Maintenacnepractices Introduction

Maintenance
Practice-I
First Semester
ByGaurav
Maintenance
The process of keeping something in useable
condition by checking or repairing it on regular

basis.
Maitenance Practice-1
Practice
Actual doing of something rather than ideas
Way of doing something
Doing an activity or training on regular basis
to improve skills
Habit or Custom
MaintenancePractice
This subject deals with the way of keeping
something in useable/good condition
Airworthy
condition
aircraft
Whythissubject?
Prime objective of an AME is to maintain an aircraft
in airworthy condition so that it can fly safe and

reach its destination with all its passenger safely.
If there is an error in maintenance or ignorance of
maintenance procedure by maintenance personnel
then the life of passengers and crews and machine
is at stake.
So it is important that the persons involved in
maintenance of aircraft must have proper
knowledge of procedures and practices involved in
maintenance of aircraft
MaintenancePractice
This Subject is divided in 03 parts
Maintenance Practice -1- Ist Semester
Maintenance Practice -2- IInd Semester
Maintenance Practice -3-IIIrd Semester
MaintenancePractice1
Safety Precaution-Aircraft and Workshop
Workshop Practices
Tools
Operation, Function and Use of Electrical
General Test Equipment

Fits and Clearances
Weight and Balance
Chapter1
Safety Precaution
Aircraft
and
Workshop
SafetyPrecaution
An action taken in advance
to protect against possible

danger, failure, or injury.
Maintenance Practice-1
Aircraft
Any machine which can derive support in
the atmosphere from reactions of the air

other than reactions of the air against the
earth's surface and includes balloons
whether fixed or free, airships, kites, gliders
and flying machines. (source: Aircraft Rules
1937)
Any vehicle designed to be supported by
air, heavier or lighter than air, mechanically
or non-mechanically driven
Maintenance Practice-1
Workshop
A room or shop where work is done
It includes
-Aircraft hanger maintenance bays
-Mechanical and electrical bays
-Machine shops
-Cleaning plants
-Battery rooms
-Basic bench tool work areas
Accident
An unfortunate incident that happens
unexpectedly and unintentionally, and may

result in injury or death of people and/or
damage to equipments or facilities
Accident always have a cause.
That cause may be
-unsafe human condition
-unsafe environmental condition ( Humans are
responsible for choosing or creating

unsafe condition )
Hazard
anything that has the potential to create
danger and thus harm.

Most hazards are dormant or potential,
with only a theoreticalriskof harm;

however, once a hazard becomes "active",
it can create anemergencysituation.
Hazard
Hazards occurs as a result of day-to-day
activities in and around the workplace. e.g.

Slippery floor
Defective tools
Spilled chemicals
Overconfidence
Fatigue
Stress
Lack of fitness
Inappropriate or incorrectly worn dresses
Risk
risk is the likelihood/chance that a person may be harmed
or suffers adverse health effects if exposed to a hazard.

The level of risk is often categorised upon the potential
harm or adverse health effect that the hazard may cause,
the number of times persons are exposed and the number
of persons exposed.
Exposure to airborne asbestos fibres will always be
classified as high because a single exposure may cause
potentially fatal lung disease, whereas the risk associated
watching a television for a short period could be
considered to be very low as the potential harm or
adverse health effects are minimal.
RiskandHazard
The terms Hazard and Risk are often used
interchangeably but this simple example explains

the difference between the two.
If there was a spill of water in a room then that
water would present a slipping hazard to persons

passing through it. If access to that area was
prevented by a physical barrier then the hazard
would remain though the risk would be minimised.
So, Risk and Hazard collectively leads to Accident.
RiskAssessmentforSafety
A risk assessment would involve identifying
a hazard and then evaluating the risk in the

light of precautions to reduce the danger or
remove it.
First hazard must be recognized; then they must
be assessed; and finally, if necessary, they must

be controlled.
RecognitionofHazard
Slippery floors
Untidy work areas
Cluttered walkways
Insecure handrails
Defective tools
Spilled chemicals
Inadequate lighting
Poor ventilation
Lack of equipment
Excessive noise
Unsafe
Environmen
tal
Condition
RecognitionofHazard
APATHY
BOREDOM
NEGLIGENCE
COMPLACENCY
DISOBEDIENCE
TOMFOOLERY
SHOWING-OFF
OVER CONFIDENCE
FATIGUE
STRESS
Unsafe Human Condition
SafetyPrecautionAircraft
Airport Terms
Airport
Anairportis a location whereaircraft such
asfixed-wing
aircraft,helicopters,
andblimpstake off and land. Aircraft may
be stored or maintained at an airport. An
airport consists of at least one surface such
as arunwayfor a plane to take off and
land,
ahelipad,
or
water
fortakeoffsandlandings,
and
often
includes
buildings
such
ascontrol
towers,hangarsandterminalbuildings.
AirsideandLandside
Airports are divided into landside and
airside areas.
Landside areas includeparking
lots,public transportationtrain stations
and accessroads. It is the area accessible
to normal public.
Airside areas include all areas accessible
to aircraft, including runways,taxiways
andramps.
Access from landside areas to airside areas
is tightly controlled
at most airports.
AirsideandLandside
AirsideandLandside
APRON
Area that accommodates aircraft for
the purpose of loading/off-loading

passengers and cargo, refueling,
parking and maintenance.
APRON
APRON
Tarmac: Though commonly used to describe
the area where planes park,tarmacisnt

officially a place. That word is the name of a
product produced by a British company that
produces a surface coating that is applied to
roads and airfields.
Using tarmac to describe where planes park
is like calling the area outside a building
where cars park the concrete instead of
calling it the parking lot. Tarmac with a
capital T is a registered trademark.
APRON
Ramp: Its a common unofficial term that is
very much in use at airports

American and Asian countries.
of
some
APRON
Apron: This is in fact the official term used by both
the International Civil Aviation Organization (ICAO),

which advises on aviation practices worldwide, and
the Federal Aviation Administration (FAA), which
regulates aviation in the U.S., to designate the area at
the airport where parked and serviced at airports.
The apron is a busy place. Its the part of the airport
where vehicles and airplanes share the same space.

The many movements on the apron are not generally
controlled by the air traffic control tower.
ManeuveringArea
Area other than apron, used for the
movement of the aircraft on the

ground and for the taking-off and
landing.
MovementArea
Comprises both the maneuvering area
and the apron.
Taxiway
Path connecting the runway to other aircraft
facilities, such as hangers and apron.
Runway
A strip of land or water from which aircraft can
takeoff and land on airport.
Hanger
An enclosed structure designed to hold the
aircraft in protective storage.
PointstobeObserved
Apron environment is often a busy
one and be aware of the danger.

Aware
with
airport
instructions rules.
operations
Entry to the maneuvering area require
clearance from local air traffic controller.
AirportMarking
Airport markings are used to mark structures, and
path so that these can be used by required

personnel or vehicles without confusion.
Both paint and lights are used for marking so that,
markings are visible in day as well as night.
Vehicle routes white line

Aircraft routes yellow line
Pedestrian routes green line
Delineation between apron and maneuvering area
double white lines
AircraftTaxiway
The taxiway centre-line is a single continuous
yellow line, 6 inches (15 cm) to 12 inches (30

cm) in width. This provides a visual cue to
permit taxiing along a designated path.
Taxiway edge marking are of two types:
Continuous: Consist of a continuous double
yellow line, with each line being at least 6 inches
(15 cm) in width spaced 6 inches (15 cm) apart.
They are used to define the taxiway edge from
the paved surface not intended for use by
aircraft.
AircraftTaxiway
Dashed Markings. define the edge of a taxiway or taxi-
lane on a paved surface where the adjoining pavement to

the taxiway edge is intended for use by aircraft. e.g., an
apron. Dashed taxiway edge markings consist of a broken
double yellow line, with each line being at least 6 inches
(15 cm) in width, spaced 6 inches (15 cm) apart (edge to
edge). These lines are 15 feet (4.5 m) in length with 25
foot (7.5 m) gaps.
Identified by blue edge light and sometimes green centre
line lights.
Also have red stop bar lights at various holding points.
AircraftTaxiway
Runways
Apron
Normally illuminated by an array of
overhead pylon lights.
Runways
A line of lights on an airfield or elsewhere to guide aircraft
in taking off or coming in to land or an illuminated

runway is sometimes also known as aFlare Path.
Runway center Line: embedded in surface of runway at
50 ft interval along runway center line. White light is used
for this except last 900 m, alternate white and red for
next 600m, and red for last 300m.
Runway edge lights: white elevated lights that run the
length of the runway on either side. On precision
instrument runways, the edge-lighting becomes yellow in
the last 2,000ft (610m) of the runway, or last third of
the runway, whichever is less.
Vehicles
For driving in the movement area
personnel must require Airfield Driving

Permit (ADP).
Aircraft have priority over all vehicles in
the airside.
Fire and rescue vehicles on emergency call
out have priority.
Pedestrian have priority on apron.
Vehicles
All vehicles display a roof mounted yellow
flashing obstruction light in movement area.

Fire and rescue vehicles display a flashing blue
light when emergency callout.
In apron speed of vehicles restricted to 15 mph.
Vehicles use dipped headlight while moving .
Vehicles must not approach aircraft until the
aircraft is choked and engines have been shut
down and anti-collision lights have been
switched off.
Vehicles
Vehicles have to positioned so that they do
not have to reverse in order to leave the zone.
Clothing
Wear approved high visibility anoraks or
tabards at all times.
Noise
Noise from turbine engine can cause
temporary or long-term damage to hearing.

This noise also blankets the sound of
approaching vehicles and will drown out
shouted warnings.
Personnel working on airport needs to wear
the ear defenders.
Engine
Personnel must be alert at the time of starting
of engine not to stray in front of engine

intakes, propellers or into the jet-blast.
Even at low power setting hot jet blast can be
left 100ft behind the aircraft.
At full power some engines can even pull a
full grown man into intake. And can throw a
truck, if is in the vicinity of engines exhaust.
So areas coming directly under the operation
of engine should be avoided.
Engine
Engine
Video
FuelSpill
The source of spill should be shutoff .
All sources of ignition should be removed.
All engines in Ground Power Unit and vehicles
in the area should be turned off.
TaskLighting
Overhead pylon lights are capable of
illuminating the area but this does not help

when personnel are working under aircraft.
Lighting in these area are well below what
would considered adequate for conducting
maintenance task.
Hand torches may seem to be an ideal
solution but their batteries gradually deplete
and they do restrict user to one handed
operation.
TaskLighting
Ensure that the light being used during
maintenacne is of approved flameproof type.
ForeignObjectDamage(FOD)
Unwanted object other than objects required
aircraft maintenance and operation are known

as Foreign Object. Cuts of locking wire, split
pins, plastic bags, stones etc.

Can damage the turbine engine.
Can cause serious damage to the moving
propeller blades.
WorkingonA/c
Appropriate clothing and suitable footwear, do
not wear jewellery or loose items.

Dont carry means of ignition.
Be aware that it takes time to gain fully night
vision when moving from a brightly lit area to
a dark place.
Always ground aircraft before fueling, defueling or work on oxygen system.
Approved fire extinguisher should be located
at easily accessible area.
WorkingonA/c
Aircraft should be correctly choked, and
appropriate covers and locks should be used

when required.
Before moving flight control surfaces ensure
that movement is not obstructed by ground
equipment, and dont posses hazard to
personnel.
Specified procedure and must be followed
during removal or installation of aircrafts
component.
Dont use tools carelessly as this may scratch
WorkingonA/c
Ensure that aircraft electrical bonding wires and
static discharges are left intact and connected

after work has been completed.
Always take extra care while handling the aircraft
fluids. As there spillage may damage other
aircraft parts.
Approach the helicopter in view of the pilot.
Never approach a helicopter carrying anything
with a vertical height that the blades could hit.
This could cause blade damage and injury to the
person.
ShopSafety
The
highest standards of orderly work

arrangements and cleanliness should be
observed during the maintenance of aircraft.
Where
continuous
work
shifts
are
established, the outgoing shift should
remove and properly store personal tools,
rollaway
boxes,
all
work
stands,
maintenance stands, hoses, electrical cords,
hoists, crates, and boxes that were needed
for the work to be accomplished.
ShopSafety
Signs should be posted to indicate dangerous
equipment or hazardous conditions. There

should also be signs that provide the location
of first aid and fire equipment.
Safety lanes, pedestrian walkways, and fire
lanes should be painted around the perimeter
inside the hangars. This is a safety measure to
prevent accidents and to keep pedestrian
traffic out of work areas.
ShopSafety
Technicians and supervisors should watch for
their own safety and for the safety of others

working around them.
If other personnel are conducting their actions
in an unsafe manner, communicate with

them, reminding them of their safety and that
of others around them.
ElectricalSafety
It is known that when electricity is applied to
the human body, it can create severe burns.

In addition, the nervous system is affected
and can be damaged or destroyed.
To safely deal with electricity, the technician
must have a working knowledge of the
principles of electricity, and a healthy respect
for its capability to do both work and damage.
ElectricalSafety
Wearing or use of proper safety equipment can
provide a psychological assurance at the same time it

physically protects the user.
The use of rubber gloves, safety glasses, rubber or
grounded safety mats, and other safety equipment
contributes to the safety of the technician working on
or with electrical equipment.
Two factors that affect safety when dealing with
electricity are fear and overconfidence. While both a
certain amount of respect for electrical equipment is
healthy and a certain level of confidence is necessary,
extremes of either can be deadly.
ElectricalSafety
Lack of respect is often due to lack of
knowledge. Personnel who attempt to work

with electrical equipment and have no
knowledge of the principles of electricity lack
the skills to deal with electrical equipment
safely.
Overconfidence leads to risk taking. The
technician who does not respect the
capabilities of electricity will, sooner or later,
become a victim of electricitys awesome
power.
FireSafety
Anytime current flows, whether during
generation or transmission, a byproduct of that

flow is heat. The greater the current flow, the
greater the amount of heat created.
When this heat becomes too great, protective
coatings on wiring and other electrical devices
can melt, causing shorting, which leads to more
current flow and greater heat. This heat can
become so great so that metals can melt,
liquids vaporize, and flammable substances
ignite.
FireSafety
To prevent electrical fires :
keep the area around electrical work or
electrical equipment clean, uncluttered, and

free of all unnecessary flammable substances.
Never place wires or cords where they will be
walked on or run over by other equipment
CompressedGas
Storage room for Gas cylinder should be well
ventilated
Cylinders should not be exposed to sunlight.
Gas cylinders should not be laid on damp ground.
Lightning for stores containing combustible gas
cylinder should be flameproof.
Breathing oxygen and welding oxygen should be
segregated and properly labeled to avoid confusion.
Grit, dirt and oil should be prevented from entering
the cylinder valves.
Acetylene cylinder should be stored vertically.
CompressedGas
Compressed air, like electricity, is an excellent
tool as long as it is under control.

Inspect air hoses frequently for breaks and worn
spots. Unsafe hoses should be replaced
immediately.
Keep all connections in a no-leak condition.
Air used for paint spraying should be filtered to
remove oil and water.
Never use compressed air to clean hands or
clothing. Pressure can force debris into the flesh
leading to infection.
CompressedGas
Air hoses should be straightened, coiled, and
properly stored when not in use.

Many accidents involving compressed gases
occur during aircraft tire mounting. To prevent
possible personal injury use appropriate lifting
and mounting devices in mounting or
removing heavy aircraft tires.
WeldingSafety
Welding should be performed only in
designated areas.
Any part to be welded should be removed
from the aircraft, if possible.
A welding shop should be equipped with
proper tables, ventilation, tool storage, and
fire prevention and extinguishing equipment.
Welding on an aircraft should be performed
outside, if
possible.
WeldingSafety
If welding in the hangar is necessary, observe
these precautions:
During welding operations, there should be no
open fuel tanks, and no work on fuel systems
should be in progress.
No painting should be in progress.
No aircraft are to be within 35 feet of the
welding operation.
No flammable material should be in the area
around the welding operation.
WeldingSafety
Only qualified welders should be permitted to do the
work.
Fire extinguishing equipment of a minimum rating of
20B should be in the immediate area with 80B rated
equipment as a backup.
Aircraft being welded should be in towable condition,
with a tug attached, and the aircraft parking brakes
released. A qualified operator should be on the tug,
and mechanics available to assist in the towing
operation should it become necessary to tow the
aircraft. If the aircraft is in the hangar, the hangar
doors should be opened.
FireProtection
Rapid oxidation, accompanied by a noticeable release
of heat and light, is called combustion or burning.

Requirements for Fire To Occur:
Fuel: something that will, in the presence of heat,
combine with oxygen, thereby releasing more heat
and as a result reduces itself to other chemical
compounds;
Heat: accelerates the combining of oxygen with fuel, in
turn releasing more heat
Oxygen: the element which combines chemically with
another substance through the process of oxidation.
FireProtection
Classification of Fires:
For commercial purposes, the National Fire
Protection Association (NFPA) has classified fires

into three basic types: Class A, Class B, and Class
C.
Class A fires occur in ordinary combustible
materials, such as wood, cloth, paper, upholstery
materials, and so forth.
Class B fires occur in flammable petroleum
products of other flammable or combustible
liquids, greases, solvents, paints, and so forth.
FireProtection
Class C fires occur involve energized electrical
wiring and equipment.

Class D fire Class D fires are not commercially
considered by the National Fire Protection
Association to be a basic type or category of
fire since they are caused by a Class A, B, or C
fire. Usually Class D fires involve magnesium in
the shop or in aircraft wheels and brakes, or
are the result of improper or poorly conducted
welding operations.
FireExtinguishers
Any type of fire can occur during maintenance on or
around, or operations involving, aircraft. There is a

particular type extinguisher which is most effective
for each type of fire.
Water extinguishers are the best type to use on Class
A fires. Water has two effects on fire: it deprives fire
of oxygen and cools the material being burned.
Never use water-type fire extinguishers on Class D
fires. Because metals burn at extremely high
temperatures, the cooling effect of water causes an
explosive expansion of the metal.
FireExtinguishers
Carbon dioxide (CO2) extinguishers are used
for Class A, B, and C fires, extinguishing the

fire by depriving it of oxygen.
Additionally, like water-type extinguishers,
CO2 cools the burning material.
Carbon dioxide (CO2) extinguishers are used
for Class A, B, and C fires, extinguishing the
fire by depriving it of oxygen. Additionally,
like water-type extinguishers, CO2 cools the
burning material.
FireExtinguishers
Never use CO2 on Class D fires. As with water
extinguishers the cooling effect of CO2 on the hot

metal can cause explosive expansion of the metal.
When using CO2 fire extinguishers, all parts of the
extinguisher can become extremely cold, and
remain so for a short time after operation. Wear
protective equipment or take other precautions to
prevent cold injury (such as frostbite) from
occurring.
Extreme caution must be used when operating CO2
fire extinguishers in closed or confined areas.
FireExtinguishers
Halogenated hydrocarbon extinguishers are
most effective on Class B and C fires. They

can be used on Class A and D fires but they
are less effective. Halogenated hydrocarbon,
(commonly called Freon by the industry) are
numbered according to chemical formulas
with Halon numbers.
FireExtinguishers
Bromochlorodifluoromethane (Halon 1211),
chemical formula CBrClF2,
is a liquefied gas with a UL toxicity rating of 5.
It is colorless, noncorrosive and evaporates rapidly
leaving no residue.
It does not freeze or cause cold burns, and will not
harm fabrics, metals, or other materials it contacts.
acts rapidly on fires by producing a heavy blanketing
mist that eliminates oxygen from the fire source.
It has outstanding properties in preventing reflash
after the fire has been extinguished.
FireExtinguishers
Bromotrifluoromethane (Halon 1301):
chemical formula CF3Br,
is a liquefied gas with a UL toxicity rating of 6.
It has all the characteristics of Halon 1211.
The significant difference between the two is:
Halon 1211 forms a spray similar to CO2,

while Halon 1301 has a vapor spray that is
more difficult to direct.
FireExtinguishers
Dry powder
Stored as a fine powder in a blue colored
extinguisher, pressurized by a CO2 or a

nitrogen cartridge.
Suitable for brake fires and class B, C and
D fires.
Has a little cooling effect and fires may reignited.
FireExtinguishers
Dry powder extinguishers: while effective
on Class B and C fires, are the best for use on

Class D fires. Dry powder is not recommended
for aircraft use (except on metal fires as a fire
extinguisher) because the leftover chemical
residues and dust often make cleanup
difficult, and can damage electronic or other
delicate equipment.
FireExtinguishers
Foam:
Two types of foam
Fluoroprotein (used on class B fires)
Aqueous film (used on class A & B fires)
Not suitable for class C and D fires.

Stored in white or cream colored
extinguishers pressurized with CO2
InspectionofFireExtinguishers
Fire extinguishers should be checked periodically
utilizing a checklist. If a checklist is unavailable,

check the following as a minimum:
Proper location of appropriate extinguisher
Safety seals unbroken
All external dirt and rust removed
Gauge or indicator in operable range
Proper weight
No nozzle obstruction
No obvious damage
IdentifyingFireExtinguishers
Fire extinguishers should be marked to indicate
suitability for a particular class of fire.

The markings should be placed on the fire
extinguisher and in a conspicuous place in the
vicinity of the fire extinguisher.
When the location is marked, however, extreme care
must be taken to ensure that the fire extinguisher
kept at that location is in fact the type depicted by
the marking. In other words, if a location is marked
for a Class B fire extinguisher, ensure that the fire
extinguisher in that location is in fact suitable for
Class B fires.
Markings should be large enough and in a
form that is easily seen and identifiable by the

average person with average eyesight at a
distance of at least 3 feet.
Where markings are applied to wall panels,
and so forth, in the vicinity of extinguishers,
they should be large enough and in a form
that is easily seen and identifiable by the
average person with average eyesight, at a
distance of at least 25 feet.
UsingFireExtinguishers
When using a fire extinguisher, make sure you
have the correct type for the fire. Most

extinguishers have a pin to pull that will allow
the handle to activate the agent. Stand back 8
feet and aim at the base of the fire or flames.
Squeeze the lever and sweep side to side until
the fire is extinguished.
Oils
Specified for components on the basis of
their properties in relation to operating

conditions of the component.
High viscosity oil- for heavily loaded
component at high temperature.
Low viscosity oil- for lightly loaded
application at low temperature.
Oils
Turbine engine oils
Are low viscous, synthetic ester base
formed
from
cocktail
of
chemical
compounds.
Type 1- first generation in older type
engines
Type 2 withstand the high temperature of
later engines.
Not compatible with each other.
Oils
Ester based fluid
hygroscopic nature.
Care in dispensing oil and with container.
Aggressive to most of the paints finishes.
Polyurethane provides best protection with
them.
Oils
Never mix type-1 and type-2.
Wear protective gloves, apron and face
shield when handling.

Wash hands before smoke, eat or drink.
Use correct dispensing equipment.
Follow
the
correct
replenishment
procedure.
Chemicals
Flammable Chemicals:
Spark, heat or a naked flame may ignite.
At its flash point may ignite.
Like fuels, oils, solvents and paints.
Prevent them with exposed to source of heat.
Adequate
ventilation
to
prevent
the
concentration.
Suitable containers
Adequate fire extinguisher
Wear gloves and a respirator
vapor
Chemicals
CORROSIVE CHEMICALS:
React with and attack metals and burn the skin.
Etching agents, battery electrolyte and corrosion fluids.
Mostly in liquid form but some be in powder form.
Adequate type of container.
Avoid the contact with sensitive material.
Clean the surface adequately.
Wear suitable clothing, goggles or a face shield, gloves and
apron.
Take the precaution for fire flammable or toxicity.
Check the eye wash facility.
Chemicals
Toxic Chemicals:
poisonous, can cause injuries or diseases
in short term or long term. (asthma,

cancers etc.)
Have number of routes in the bodyBreathe in the vapor, skin can absorb,
carry substances onto food and into drink
and ingest them.
Solid chemical- harmful dust, hazardous
fumes.
Required personal
protective equipment.
Chemicals
Reactive Chemicals:
Are those that experience a chemical change
when exposed to other chemicals.
Reaction may have slow change or voilent
explosion.
Some create high temperature causes to fire.
Surface
treatmentAlchrom,
Cd-plating
involve reactive chemicals.
Some create toxic vapors- phosgene, chlorine
and ferro-cyanide.
SafetyAroundHazardousMaterials
AMaterial
Safety Data Sheet(MSDS) is a

document that contains information on the potential
hazards (health, fire, reactivity and environmental)
and how to work safely with the chemical product. It
is an essential starting point for the development of
a complete health and safety program.
MSDSs are prepared by the supplier or manufacturer
of the material. It is intended to tell what the

hazards of the product are, how to use the product
safely, what to expect if the recommendations are
not followed, what to do if accidents occur, how to
recognize symptoms
of overexposure, and what to
MSDS formats can vary from source to source
within a country depending on national

requirements.
It is intended to provide workers and
emergency personnel with procedures for

handling or working with that substance in a
safe manner, and includes information such as
physical data (melting point,boiling
point,flash point, etc.),toxicity,health
effects,first aid,reactivity storage, disposal,
protective equipment,
and spill-handling
The most observable portion of the Material
Safety Data Sheet (MSDS) label is the risk

diamond.
It is a four color segmented diamond that
represents
Flammability
(Red),
Reactivity
(Yellow), Health (Blue), and special Hazard
(White). In the Flammability, Reactivity, and
Health blocks, there should be a number from 0
to 4. Zero represents little or no hazard to the
user; 4 means that the material is very
hazardous.
The special hazard segment contains a word
or abbreviation to represent the special

hazard. Some examples are: RAD for
radiation, ALK for alkali materials, Acid for
acidic materials, and CARC for carcinogenic
materials. The letter W with a line through it
stands for high reactivity to water
RiskDiamond
Flammabilit
y
Health
Reactivity
Special Hazard
SafetySignsandSignals
SafetyAroundMachineTools
Hazards in a shops operation increase when
the operation of lathes, drill presses, grinders,

and other types of machines are used. Each
machine has its own set of safety practices.
Drill Press: can be used to bore and ream holes, to do
facing, milling, and other similar types of operations.

The following precautions can reduce the chance of
injury:
Wear eye protection.
Securely clamp all work.
Set the proper RPM for the material used.
Do not allow the spindle to feed beyond its limit of travel
while drilling.
Stop the machine before adjusting work or attempting to
remove jammed work.
Clean the area when finished.
DrillPress
Lathes:
are used in turning work of a

cylindrical nature. This work may be
performed on the inside or outside of the
cylinder. The work is secured in the chuck to
provide the rotary motion, and the forming is
done by contact with a securely mounted tool.
Lathes
Lathes : following precautions can reduce the chance
of injury:
Use sharp cutting tools.
Allow the chuck to stop on its own. Do not attempt to
stop the chuck by hand pressure.
Examine tools and work for cracks or defects before
starting the work.
Do not set tools on the lathe. Tools may be caught by
the work and thrown.
Before measuring the work, allow it to stop in the lathe.
Milling machines: are used to shape or dress; cut
gear teeth, slots, or key ways; and similar work.

The following precautions can reduce the chance
of injury:
Clean the work bed prior to work.
Secure the work to the bed to prevent movement
during milling.
Select the proper tools for the job.
Do not change the feed speed while working.
Milling machines
Grinders: are used to sharpen tools, dress metal, and
perform other operations involving the removal of small

amounts of metal.
The following precautions can reduce the chance of
injury:
Wear eye protection even if the grinder has a shield.
Inspect the grinding wheel for defects prior to use.
Do not force grinding wheels onto the spindle.
Do not stand in the arc of the grinding wheel while
operating, in case the wheel explodes.
Do not force grinding wheels onto the spindle. They fit
snugly, but do not require force to install them.
Grinders:
Battery Maintenance
Battery is an integral part of the electrical
system in aircraft.
Two types of batteries are used: Pb-acid
and Ni-Cd.
Charging rooms are potential very
dangerous area.
Hydrogen is vented during every stage of
Pb-acid battery charging.
Battery Maintenance
There must be separate room for Pb-acid and
alkaline battery charging, repair/maintenance

and electrical supply and storage.
All tools and equipment must be separate and
marked for the purpose.
All electrolyte and neutralizing agents
containers must be clearly marked.
Charging rooms well vented, explosion proof
lighted and with air extraction system.
Battery Maintenance
Ambient temperature in the charging rooms must
be maintained within limits. e.g. lead acid- below

27 C and Ni-Cd 21 C.
Floor Level, dry, dust free, proof against acid or
alkali e.g. concrete.
Bench: Height should be 20 inch from floor, to
enable inspection and reduce lifting effort. Should
be made of latticed panels of waxed wood.
Co2 type fire extinguisher should be strategically

placed.
Battery Maintenance
Battery charging supply is normally D.C. but supplied
from A.C. distribution system.

When disconnecting batteries, the cable should be
removed from the battery first and then from the

charging board.
Individual
charging boards should be mounted

adjacent to each charging point and be mounted
adjacent to each charging point and be mounted
directly above and to rear of the bench to minimize the
need for long connecting cables.
Battery Maintenance
H2SO4 SPILLAGE- should be washed in
solution of bicarbonate of soda and fresh

water. Other neutralizing agent Ammonia
powder or borax powder.
Alkaline Solution- washed in saturated
solution of boric acid (crystal and powder)

and fresh water.

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Maintenance

condition by checking or repairing it on regular

something in useable/good condition

in airworthy condition so that it can fly safe and

General Test Equipment

to protect against possible

the atmosphere from reactions of the air

unexpectedly and unintentionally, and may

responsible for choosing or creating

danger and thus harm.

with only a theoreticalriskof harm;

activities in and around the workplace. e.g.

or suffers adverse health effects if exposed to a hazard.

interchangeably but this simple example explains

water would present a slipping hazard to persons

a hazard and then evaluating the risk in the

First hazard must be recognized; then they must

be assessed; and finally, if necessary, they must

Unsafe Human Condition

the purpose of loading/off-loading

the area where planes park,tarmacisnt

very much in use at airports

the International Civil Aviation Organization (ICAO),

where vehicles and airplanes share the same space.

movement of the aircraft on the

and the apron.

facilities, such as hangers and apron.

takeoff and land on airport.

aircraft in protective storage.

one and be aware of the danger.

Entry to the maneuvering area require

clearance from local air traffic controller.

path so that these can be used by required

Both paint and lights are used for marking so that,

markings are visible in day as well as night.

Vehicle routes white line

double white lines

yellow line, 6 inches (15 cm) to 12 inches (30

lane on a paved surface where the adjoining pavement to

in taking off or coming in to land or an illuminated

personnel must require Airfield Driving

flashing obstruction light in movement area.

not have to reverse in order to leave the zone.

tabards at all times.

temporary or long-term damage to hearing.

of engine not to stray in front of engine

in the area should be turned off.

illuminating the area but this does not help

maintenacne is of approved flameproof type.

aircraft maintenance and operation are known

pins, plastic bags, stones etc.

not wear jewellery or loose items.

appropriate covers and locks should be used

static discharges are left intact and connected

highest standards of orderly work

equipment or hazardous conditions. There

their own safety and for the safety of others

in an unsafe manner, communicate with

the human body, it can create severe burns.

provide a psychological assurance at the same time it

knowledge. Personnel who attempt to work

generation or transmission, a byproduct of that

electrical equipment clean, uncluttered, and

tool as long as it is under control.