincides with the axial line on the sleeve. Suppose that the thimble were screwed out so that graduation
5, and one additional 0.5 subdivision were visible (as shown in the image), and that graduation 28 on
the thimble coincided with the axial line on the sleeve. The reading then would be 5.00 + 0.5 + 0.28 =
5.78 mm.

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1.
2.
3.
4.

Lab 01

It is a measuring tool which is used measure the diameter.

Its least count is 0.01mm.
It is very important in physics lab.
The observation with these instruments should be very careful and precisely carried out because
of human error are high.

11. Wrenches
A wrench or spanner is a tool used to provide grip and mechanical advantages in applying torque to
turn objects, such as nuts and bolts.
An important note is that wrench is the standard term, while spanner refers to specialized wenches
with a series of pins or tabs around the circumference.
Types of Wrenches
There are many types of wrenches. Some important types of wrenches are given below.

Open ended wrench

A wrench with U- shaped opening that grips
two opposite forces of the bolt or nut. The
wrench is often double ended with different
sizes. This allows greater range of movement.

Box end wrench or ring spanner

A wrench with an enclosed opening

that grips the faces of the bolt or nut.
The recess is generally a six point or
twelve points opening for use with
nuts or bolts heads with a hexagonal
shape. Ring spanner is also often
double-ended.
Ratcheting box wrench
It is the type of ring spanner, or reversed by flipping over the wrench, whose end section ratchets.
Ratcheting can be reversed by flipping over the wrench, or by activating a reversing lever on the
wrench.

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Combination wrench
It us double-ended tool with one end being like an
open-end and other end being like a box-end wrench.

Adjustable wrench
Adjustable wrench or shifting spanner a type of
wrench with a movable jaw that adapts the tool
different sized objects.

Socket wrench
A hollow wrench that fits over one end of a
nut or bolt head. It may include a handle, but
is usually used with various drive tools.

Striking face box wrench

It is also called slogging/flogging spanner,
this is a specialized wrench with a block end
the handle specifically designed for used
with a hammer.

Allen wrench
It is L-shaped wrench fabricated from hexagonal wire stock of various sizes, used to turn screw or
bolt heads with a hexagonal recess to receive the wrench.

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Alligator wrench
A common type of wrench, the wrenchs shape suggests the mouth of an alligator.

Tap wrench
A doubled-handled wrench for turning the square drive on taps used in threading operation or a
precision steamer.

Plumber wrench
A tool to screw (rotate with force) various pipes during
plumbing.

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Tuning wrench
A socket wrench used to tune some stringed musical
instruments.

Wing nut wrench

A tool specifically for use with wings nuts, allowing the
application of greater torque than is possible by hand.

Oil-filter wrench
A wrench used to remove cylindrical oil
filters.

Lab 01

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Cone wrench
A special wrench required to adjust the bearing cones
on a hub.

Power wrench
A broad type of wrench that use electricity or compress air to power the wrench.

Lab 01