SAFETY

CH6703 Chemical Process Plant Safety 2019-2020
UNIT I
INTRODUCTION TO SAFETY PROGRAMMES
Introduction to safety:
Safety is very important aspect for any industry as an accident free work environment boosts the
morale of the team members working in any hazardous situations. Recognising these facts industries
involving various hazards and risks industries prepare their own safety policy, safety manual and
have a separate department/section for safety so as to create proper awareness and provide the know-
how-about the safety.
Adherence to the useful information, rules, and mandatory requirements governing the safety and
guidelines will help prevent occupational injuries and accidents which constitute an unavoidable
and needless waste of human and material resources.
Safety means continuing and healthful living without injury. Safety is freedom from harm or the
danger of harm. The word safety also refers to the precautions people take to prevent accidents,
harm, danger, damage, loss and pollution. Safety also deals with improvement in working conditions
for better health. Management is responsible to provide safe working condition and individual’s
safety.
Safety and health requirement in chemical industry

The significance of Safety & Health in chemical industries has been a vital issue in achieving
productivity and an edge in the competitive world. This paper is an effort to present the various
factors governing the safety and Health of chemical industries with a special focus on IFFCO Aonla
Unit – the flagship Ammonia-Urea Complex of Indian Farmers Fertiliser Coop. Ltd.
Facts of Safety & Health in a Chemical Industry

Risk Of Accidents And / Or Harmful Exposures : Areas of Concern
i) Dangerous Materials ii) Hazards of Pressure Vessels iii) Hazardous Chemical Reactions
iv) Hazardous of Unit Operations v) Flammable Gases, Vapours And Dust Hazards
vi) Health Hazards vii) Hazards due to corrosion viii) Entry in To Confined Spaces ix) Working
with Pipelines x) Plant Alteration and modification xi) Sampling and Gauging xii) Hazards due to
Instrument Failures.
Dangerous Materials
i)Explosives ii) Gases iii) Inflammable Liquids iv) Inflammable Solids v) Oxidising substances
vi) Toxic and Infectious substances vii)Radio Active Substances viii)Corrosive Substances
ix)Miscellaneous Dangerous Substances
St.Joseph’s College of Engineering 1 Department of Chemical Engineering
Hazards Of Pressure Vessels

1.Leakage or Bursting of Pressure Vessels 2.Design defects 3.Failure of Relief Systems 4.Lack of
hydraulic testing. 5. Lack of Proper Instrumentation or Instrumentation Failure 6.Lack of N.D.Tests
7.Corrosion of Vessels. 8. Lack of routine inspections 9. Attempt of Pneumatic testing
Hazardous Chemical Reactions
Understanding about the behaviours of reactions and adopting precautionary and emergency
measures.
Psychological behaviour based safety

Behavior-based safety (BBS)
Behavior-based safety (BBS) is the "application of science of behavior change to real world
problems".BBS "focuses on what people do, analyzes why they do it, and then applies a research-
supported intervention strategy to improve what people do. At its very core BBS is based on a larger
scientific field called Organizational Behavior Analysis.
To be successful a BBS program must include all employees, from the CEO to the floor associates.
To achieve changes in behavior, a change in policy, procedures and/or systems most assuredly will
also need some change. Those changes cannot be done without buy-in and support from all involved
in making those decisions.
BBS is not based on assumptions, personal feeling, and/or common knowledge. To be successful,
the BBS program used must be based on scientific knowledge.
A good BBS program will consist of:
 Common goals – Both employee and managerial involvement in the process

 Definition of what is expected – Specifications of target behaviors derived form safety
assessments[4]
 Observational data collection
 Decisions about how best to proceed based on those data
 Feedback to associates being observed
 Review
All of the BBS programs reviewed included multilevel teams. Some programs use them in the
assessment phase, some in observation and some in review. Some had all three areas using
multilevel teams.

Some argue that behavior-based safety must also have attitude adjustment to be sustaining as it has
been proven that "behavior influences attitude and attitude influences behavior".[5] The goal should
be small gains over and over again; continuous growth. BBS is not a quick fix. It is a commitment.
Elements of safety programme
Safety policy - Prepare a statement, signed by top management, identifying the responsibilities
of management and employees for ensuring a safe workplace. Review this policy with all
employees on an annual basis.
1. Accident Investigation and Near-Miss Program- Develop procedures for investigating all
accidents and “near misses” (those incidents resulting in neither injury nor property
damage).
2. General safety rules - Establish written minimum safety standards that apply to all
employees and post them in areas where employees are sure to see them.
3. Safe operating procedures - Develop written guidelines for procedures and tasks involving
recognized hazards.
4. Essential job functions - Develop a list of essential job functions for each job category (for
employers with 15 or more employees). These lists help you properly place workers in jobs
and assign injured workers to transitional duties.
5. Ergonomics program - Establish an ergonomics program designed to maximize productivity
while reducing employee fatigue and discomfort. Educate employees about basic ergonomic
principles and proper body mechanics.
6. Self-inspection programs - Inspect your workplaces regularly to detect unsafe acts and
conditions. Keep an ongoing record of your findings.
7. Safety training program - Establish a written training program through which all employees
learn about general safety rules, safe operating procedures, claims management principles,
and ergonomic hazards.
8. Safety coordinator - Assign a coordinator who is responsible for implementing your
company’s risk management program.
9. Substance abuse program - Establish a written substance abuse policy to include supervisory
and employee education along with identifying an Employee Assistance Program.
Social environmental set up.

The social environment, social context, sociocultural context, or milieu, refers to the immediate
physical and social setting in which people live or in which something happens or develops. It

includes the culture that the individual was educated or lives in, and the people and institutions with
whom they interact.
The interaction may be in person or through communication media, even anonymous or one-way,
and may not imply equality of social status. Therefore the social environment is a broader concept
than that of social class or social circle.
Solidarity
People with the same social environment often develop a sense of social solidarity; they often tend
to trust and help one another, and to congregate in social groups. They will often think in similar
styles and patterns even when their conclusions differ.
Natural/artificial environment
In order to enrich his life, man has used natural resources and in the process he has brought about
many changes in the natural environment. Human settlements, roads, farmlands, dams and many
other things have all developed through this. All these man made components are included in our
cultural environment, Erving Goffman in particular stressing the deeply social nature of the
individual environment.
Milieu/social structure
C. Wright Mills contrasted the immediate milieu of jobs/family/ neighbourhood with the wider
formations of the social structure, highlighting in particular a distinction between "the personal
troubles of milieu" and the "public crises of social structure.
Aspects to be looked upon carefully for setting up a chemical industry

Technical aspects of safety have to be thoroughly understood and applied at design stage itself while
implementing a chemical process plant. The general norm covering the technical aspects of safety
for a chemical plant are as follows:
 Instrumentation
It is the key to the prevention of disasters. Instruments offer the first opportunity to regain
control over a process upsets within manageabale limits.
 Pressure Vessels, Pumps & Compressors
Allowance should be given for pressure increment due to process surges. Vessels with
heating jackets should be rated to take the highest pressure of any heating medium in the
plant.

Pumps and compressors should have system for shutting down safely in an emergency and
other provisions for maintenance without endangering other equipment or the repair crew.
 Buildings
The design of the building should be integrated with its function. For example especially
hazardous chemical in a warehouse segregated from less hazardous material by means of
a fire wall.
 Electrical Systems
Minimum interaction between personnel and high voltage system should be allowed with
provisions to cope up with corrosive flammable atmosphere.
 Purging Systems
Provisions are required for purging the noxious and inflammable gases, fluids from the
system for handing over the same for maintenance work.
In addition to the above, there should be a system to identify hazards as early in the design
phase as possible, and then to control the identified hazards.
Safety design criteria for chemical plants

 Appropriate personal protective clothing shall be worn for all chemical handling
operations.
 All piping and transfer systems shall be designed to minimize effects of leakage.
 All filters, lines and connectors shall be designed to preclude blockage by
particulate and/or contamination.
 All cleaning agents shall be removed from the system after cleaning.
 All welds, valves and other propeller fan interface connections shall be leak proof
and should be verified by leak tests.
 All chemical piping and storage tanks shall be appropriately marked and color
coded in accordance with I.S.I standards.
 All pipe fittings and materials used in given system will be compatible with the
chemicals being handled.
Trade union in industrial safety

Each worker being poor and ignorant about the existing legislations is unable to fight against the
injustice done to him. As a group they can settle terms with the employers in a better way. Such
associations formed by workers are known as Trade Unions

Trade Union is an association of workers engaged in a particular trade and formed chiefly with the
object of helping the members in times of distress and getting their grievances settled and legitimate
a rights established.
They can register their union with Registrar of trade unions.
Rights and Liabilities

They can collect membership fees and fix up notices regarding meetings.
They can use general funds for specific purposes.
They can conduct strike by peaceful methods.
By using the last right, Trade unions can always demand safe working environments from the
management. A better environment and good sanitary surroundings, supply of pure water and
fresh air, sufficient medical aid, always promote industrial safety altogether.
Industrial Health Hazards

Most of the chemical and physical agents in the industry are potentially harmful to man.
Prolonged regular exposure at some air-borne contain can give chronic occupational diseases.
Brief contact may cause acute diseases. Examples of adverse effects on human body are given
below.
1.Respiratory system
 Sulfur dioxide, aerolein, chromic acid mist and other chemical causes coughing initially
and chronic bronchiotis on prolonged periods.
 Chlorine, phosgene, nitrogen oxides will cause damages to tissues of respiratory system
resulting in accumulation of fluids in lungs.
 Repeated inhalation of fumes form coal tar pitch, nickel refining, fibres of asbestos may
result in lung cancer.
2. Skin
 Prolonged contact of acid and alkali causes skin irritation.
 Original solvents cause dermatitis by their irritant action.
 Unrefined mineral oils, coal tar pitch and arsenic compounds causes skin cancer.
3. Eye
 Eyes are vulnerable to attack by all air-borne contaminants. Eye surface is more sensitive
to mild compounds.
4. Blood
 Lead and benzene causes anemia by affecting blood forming process in bone marrow.

 Carbon dioxide and some nitrates react with hemoglobin and reduce the capacity if blood
to transport oxygen.
5. Liver
 Carbon tetrachloride, selenium compounds have toxic effect on the liver, which may lead
to jaundice.
 Vinyl chloride on prolonged exposure induces liver cancer.
6.Kidneys
 Heavy metals can produce injury to the kidneys.
7. Bladder
 Aromatic amines like naphthylamine and benzedine cause bladder injury.
8. Nervous System
 Organic chemicals like hexane, methyl butyl ketone and tri-cresylphosphate damage
nerves.
 Some organ phosphorous compounds interfere with nerve impulses.
Safety training
Induction Training:
Induction Training should be given to all the persons prior to permitting them
to go to work.
This training should include the following:

(а) General safety awareness.
b) First aid.
(c) Use of personal protective equipment (PPE).
(d) Specific worksite hazards.
2. Refresher Training:
Refresher Training should be conducted at regular intervals to ensure that
all workers are kept up-to-date with safety requirements.
3. Specific Training:
Specific Training should be provided to the persons with safety related tasks
such as crane operators, slingers, plant operators etc.
Safety Efforts by Government:

In order to ensure industrial safety, government has made number of legislations like, the Factories
Act 1948, Indian Electricity Act 1884, Mines Act 1952, Indian Boilers Act 1923; Workmen’s

Compensation Act; Indian Electricity Act 1910; Petroleum Act 1934 which governs the safety of
personnel and equipment in industrial units in the country.
But we know that legislation alone cannot ensure safety in industrial operations, unless effective
approach to prevention of accidents and promotion of safety consciousness in industry is achieved.
This is possible by adopting proper control measures including safe designs of machines and
processes, use of protection devices and personal protective equipment’s, effective safety
procedures and practices as well as creation of self-regulating system on the shop-floor.
To assure safety to workers and eliminating chances of damage to machinery and equipment, Indian
Standards Institute has done commendable job.
It lays down:
(i) Safety precautions to be taken during manufacturing operations.
(ii) Requirements for effective maintenance of tools and equipment’s.
(iii) Standards for proper layout, proper lighting and ventilation of factory building.
(iv) Guidance on safe welding and cutting, use of powered industrial trucks, belt conveyors fire-
fighting equipment’s.
(v) Standards and specifications of safe industrial operations and practices.
(vi) Classification of hazardous chemicals and use of accident prevention tags and pictorial
markings for handling and labeling of dangerous goods.
(vii) Safety codes for handling acids and other chemicals.
(viii) Safety requirements for personal protective equipment’s.
(ix) Standards for fire safety in industrial buildings and safety procedures to be followed in electrical
work and use of electrical appliances in hazardous area and explosive atmosphere.
(x) Specifications for protective clothing, safety helmets, face shields and safety equipment are for
eyes, ears, lungs, hands, feet and legs. These include eye and ear protectors, gas mask, gloves, safety
boots and shoes for mines and heavy metal industries etc.
Safety Programme:
Certain persons are made responsible for safety aspect in the organisation. Now-a-days, safety
committee concept is becoming popular. A safety committee consists of executives, supervisors and
shop floor workers. This also helps in creating safety consciousness. This is a body which deals all
matters related to safety.
programmes analyses causes of accidents, and takes remedial measures which aim at r educing
accidents and losses which might occur due to them. Safety programme is a continuous process and
minimises the factors related to personal and environmental which may cause accidents Safety

equipment’s are provided to save employees from accidents. Special trainings are imparted to
employees on safety aspects.
In order to create awareness, safety weeks are organised, safety instructions are displayed. It is also
necessary to make necessary safety rules and enforce them.
For effectiveness of the safety programmes in an industry, it is necessary to identify the causes of
accidents, study them, and take effective steps for their prevention.
For effectiveness of the plant safety programme, following areas should be covered:
i. Plant layout.
ii. House keeping.
iii. Maintenance of the equipment.
iv. Training programme for the employees.
v. Protective equipment requirement.
vi. Separate safety department, with proper communication system.
vii. Fire-fighting facilities.
Lack of training has been identified as one of the major causes of accidents. Safety awareness is the
basic requirement for reducing accidents. Most of the accidents take place due to adoption of short
cuts and/or ignoring the safety guidelines.
There is a need to prepare a safety manual which should include the mandatory use of personal
protection equipment, safety awareness training programme, fire protection, first-aid, safety
signages, accidenting reporting procedure etc., each operation has its own hazards and a safety
programme should be developed to mitigate the particular hazards.
Safety programme in an industry must receive the full support of an entire organisation beginning
with top management and continuing down through the ranks to include the managers, supervisors
and workers.
In any safety programme, following are essential

 Secure full support of top management. Direct one executive of appropriate level to direct
safety programmes.. Give publicity to safety programmes.
 Develop a safety programme for each job.
 Install safety programme, creating the competition with appropriate rewards for outstanding
performance.
 Train new employees.
 Safety practice be made effective.
 Promote good house-keeping.

 Maintain adequate first-aid facilities.

 Seek assistance from insurance companies.
Safety programme is carried out in following three phases:

Safety Awareness
This includes educational, on-the-job instruction training, ergonomics, and job safety analysis
techniques.
Safety Implementation
Implementation of safety programme should be the responsibility of all concerned.
Safety Programme Maintenance
This phase is necessary to maintain enthusiasm and energy levels which do not deteriorate with
time.
Factors Affecting Industrial Safety

There are large numbers of factors affecting the safety, but they can be divided into following
categories:
i. Equipment related factors.
ii. Work area related factors.
iii. Environmental factors.
Now-a-days equipment are manufactured keeping all safety aspects in mind, therefore, not much
concentration is required for safety aspects related to equipment, except maintenance.
Working Environment:
environment is the single biggest factor affecting safety aspects. It varies from concern to concern,
and on the type of industry, and not always possible to establish ideal conditions. However serious
efforts should be made to arrive at them.
Following are the range of ideal conditions for different environmental factors that are conducive to
ideal working conditions:
i. Temperature:
(a) 20-22°C in winter
(b) 21-24°C in summer
ii. Humidity:
25—50 percent relative humidity
iii. Noise:
Conversation from a distance of one metro should be possible without extra effort.
iv. Ventilation:

0.6 cubic metre of fresh air per man or sufficient enough to remove odour
Lifting of Load:
Although most works are done mechanically in the process of manufacturing, still many material
handling works involving load lifting are done manually. It has been experienced that a man can
easily lift about 22 kg and woman about 16 kg.
But while doing work continuously in a bent position even with a small load, there will be immense
strains on spine and back muscles that may result in injury especially for aged workers. Therefore,
efforts must be made to keep the material at a certain height so as to minimise the strain and fatigue.
Chemical Safety
Many processing and manufacturing industries use chemicals in one or other form. The chemical
are hazardous mainly for their toxicity, flash point below 100°F, their reactions when mixed with
other chemicals, and their decomposition under heat.
Therefore, extra care should be made and recommended safe practices should be adopted for the
receipts, storage, handling and disposal of chemicals and other hazardous materials. Where
necessary respiratory devices, protective clothing, safety showers, and eye wash facilities should be
used and located at suitable places, the use of exhaust hoods, air filtering and to provide protection
from gases and air borne hazards.
Economic and social benefits

Occupational safety and health management is basically concerned with the principles of how to
organise this activity in companies and other organisations. The economic dimension adds an
optimization approach to the organisational and principal perspectives. The non-economic approach
typically assumes that health and safety have an intrinsic value of their own, which for instance
forms the basis for the zero-accident-principle is based. The economic approach takes a more
relative stance, stressing that resources are always limited and must always be rationed. From this
point of view, even life and health must be compared to other values, and resources must be allocated
accordingly. This chapter describes the principles of how to conduct this type of analysis.
System view and efficiency approach

The economic approach to occupational safety and health (OSH) management implies that one takes
a system view or adopts an efficiency approach. Most often this kind of analysis is made
in monetaryterms. In a system view, the inputs and outputs of OSH activity are compared in order
to draw conclusions and decisions. The highest productivity is attained when the greatest output is

achieved with the smallest relative input. The best efficiency is attained when the greatest intended
effectiveness as a result of the output is reached through the relatively smallest amount of input.
When both the input and the output are measured in monetary terms, the efficiency can be expressed
as a cost-benefit ratio.
When the analysis is constrained to the boundaries of an enterprise one can talk about a financial
appraisal. However, a financial appraisal can also be conducted in public organisations. The so-
called new public management approach places a major emphasis on this principle. The problem
with public organisations is that their output is usually not subject to market demand, which can be
measured in the consumers' willingness to pay.
Therefore the true application of financial appraisal would require a use of some kind of artificial
pricing of consumer value. In general, the benefits of occupational safety and health (OSH) are
related to cost reduction, improved productivity and to the generation of new assets. According to
Chapman´s (2005) meta-analysis, the results of well-managed occupational health promotion
programmes can be seen in 27% less sickness absenteeism, 26% less health care costs and 32% less
insurance costs. On average, the benefit to cost ratio among these cases was found to be 5.81.
Cost reducing
Poor health and safety create costs for organisations. The most common costs are related to sickness
absenteeism, health care, individual productivity losses or presenteeism, personnel turn-over,
insurance and pension costs and indirect cost effects, such as hiring replacement, paying for
overtime, subcontractor work etc. The cost reducing effects of OSH are well documented. Taken
together, they send a consistent message: well planned and systematically carried out occupational
safety and health measures deliver economic returns which are 3-10 times greater than the monetary
investment. This appears to be the case even if there are difficulties in estimating exactly the positive
productivity effects of work. Systematic literature reviews have indicated that both small-scale
measures and comprehensive occupational health and safety programmes can be profitable to
organisations. Finnish intervention studies have revealed that there can be positive profitability
effects even without immediate measurable productivity effects, which indicates that the economic
benefit-mechanisms of OSH are more subtle than often assumed.
The economic approach to occupational safety and health can be divided
into macro and micro subtypes. In the macro approach, work related activities or phenomena are
analysed from a social or societal point of view, in contrast to the business economic or financial
approach used in the macro approach where the effects are analysed on real values and resources,
not only cash-flow effects.

Cost of illness analysis

The Cost of illness (COI) analysis is the most typical macro approach, in which the total costs of
health care and lost production due to an illness, injury or working conditions are calculated.
Estimating such costs helps to identify the maximum benefit of affecting these illnesses attributable
to poor working conditions. Loss of production usually covers absenteeism, presenteeism, early
retirement, premature death. Presenteeism refers to the situation where the ill worker is present at
work but contributes a sub-normal individual output due to his/her poor health. Several studies have
demonstrated that early retirement reduces significantly the productive potential of the highly
developed countries, i.e. the OECD average is 6.3% of GDP.
Recent calculations from Finland show that the annual loss due to early retirement is even greater,
as much as 13% of GDP and some estimates have been even higher[10]. The productive loss caused
by sickness absenteeism is smaller (about 4%) but much more apparent In addition, the hidden costs
of occupational accidents are many times greater than their direct costs. In summary the total cost
burden of poor health and safety is enormous, and those costs in some way or other will ultimately
affect the competitiveness of individual companies.
In addition, the identification of the total amount of investment in OSH may help in policy formation
at the national level. In Finland the first national survey of the total direct investment in wellness at
work has been made[12]. In this survey, the annual investment in training and development,
occupational health services, work ability promotion personnel fitness, cultural activities and other
personnel promotion were estimated at the company level. It was estimated that the total annual
direct investment in occupational safety and health was less that one tenth of the annual cost of
illness (COI). The economic return of investing in health in general has been estimated to vary
between 47% and 252%.
Cost-effectiveness analysis
Cost-effectiveness analysis (CEA) is a commonly used macro economic approach to compare and
analyse alternative courses of action, usually related to alternative treatments of illnesses. In this
approach, the costs and related health effects of the alternatives are compared by calculating cost-
effectiveness ratios in the form of X effect units per $ or € spent. The alternative that displays the
most effect units per monetary unit is the most efficient choice. Although CEA is often used on a
macroeconomic level to analyse costs and effects at the national level, it can also be applied on
a micro level.
Micro approaches
The microeconomic approach to the management of occupational health and safety is concerned
with optimizing the resource allocation at the enterprise level. Microeconomic analysis can be
applied also to public organisations. Micro approaches include management control principles and
procedures, financial appraisal and various calculation methods, and these will be considered in the
following paragraphs.
Management control methods

Management control is about ensuring the strategic goals of an organisation. Typically the
accounting system, budgeting and reward systems are used as tools for management control.
Recently its has been observed that one major reason for not sufficiently taking work health into
account in organisations is that these items are not properly budgeted in management control
systems. Therefore, there is a need to develop management control concepts and tools which include
work related health aspects. Work health can be included for instance as an element in Balanced
Scorecards (BSC), human resource accounts and health accounts.
Financial appraisal method

Financial appraisal refers to an analysis conducted at the micro level in an enterprise or some other
organisation. In financial appraisal all cash-flow effects of an OSH related activity or phenomenon
are estimated. The simplest form is to make an estimate of the financial effects of a certain state of
affairs, e.g. the current level of sickness absenteeism.
A more advanced form is to analyse the economic feasibility of a specific occupational safety and
health intervention, for example, a reduction of the noise level. In such an analysis, the annual input
costs and the annual cost reductions and other economic benefits are compared for a number of
years. By discounting the present value of the annual effects, the economic feasibility can be
expressed in financial terms, e.g. return of investment (ROI).
Value-based health promotion methods

Porter and Teisberg coined the term value-based promotion of health. The term refers to an approach
that is based on the total economic effects of health care. At the other end of this spectrum is
transaction-based health care, which optimises the costs of each health care transaction. There is
also a need to apply the value-approach in developing work health management. This places certain
requirements on the information to be used in a decision-making system. One needs to know exactly
what kind of information is necessary in order to make adequate decisions and the type and
magnitude of work health investments. Adoptions of a value-based strategy indicate that the current
levels of investment in work health are sub-optimal and directed towards the wrong activities.
In a Finnish study it was demonstrated that the adoption of a value-based strategy to promote work-
wellbeing, reduced significantly sick-leave, insurance and pension costs for the company. The total
benefits of the program were estimated to be 11.5 M€ this being achieved in a company with total
profits in the region of 600 M€. The subjective estimate made by the management was that the real
savings were much higher, around 60 M€.
Calculation models
Various calculation models have been developed to help in the estimation of the input costs and
related financial benefits. Two such models are The Productivity Model and the Potential Model.
The Potential model is an input-output model, or a before-after model. It compares two states of
affairs; the one before some measure is taken or investment made and the second after the
intervention is made. The effects of the differences between these two states are calculated in order
to establish the financial benefit, achieved by the investment. Also the cost of the investment is
calculated. Both the cost and the benefit are calculated on an annual basis.
For multi-period calculations annual effects are transformed to the present value, by taking account
of the interest rate in the calculation. The overall assumption when calculating the benefits is that
the real value of work equals the total cost of labour divided by efficient work hours. This
assumption is based on the principle that when a company is making an investment it has to be able
to cover its current costs by selling what is produced by its personnel, otherwise the firm would go
bankrupt.
Based on this assumption, the calculation must include all labour costs, the number of all annual
paid work hours, and the number of all annual non-productive work hours. In basic terms the
calculation of benefits is based on the total cost of productive work hours. Ultimately, the benefit
will be dependent on changes in either productive hours or the unit cost of production. The
production cost of personnel turnover is calculated by applying the productivity gap concept.
The existence of the personnel turnover productivity gap is well known. It appears as a result of
departing individuals reducing their effort as a result of deteriorating motivation, cooperation and
morale, and slowly increasing productivity of newcomers. In the Potential Model, the productivity
reductions and increases are assumed to be linear. In order to calculate the value of the productivity
gap, only the number of annually departing and arriving people and the average exit period and
introduction period have to be entered into the model.
The model assumes the value of the productivity gap to be equal to the product of lost hours and the
value of a productive hour of the firm's time.In these models depreciated initial investments and
annual operations costs make up the annual input costs. The benefits include changes in productive
time (sickness absenteeism), overtime costs, subcontracting costs, personnel turnover costs health
care costs and productivity. The use of these models demonstrate that the total financial benefits of
occupational health and safety investments often greatly exceed the direct benefit effects.
A reduced number of sickness-leave days for instance often leads to reduced overtime-work and
less subcontractor work. In addition, reduced personnel turnover and increased individual
productivity can be a by-product of health promotion projects. In some cases, the benefits related to
improved individual productivity have been the main effect. In several cases the actual productivity
effects have not been measured, though they have been assumed to be considerable. For instance
the Potential Model was used to calculate the economic feasibility of the so-called Druvan-project,
in which a 20-fold increase in OSH-expenditure lead to a 46% return of investment.
Benefits
A safe and healthy workplace not only protects workers from injury and illness, it can
also lower injury/illness costs, reduce absenteeism and turnover, increase productivity and quality,
and raise employee morale. In other words, safety is good for business.
Protect your staff

Effective health and safety practices help you protect your staff from injury. This may mean you are
more likely to retain skilled and loyal employees by preventing: back pain and other musculoskeletal
disorders - eg upper limb disorders - see safe manual handling at work and prevent RSI and upper
limb disorders injuries from slips and trips - see avoid slips and trips falls from height - see work
safely at height or in a confined space accidents involving vehicles at work - see transport safety in
the workplace aches, pains and strain from using display screen equipment - see computer health
and safety at work
Looking after your employees' health will mean that your staff are less likely to suffer from:
 the effects of noise and vibration
 asthma - manage risks from substances which can trigger allergies or asthma
 work-related skin disease
 asbestos-related illness - key occupational health issues
Reduce absences and sick leave

Another benefit of good health and safety measures at work is that employees are less likely to take
sick leave. This saves the business the direct and indirect costs of staff absence.
Retain staff
If you reduce staff absence due to illness or accidents at work, you will save the time and costs of
recruiting and training a new member of staff.
Reputation
Good health and safety measures will help you to build a positive reputation with your clients and
staff and their friends and associates. The resulting good public relations could help to increase sales
and generate more leads.
Productivity and profits

Good health and safety measures mean that your staff can do their work more easily and safely. This
will boost morale, increase productivity and reduce costs.
Save insurance and legal costs

A good standard of health and safety in the workplace can reduce your insurance premiums, as well
as the costs of accidents that aren't covered by your insurance, such as sick pay, production delays
or repairs to plant or equipment. Uninsured costs can be greater than insured costs, and they have to
be paid out of your business' income.
Importance of Communication skill training

Better listening skills
Listening, just like good communication, is an essential workplace skill. It is very easy (and very
tempting on occasion) to look at a person and nod your head at regular intervals without really
paying attention to what they are saying. It's much more difficult to learn how to understand
precisely what the person is saying and what they want from the conversation.
Communication skills training will help your colleagues to have open and useful exchanges, where
each contributor’s point of view is expressed and heard. This should in turn lead to a more positive
working environment.
A greater sense of empathy
When you’re stressed out, it can be hard to sit in on an advisory team meeting and try to think about
other people’s needs. However, in order to be a member of a team, workers need to be able to put
themselves in their colleagues’ shoes and understand where they are coming from. Communication
skills training involves exercises doing just this, which should help to enhance your
employees’ empathetic sides. At the same time it teaches how to be patient in their dealings with
other people.
The ability to speak precisely

How many times have you suffered an attack of nerves, a dry throat or a cough, just moments before
you were due to give a presentation or speak to an important person within your business? It is
natural to feel some trepidation when speaking to superiors or to clients. The fact is, however, that

people are far more likely to listen to a person who is to the point. Communication skills training
will help you learn how best to communicate effectively in a wide range of situations, and how to
be direct in order to get the most out of your dealings with others.
A better rapport with customers

Customers desire nothing more than to be understood by a company and they wish to feel like they
are being heard and listened to – look at the Hawthorne Effect I mentioned earlier. This is a
particularly important point if your business involves a large amount of contact with customers,
either face-to-face or over the phone. Sending your customer service staff on a training course will
ensure that customers are given the level of attention they deserve.
Although it might seem like we spend our entire working lives looking at a screen of some sort,
communication of the verbal kind is, in fact, the key to humanity’s continued existence. As such, it
should be a number one priority for companies everywhere.
Communication skills training will help your business to be more efficient and productive.
This is because by teaching your staff how to communicate better, they will interact in a more
constructive and productive manner, making the workplace a positive and thriving environment. In
the long run, the company will see an increase in its profits and its customer and staff retention rate.
UNIT II
INDUSTRIAL SAFETY
Control measures to industrial hazards

The hazardous chemicals can be substituted. Ex:Use of toluene instead of benzene, Chloroform
instead of carbon tetrachloride, Chalk instead of talc.
Segregation
Segregation by time: The hazardous can be conducted when the minimum numbers of workers are
present. By placing hazardous operation at one end of a workshop in a separate room or in a separate
building minimizes the number of workers at risk.
Providing complete enclosures

Hazardous operations can be completely enclosed with the operators operating for outside the
enclosures.
Job safety analysis
A job safety analysis (JSA) is a procedure which helps integrate accepted safety and health
principles and practices into a particular task or job operation. In a JSA, each basic step of the job

is to identify potential hazards and to recommend the safest way to do the job. Other terms used to
describe this procedure are job hazard analysis (JHA) and job hazard breakdown.
Some individuals prefer to expand the analysis into all aspects of the job, not just safety. This
approach is known as total job analysis. Methodoly is based on the idea that safety is an integral
part of every job and not a separate entity. In this document, only health and safety aspects will be
considered.
The terms "job" and "task" are commonly used interchangeably to mean a specific work assignment,
such as "operating a grinder," "using a pressurized water extinguisher," or "changing a flat tire."
JSAs are not suitable for jobs defined too broadly, for example, "overhauling an engine"; or too
narrowly, for example, "positioning car jack.
One of the methods used in this example is to observe a worker actually perform the job. The major
advantages of this method include that it does not rely on individual memory and that the process
prompts recognition of hazards. For infrequently performed or new jobs, observation may not be
practical.
One approach is to have a group of experienced workers and supervisors complete the analysis
through discussion. An advantage of this method is that more people are involved in a wider base
of experience and promoting a more ready acceptance of the resulting work procedure. Members of
the joint occupational safety and health committee must participate in this process.
Initial benefits from developing a JSA will become clear in the preparation stage. The analysis
process may identify previously undetected hazards and increase the job knowledge of those
participating. Safety and health awareness is raised, communication between workers and
supervisors is improved, and acceptance of safe work procedures is promoted.
A JSA, or better still, a written work procedure based on it, can form the basis for regular contact
between supervisors and workers. It can serve as a teaching aid for initial job training and as a
briefing guide for infrequent jobs. It may be used as a standard for health and safety inspections or
observations. In particular, a JSA will assist in completing comprehensive accident investigations.
Benefits of doing a Job Safety Analysis

One of the methods used in this example is to observe a worker actually perform the job. The major
advantages of this method include that it does not rely on individual memory and that observing or
performing the process prompts the recognition of hazards. For infrequently performed or new jobs,
observation may not be practical.
One approach is to have a group of experienced workers and supervisors complete the analysis
through discussion. An advantage of this method is that more people are involved in a wider base
of experience and promoting a more ready acceptance of the resulting work procedure. Members of
the health and safety committee must also participate in this process.
Initial benefits from developing a JSA will become clear in the preparation stage. The analysis
process may identify previously undetected hazards and increase the job knowledge of those
participating. Safety and health awareness is raised, communication between workers and
supervisors is improved, and acceptance of safe work procedures is promoted.
A JSA, or better still, a written work procedure based on it, can form the basis for regular contact
between supervisors and workers. It can serve as a teaching aid for initial job training and as a
briefing guide for infrequent jobs. It may be used as a standard for health and safety inspections or
observations. In particular, a JSA will assist in completing comprehensive accident investigations.
Basic stages in conducting a JSA are:
 selecting the job to be analyzed
 breaking the job down into a sequence of steps
 identifying potential hazards
 determining preventive measures to overcome these hazards
Important to know when "selecting the job"
Ideally, all jobs should be subjected to a JSA. In some cases there are practical constraints posed by
the amount of time and effort required to do a JSA. Another consideration is that each JSA will
require revision whenever equipment, raw materials, processes, or the environment change. For
these reasons, it is usually necessary to identify which jobs are to be analyzed. Even if analysis of
all jobs is planned, this step ensures that the most critical jobs are examined first.
Factors to be considered in setting a priority for analysis of jobs include:
 Accident frequency and severity: jobs where accidents occur frequently or where they occur
infrequently but result in serious injuries.
 Potential for severe injuries or illnesses: the consequences of an accident, hazardous
condition, or exposure to harmful products are potentially severe.
 Newly established jobs: due to lack of experience in these jobs, hazards may not be evident
or anticipated.
 Modified jobs: new hazards may be associated with changes in job procedures.
 Infrequently performed jobs: workers may be at greater risk when undertaking non-routine
jobs, and a JSA provides a means of reviewing hazards.
How do I break the job into "basic steps"?
After a job has been chosen for analysis, the next stage is to break the job into steps. A job step is
defined as a segment of the operation necessary to advance the work. See examples below.
Care must be taken not to make the steps too general. Missing specific steps and their associated
hazards will not help. On the other hand, if they are too detailed, there will be too many steps. A
rule of thumb is that most jobs can be described in less than ten steps. If more steps are required,
you might want to divide the job into two segments, each with its separate JSA, or combine steps
where appropriate. As an example, the job of changing a flat tire will be used in this document.
An important point to remember is to keep the steps in their correct sequence. Any step which is out
of order may miss serious potential hazards or introduce hazards which do not actually exist.
Each step is recorded in sequence. Make notes about what is done rather than how it is done. Each
item is started with an action verb. Appendix A (below) illustrates a format which can be used as a
worksheet in preparing a JSA. Job steps are recorded in the left hand column, as shown here:
Sequence of Events Potential Accidents or Hazards Preventive Measures
Park vehicle
Remove spare and tool kit
Pry off hub cap and loosen lug bolts (nuts)
And so on.....
This part of the analysis is usually prepared by knowing or watching a worker do the job. The
observer is normally the immediate supervisor. However, a more thorough analysis often happens
by having another person, preferably a member of the health and safety committee, participate in
the observation. Key points are less likely to be missed in this way.
The job observer should have experienced and be capable in all parts of the job. To strengthen full
co-operation and participation, the reason for the exercise must be clearly explained. The JSA is
neither a time and motion study in disguise, nor an attempt to uncover individual unsafe acts. The
job, not the individual, is being studied in an effort to make it safer by identifying hazards and
making modifications to eliminate or reduce them. The worker's experience contributes in making
job and safety improvements.
The job should be observed during normal times and situations. For example, if a job is routinely
done only at night, the JSA review should also be done at night. Similarly, only regular tools and
equipment should be used. The only difference from normal operations is the fact that the worker is
being observed.
When completed, the breakdown of steps should be discussed by all the participants (always
including the worker) to make that all basic steps have been noted and are in the correct order.

Potential hazards
Once the basic steps have been recorded, potential hazards must be identified at each step. Based
on observations of the job, knowledge of accident and injury causes, and personal experience, list
the things that could go wrong at each step.
A second observation of the job being performed may be needed. Since the basic steps have already
been recorded, more attention can now be focused on each potential hazards. At this stage, no
attempt is made to solve any problems which may have been detected.
To help identify potential hazards, the job analyst may use questions such as these ( this is not a
complete list):
 Can any body part get caught in or between objects?
 Do tools, machines, or equipment present any hazards?
 Can the worker make harmful contact with moving objects?
 Can the worker slip, trip, or fall?
 Can the worker suffer strain from lifting, pushing, or pulling?
 Is the worker exposed to extreme heat or cold?
 Is excessive noise or vibration a problem?
 Is there a danger from falling objects?
 Is lighting a problem?
 Can weather conditions affect safety?
 Is harmful radiation a possibility?
 Can contact be made with hot, toxic, or caustic substances?
 Are there dusts, fumes, mists, or vapours in the air?
How do I "identify potential hazards"?

Once the basic steps have been recorded, potential hazards must be identified at each step. Based
on observations of the job, knowledge of accident and injury causes, and personal experience, list
the things that could go wrong at each step.
A second observation of the job being performed may be needed. Since the basic steps have already
been recorded, more attention can now be focused on each potential hazards. At this stage, no
attempt is made to solve any problems which may have been detected.
To help identify potential hazards, the job analyst may use questions such as these (this is not a
complete list):
 Can any body part get caught in or between objects?

 Do tools, machines, or equipment present any hazards?
 Can the worker make harmful contact with moving objects?

 Can the worker slip, trip, or fall?
 Can the worker suffer strain from lifting, pushing, or pulling?
 Is the worker exposed to extreme heat or cold?
 Is excessive noise or vibration a problem?
 Is there a danger from falling objects?
 Is lighting a problem?
 Can weather conditions affect safety?
 Is harmful radiation a possibility?
 Can contact be made with hot, toxic, or caustic products?
 Are there dusts, fumes, mists, or vapours in the air?
Potential hazards are listed in the middle column of the worksheet, numbered to match the
corresponding job step. For example:
Preventive
Sequence of Events Potential Accidents or Hazards
Measures
Park vehicle a) Vehicle too close to passing traffic
b) Vehicle on uneven, soft ground
c) Vehicle may roll
Remove spare and tool kit a) Strain from lifting spare
Pry off hub cap and loosen lug a) Hub cap may pop off and hit you b) Lug
bolts (nuts) wrench may slip
And so on..... a) ...
Determination of preventive measures:

The final stage in a JSA is to determine ways to eliminate or control the hazards identified. The
generally accepted measures, in order of preference, are:
1. Eliminate the hazard
Elimination is the most effective measure. These techniques should be used to eliminate the
hazards:
 Choose a different process
 Modify an existing process
 Substitute with less hazardous product
 Improve environment (e.g., ventilation)

 Modify or change equipment or tools

2. Contain the hazard
If the hazard cannot be eliminated, contact might be prevented by using enclosures, machine
guards, worker booths or similar devices.
3. Revise work procedures
Consideration might be given to modifying steps which are hazardous, changing the sequence of
steps, or adding additional steps (such as locking out energy sources).
4. Reduce the exposure
These measures are the least effective and should only be used if no other solutions are possible.
One way of minimizing exposure is to reduce the number of times the hazard is encountered. An
example would be modifying machinery so that less maintenance is necessary. The use of
appropriate personal protective equipment may be required. To reduce the severity of an incident,
emergency facilities, such as eyewash stations, may need to be provided.
In listing the preventive measures, do not use general statements such as "be careful" or "use
caution". Specific statements which describe both what action is to be taken and how it is to be
performed are preferable. The recommended measures are listed in the right hand column of the
worksheet, numbered to match the hazard in question. For example:
Sequence of Potential Accidents
Preventive Measures
Events or Hazards
Park vehicle a) Vehicle too close a) Drive to area well clear of traffic. Turn on
to passing traffic emergency flashers
b) Vehicle on b) Choose a firm, level parking area
uneven, soft ground c) Apply the parking brake; leave transmission in
c) Vehicle may roll PARK; place blocks in front and back of the wheel
diagonally opposite to the flat
Remove spare and a) Strain from lifting a) Turn spare into upright position in the wheel well.
tool kit spare Using your legs and standing as close as possible, lift
spare out of truck and roll to flat tire.
Pry off hub cap a) Hub cap may pop a) Pry off hub cap using steady pressure
and loosen lug off and hit you b) Use proper lug wrench; apply steady pressure slowly
bolts (nuts) b) Lug wrench may
slip
How should I make the information available to everyone else?

JSA is a useful technique for identifying hazards so that workers can take measures to eliminate or
control hazards. Once the analysis is completed, the results must be communicated to all workers
who are, or will be, performing that job. The side-by-side format used in JSA worksheets is not an
ideal one for instructional purposes. Better results can be achieved by using a narrative-style
communication format. For example, the work procedure based on the partial JSA developed as an
example in this document might start out like this:
1. Park vehicle
a) Drive vehicle off the road to an area well clear of traffic, even if it requires rolling on a flat tire.
Turn on the emergency flashers to alert passing drivers so that they will not hit you.
b) Choose a firm and level area for parking. You can jack up the vehicle to prevent rolling.
c) Apply the parking brake, leave the transmission in PARK, place blocks in front and back of the
wheel diagonally opposite the flat. These actions will also help prevent the vehicle from rolling.
2. Remove spare and tool kit
a) To avoid back strain, turn the spare up into an upright position in its well. Stand as close to the
trunk as possible and slide the spare close to your body. Lift out and roll to flat tire.
3. Pry off hub cap, loosen lug bolts (nuts)
a) Pry off hub cap slowly with steady pressure to prevent it from popping off and striking you.
b) Using the proper lug wrench, apply steady pressure slowly to loosen the lug bolts (nuts) so that
the wrench will not slip, get lost or and hurt your knuckles.
Safety measures in high temperature and high pressure operations

If the proper safety precautions are installed and sound working practices are adherred to then using
high-pressure equipment is very safe. We would therefore like to encourage you to work in this
exciting and very rewarding field. The dangers of high-pressure should always be borne in mind
and therefore it is essential to maintain the highest safety precautions at all times. Every user of
high-pressure equipment has to be aware that high-pressure also means potential energy. The energy
depends on pressure, temperature, volume and the compressibility of the fluid.
Gases are very compressible and therefore contain a lot of energy when compressed, but liquids are
also compressible, for example water is compressed by 12 % at 4000 bar. The power of a high-
pressure liquid can be demonstrated by the industrial high-pressure water jet cutting. However the
potential dangers of high-pressure technology can be kept under control if the necessary precautions
have been taken and a suitable material of construction is chosen for each specific application. Most
high-pressure units can be built with SITEC components. These stainless steel components should
be used whenever possible because of their proven reliability in many situations over a long period
of time. The pressure containing components are monitored at all stages of their manufacture.
Details of the tests may be known by use of the Heat-No which is stamped on each body part.
Special working conditions of high temperature and high pressure operations

• High temperatures: Use of nickel- and cobalt-base superalloys. Strength calculations based on
creep and rupture strength. Increased danger of corrosion.
• Low temperatures: Danger of brittle fracture. Improvement of the notched-bar impact strength by
increased nickel content.
• Corrosion: Pitting, stress corrosion cracking, galvanic corrosion, oxydation.
• Hydrogen embrittlement: Depends on H2 partial pressure and the working temperature.
Austenitic stainless steels are best suited for this application.
• Oxygen service: Absolute cleanliness mandatory for all wetted parts.
• Cycling pressures: May reduce the material strength after 106 - 107 cycles to 25-30% of the tensile
strength. By autofrettage or with shrunk cylinders the strength for infinite life expectancy may be
increased by 80-150%.
Additional safety precautions:

• Professional introduction and training of staff and operators. Request the SITEC HP catalogue for
the maintenance and technical staff.
• Externally heated pressure vessels operated at high internal pressures should only be
subjected to moderate temperature gradients across the wall. Pressure and temperature
induced stresses are additive and may exceed the safe operating strength.
• High-pressure tubing must never be heated for bending as this would reduce its material
Strength.
• Emergency instructions have to be fixed visibly to the plant.
• Fire extinguishers and a first-aid kit should be ready at hand.
• Safety devices should protect the operating staff. They may range from a simple mirror-system
Dangerous and toxic chemicals

Many common household chemicals are dangerous. They may be reasonably safe when used as
directed, yet contain toxic chemicals or degrade over time into a more dangerous chemical. Here's

a list of some of the most dangerous household chemicals, including the ingredients to watch for
and the nature of the risk.
Air fresheners
Air fresheners may contain any of a number of dangerous chemicals. Formaldehyde irritates the
lungs and mucous membranes and may cause cancer. Petroleum distillates are flammable, irritate
the eyes, skin, and lungs, and may cause fatal pulmonary edema in sensitive individuals. Some air
fresheners contain p-dichlorobenzene, which is a toxic irritant. The aerosol propellants used in some
products may be flammable and may cause nervous system damage if inhaled.
Ammonia
Ammonia is a volatile compound that can irritate the respiratory system and mucous membranes if
inhaled, can cause a chemical burn if it is spilled on skin, and will react with chlorinated products
(e.g., bleach) to produce deadly chloramine gas.
Antifreeze
Antifreeze is ethylene glycol, a chemical which is poisonous if swallowed. Breathing it can cause
dizziness. Drinking antifreeze can cause serious brain, heart, kidney, and other internal organ
damage. Ethylene glycol has a sweet flavor, so it is attractive to kids and pets. Antifreeze typically
contains a chemical to make it taste bad, but the flavor is not always a sufficient deterrent. The sweet
smell is enough to lure pets.
Bleach
Household bleach contains sodium hypochlorite, a chemical that can cause irritation and damage to
the skin and respiratory system if inhaled or spilled on the skin. Never mix bleach with ammonia or
with toilet bowl cleaners or drain cleaners, as dangerous and possibly deadly fumes may be
produced.
Drain cleaners
Drain cleaners typically contain lye (sodium hydroxide) or sulfuric acid. Either chemical is capable
of causing an extremely serious chemical burn if splashed on the skin. They are toxic to drink.
Splashing drain cleaner in the eyes may cause blindness.
Laundry detergent
Laundry detergents contain a variety of chemicals. Ingestion of cationic agents may cause nausea,
vomiting, convulsion, and coma. Non-ionic detergents are irritants. Many people experience
chemical sensitivity to dyes and perfumes present in some detergents.
Mothballs
Mothballs are either p-dichlorobenzene or naphthalene. Both chemicals are toxic and known to
cause dizziness, headaches, and irritation to the eyes, skin, and respiratory system. Prolonged
exposure can lead to liver damage and cataract formation.
Motor oil
Exposure to the hydrocarbons in motor oil can cause cancer. Many people are unaware that motor
oil contains heavy metals, which can damage the nervous system and other organ systems.
Radioactive materials
Develop a detailed plan and practice with a dry run to rehearse the experiment. With planning you
will improve dexterity and speed and minimize the potential for a spill, decrease the time you spend
working with radioactive materials, and improve shielding.
Arrange your workplace and minimize the amount of unnecessary equipment. This lessens the
possibility of spills and/or contaminating a bench with radioactive materials.
Wear personal protection equipment, such as gloves, a laboratory coat, and safety glasses. Do not
wear open-toed shoes in the laboratory. Wear whole-body dosimeters (e.g. Luxel dosimeter) when
handling ANY radioactive material and extremity dosimeters (e.g. finger ring), if one is provided
by EH &S. Use an appropriate survey meter and probe while working with radioactive materials.
Monitor work surfaces and gloves regularly to maintain control over contamination and exposure.
Use remote handling devices (forceps or tongs) to handle stock vials, sources, or potentially
contaminated items.
Use potentially volatile chemicals/radionuclides in designated fume hoods. Use shielding
appropriate for the radionuclide. An effective shield should provide protection in all directions.
Place the radioactive material close to the shield to maximize the "shadow area" (area where
radiation is blocked out by the shield) cast by the shield. Check the work area and adjoining areas
for contamination with a survey meter. Perform a personal survey to check for contamination
(hands, hair, eyeglasses, clothing, etc.). Decontaminate all points of contamination. Click here for
what to do in case of a radioactive spill.
Periodic inspection and its types
Accidents do not just happen. They are definitely caused by unsafe conditions or unsafe
practices. Well planned inspection procedure thoroughly and systematically applied is an effective
way of discovering hazardous conditions. The cost of inspection to discover hazards in advance is
much less than cost of discovering each hazard by the accidents it will inevitably bring if lest
uncorrected. To give an example insecurely piled empty drums in the working area may roll down
on a man working nearby. Adequate planning, instruction, training, and supervision would prevent
creation of such hazards. But even the best performance in these aspects has to be powerfully aided
by an effective safety inspection service. Such inspection can also be helpful in discovering unsafe
practices and procedures.
Types of Periodic Inspection

There are two types of safety inspection that are commonly adopted.
(i). The one call inspection to appraise safety conditions and safety performance in a plant done by
an insurance engineer, a state government safety inspector or a consultant who comes at the request
or the approval of the management. The second is continuing activity set-up an maintained by the
management to discover conditions, procedures and practices that if uncorrected can cause
accidents.
One call type inspection

Purpose of the visit is to make an appraisal of the safety performances and present the facts
thus gained to the management for using in improving performance. As the time available for
appraisal is limited the inspector should plan his work and set-down in orderly form the conditions,
factors and matters that should be investigated. Engineers usually recommend check list to be used
which can be as follows.
(i). House Keeping.
(ii). Materials handling methods.
(iii). Adequacy of Aisle space and working space.
(iv). Guarding of transmission machinery.
(v). Maintenance.
(vi). Hand tools.
(vii). Ladders and portable steps.
(viii). Floors and platforms.
(ix). Lighting.
(x). Electrical equipments.
(xi). Elevators.
(xii). Eye protection and other personnel protective equipments.
(xiii). Pressure vessels.
(xiv). Any other explosion hazards as volatile liquids, chemicals, and other dangerous substances.
(xv). Oiling methods.
(xvi). Access to overhead equipments.
(xviii). Exits.
Inspection as a continuing plant activity

Inspection as a check on quality of product is an essentiality f production. Inspection to discover
conditions that if uncorrected may be the cause of accidents and injuries is essential to first rate
safety performance. A person working in the plant would have a considerable advantage when he
is asked to undertake an inspection of his own establishment. Most of the discussed points on the
one call inspection are valid for the continued inspection work also.
Inspection schedule: In theory at least safety inspection should be added only where inspection
incidental to production is not adequate for safety
Safety inspection check list for a chemical plant.
(i). Pessure vents.
(ii). Relief Valves.
(iii). Control Valves.
(iv). Sparger – To disperse a gas through a liquid.
(v). Heat Exchangers and condensers.
(vi). Pressure vacuum stills.
(vii). Reactors.
(viii). Lagging.
(ix). Recorders, meters, gauges.
(x). Heating coils.
(xi). Drains,
(xii). Exhaust equipments.
(xiii). Manhole.
(xiv). Escape facilitates during emergencies.
Corrective Action
Prompt and reasonably through corrective action should follow the inspection findings. If this
does occur, the blame is on the management only. Each report should be kept active until every
item on it has received considerable and proper disposal.
Plant layout
It is the arrangement of machines within a factory, so that each operation is performed at a point of
greatest convenience.
Objectives: (I). Minimum Utilization of floor area
(ii). Lighting and ventilation of area.
(iii). Minimizing accidents.
(iv). Space for future developments.
(v). Safety of equipments, and personnel.
(vi). Better working conditions.
(vii). Easy supervision.

(viii). Neatness.
A good plant planning and layout is a big help in promoting safe working environment. Site
choice and planning, transportation facilities, layout etc., should normally receive detailed
consideration at the early stages of planning a new project. Safety requires constant attention to .,
(i). Storage and handling facilities for explosive and flammable substances as raw materials,
intermediate products and finished product stages.
(ii). Electrical equipment, wiring and installation lighting power supply including emergency stand
by power.
(iii). Boiler and other pressure equipments.
(iv). Ventilation, heating and air Conditioning.
(v). Fire protection.
(vi). Waste and effluent disposal.
(vii). First aid, medical facilities, personnel protective equipments, noise and sanitation etc.
The important points to be remembered in lay out are.,
(i). Segregation of hazardous process areas.
(ii). Provision of a separate area for storage of flammable and hazardous materials.
(iii). Provisions of separate location for furnaces, heaters etc.,
(iv). Using flame at a safe distance from areas where flammable and volatile materials are housed.
(v). Ventilation and lighting.
Plant layout is a “technique of locating different machines and plant services within the factory so
that the greatest possible output of high quality at the lowest possible total cost can be available”.
It signifies the arrangement of machines, work areas, material handling equipment’s, transport, and
storing of different materials, products, tools and fixtures etc. Proper plant layout is one of the keys
of success in factory management. The layouts for the same product may be numerous, but which
costs less in the long run is the best. Since plant layout is responsible for an orderly flow of materials,
productivity and morale of the workers, it is necessary to have systematic layout planning. This has
become all the more necessary with the increasing costs of the land, labour and building materials.
Layout should be such that, it can be changed without much difficulty due to expansion,
diversification, change in product design or change in technology. In such cases we need to
minimise the effects of dislocation i.e., the transition has to be made quickly from old layout to new
layout, so as to minimise the production loss.
Most of the handling operations are performed repeatedly throughout the course of production,
therefore, if shortest manner of handling is not adopted, this will result wastage of time and shall
loose total effectiveness.
Type of building-single storey or multi storey depends upon the availability of land and the type of
products to be manufactured and its manufacturing methods. Where manufacturing process involve
the gravity flow of products such as chemicals, paints, sugar, refineries, fertilisers etc., multi-storey
building must be designed. A good layout minimises the handling time and efforts, saves the floor
space, shortens the travel of materials, increases production and reduces cost by utilising labour
more efficiently. If the layout is haphazardous, the products will not be economical and cost may
be very high resulting in losses.
Analytical Tools of Plant Layout

This is a procedure of making the layout of the plant or making improvement in the existing layout
with the help of a number of tools and techniques. In this, a plan showing the position of machines,
flow of work and material handling devices etc. is prepared to a scale on a drawing sheet or floor.
The various tools and techniques used for the preparation of plant layout are described in
short below:
(a) Flow process chart,
(b) Process flow diagram,
(c) Machine data card,
(d) Templates, and
(e) Scale models.
(a) Flow Process Chart:
This is a graphic representation of sequence of operation, transportation, inspection, delays and
storage occurring during manufacture. This gives the information regarding distance moved and
time required for various activities such as transportation, delay, inspection etc. This chart helps in
determining hidden efficiencies in the processes and may suggest rearrangement of layout.This also
points out elimination of unnecessary movement and processes.
(b)Process Flow Diagram
It is the diagram of building plan representing graphically the movement of materials on the
drawing. With its help proper material handling arrangements can be made and it indicates long
material hauls and back tracking of present layout, which thereby helps in improving the layout.
(c) Machine Data Cards:
These cards give complete specification of each machine to be installed such as output capacity,
foundations, space needed, method of operation, maintenance and handling devices of machines etc.
(d) Templates
After studying the flow process chart, process flow diagram and machine data cards, a floor plan is
prepared by fixing the area occupied by each item to be erected in the shops. This floor plan is
prepared at certain scale say 1 cm2 = 1 m2.
Now from thick sheets of paper or card board pieces are cut (known as templates) to represent
various items which are to be housed in the plants, and are placed on the floor plans at suitable
places. These templates are so arranged as to give best layout. The changes if any, required are made
before making the actual layout drawing.
(e) Scale Models:
It is an improvement over the template method. In this tool, instead of templates, use of three
dimensional scale models is made. These models may be of wood or metal and when used on a
layout, series of additional information about the height and of the projected parts of the machines
are obtained. This is similar to a child’s doll house.
This technique is useful for complex layout, requiring initially huge investment.
In conclusion, plant layout is an important consideration. Hence various experts such as production
engineer, materials handling engineer, safety engineer and work study engineer etc. should all sit
together to arrive for final best shape of layout.
Advantages of Scientific Layout:

A scientific layout has got the following important advantages:
1. It reduces internal transport to a minimum.
2. It minimises accidents and makes supervision easy and quick.
3. It makes repairs and maintenance easy.
4. It yields higher profits. Therefore, higher wages can be paid to workers.
5. It reduces labour turn-over.
6. It reduces production delays to a large extent.
7. It keeps the shops neat and clean.
8. It minimises changes in the layout to a large extent every time.
9. It keeps control over production.
10. It eliminates waste effort and thus speeds of production increases.
11. Back tracking is reduced.
12. Less capital is spent on machinery.
13. It reduces set up and total operation time.
14. It reduces wastage and spoiled work.
15. Time and motion study can be easily and accurately performed.
16. Better utilisation of manpower.
17. Improvement in methods of production can be made.
Layout of Services
The tool rooms, store rooms, water, power, transportations, cafeteria, wash rooms, lavatories etc.
include the service centres of a plant. The shorter the distance from the operations to these centres,
the less time will be consumed by workers in using these services.

Generally the service centres are located where the space is available after planning for
manufacturing. The exact location is determined by its nature, number of persons to avail such
services and how much this service is made use of.
Good layout can easily be observed by following characteristics:

1. Minimum handling between operations.
2. Minimum handling distances.
3. Straight passages.
4. Minimum backtracking.
5. Minimum goods in process.
6. Planned material flow pattern.
7. Layout adoptable to changing conditions.
8. Proper location of services.
9. Maximum automatic handling.
10. Control over noise, dirt, fumes, dust, humidity, temperature etc.
11. Minimum walking by operation people.
12. Minimum handling by skilled workers.
13. Scrap removal be properly planned.
14. Minimum re-handling.
UNIT III
SAFETY PERFORMANCE
Introduction to Safety appraisal

The International Atomic Energy Agency is authorized, by its Statute to establish Safety Standards
for protection of health and minimization of danger to life and property and to provide for the
application of those standards at the request of Member States.
Effective implementation of these Standards is essential for ensuring a high level of safety, therefore
the Agency also has to appraise the compliance of these Standards in Member States to ensure they
are being applied. These appraisals are carried out whenever there is a request from the Member
State.
While each Member State is responsible for the system of regulation and monitoring of occupational
radiation protection, the IAEA can also provide, at the request of the Member State or for its own
purposes, an independent appraisal service for some or all aspects of occupational radiation
protection. Such an appraisal provides an opportunity for a Member State to have its occupational
radiation protection programme independently assessed and evaluated. An independent assessment

is often useful to maintain or enhance the effectiveness of the programme and to identify in an
objective and unbiased manner the areas where improvements may be required.
A secondary benefit is that an independent appraisal allows information on best practices from the
host country to be made available to other Member States.
The occupational radiation protection appraisal service is an assessment conducted by international
experts selected for their experience in such reviews, for their knowledge of international guidance
and best practices, and for their ability to recognise and understand the strengths of different national
systems and arrangements. Although the appraisal is based on international guidelines and best
practices, it is not prescriptive nor is it rigid: it takes into account the practical context in the host
country and emphasises the positive features of “how things are done” in that country
Types of safety Appraisal

The safety appraisal consists of the following elements:
 Strategic Plan
 Program Review
 Employee Interviews/Site Visits
 Safety Perception Survey
Once the client’s motivation is determined, a strategic plan will be developed to ensure the desired
information is obtained and effectively communicated.
Strategic Plan
The most important step in the Corporate Safety Appraisal process is to determine what it is the
client wants to know about their company’s safety function.
 Are losses due to injuries and illnesses increasing?
 Have recent incidents suggested a problem with the implementation of the safety program?
 Are resources allocated to the safety function being managed effectively?
 Have changes in the company’s activities prompted an assessment of the safety program?
 How is effective is the company’s safety philosophy & programs/policies being
communicated throughout the organization?
 What input do employees have in the safety process within the organization?
 Do employees feel the company is concerned about their safety and health while performing
their daily jobs?
Once the client’s motivation is determined, a strategic plan will be developed to ensure the desired
information is obtained and effectively communicated.

Personal protective equipment (PPE)

It refers to protective clothing, helmets, goggles, or other garment or equipment designed to protect
the wearer's body from injury by blunt impacts, electrical hazards, heat, chemicals, and infection,
for job-related occupational safety and health purposes, and in sports, martial arts, combat, etc.
Personal armor is combat-specialized protective gear. In British legislation the term PPE does not
cover items such as armour. The terms "protective gear" and "protective clothing" are in many cases
interchangeable; "protective clothing" is applied to traditional categories of clothing, and "gear" is
a more general term and preferably means uniquely protective categories, such as pads, guards,
shields, masks, etc.
Items such as fire extinguishers, first aid kits are not protective gear, but rather equipment to support
the personal protection of the subject. Handcuffs, tasers, batons and handguns used by police forces
fall under this category.
The use of personal protective equipment is to reduce employee exposure to hazards when
engineering and administrative controls are not feasible or effective to reduce these risks to
acceptable levels.
List out personal protective equipments

Biological hazard protection
Protective equipment for biological hazards includes masks worn by medical personnel (especially
in surgery to avoid infecting the patient but also to avoid exposing the personnel to infection from
the patient.) Gloves, frequently changed, are used to prevent infection but also transfer between
patients. One measure to reduce the risks of transmitting skin microorganisms from one person to
another is in the use of single use disposable blood pressure cuff covers. Reports of hospitals
reducing their hospital acquired infection rate by nearly 50% through the use of disposable
protective covers for blood pressure cuffs have been reported.
Ballistic
Ballistic personal protective equipment (or armor) is used in combat by military personnel and in
lesser conflicts by law enforcement.
Chemicals
A hazmat suit is an impermeable garment that covers the whole body, worn as protection from
hazardous substances. It is generally combined with breathing apparatus, and may be used by
firefighters, emergency personnel responding to toxic spills, researchers, specialists cleaning up

contaminated facilities, or workers in toxic environments, where there is exposure to hazardous

materials.
Flying debris or splashing liquids

A face shield protects from flying debris such as produced by cutting, welding, chipping, or sanding,
and protects against splashes or spray of liquids. Safety glasses provide protection for the eyes and
may additionally be tinted to block UV or laser light. Goggles seal tightly about the eyes and provide
superior protection from dust, dirt, and fumes.
Sharp injuries
Meat packers and others who routinely use hand-held knives in their work may use mail gloves to
protect the hands from cuts. Those in other professions where sharps injuries are a concern often
utilize cut and puncture resistant protective gloves, and hand held safety tools that offer critical
stand-off distance between themselves and whatever they may come into contact.
Blunt trauma
Law enforcement and Corrections officers wear for crowd management, civil disturbances, cell
extractions, riot control, violent disturbances, and other emergency response operations. To assure
their equipment is safe, end-users and industry refer to standards:
Periodic inspection
A periodic inspection is an inspection and associated testing to check whether an electrical
installation is in a satisfactory condition for continued service. On completion of the necessary
inspection and testing, an Electrical Installation Condition Report will be issued detailing any
observed damage, deterioration, defects, dangerous conditions and any non-compliances with the
present-day safety standard which might give rise to danger.
Periodic inspection and testing should be carried out only by electrically competent persons,
such as registered electricians.
It is recommended that periodic inspection and testing is carried out at the following times:
for tenanted properties, every 5 years or at each change of occupancy, whichever is
sooner
at least every 10 years for an owner-occupied home
at least every 5 years for a business
The Landlords and Tenant Act 1985 requires landlords of properties with short leases to keep the
electrical wiring in repair and in proper working order. We recommend landlords arrange for

periodic inspection and testing to be carried out by a registered electrician at the relevant intervals
shown above.
Periodic inspection and testing of the electrics should be carried out more frequently on the places
and premises listed here:
3 years for a caravan
1 year for a swimming pool
Types of safety
It is important to distinguish between products that meet standards, that are safe, and those that
merely feel safe. The highway safety community uses these terms:
Normative safety
Normative safety is a term used to describe products or designs that meet applicable design
standards and protection.
Substantive safety
Substantive, or objective safety means that the real-world safety history is favorable, whether or not
standards are met.
Perceived safety
Perceived, or subjective safety refers to the level of comfort of users. For example, traffic signals
are perceived as safe, yet under some circumstances, they can increase traffic crashes at an
intersection. Traffic roundabouts have a generally favorable safety record yet often make drivers
nervous.
Risks and responses
Safety is generally interpreted as implying a real and significant impact on risk of death, injury or
damage to property. In response to perceived risks many interventions may be proposed with
engineering responses and regulation being two of the most common. Probably the most common
individual response to perceived safety issues is insurance, which compensates for or provides
restitution in the case of damage or loss.
System safety and reliability engineering

System safety and reliability engineering is an engineering discipline. Continuous changes in
technology, environmental regulation and public safety concerns make the analysis of complex
safety-critical systems more and more demanding.
A common fallacy, for example among electrical engineers regarding structure power systems, is
that safety issues can be readily deduced. In fact, safety issues have been discovered one by one,
over more than a century in the case mentioned, in the work of many thousands of practitioners, and

cannot be deduced by a single individual over a few decades. A knowledge of the literature, the
standards and custom in a field is a critical part of safety engineering.
A combination of theory and track record of practices is involved, and track record indicates some
of the areas of theory that are relevant. (In the USA, persons with a state license in Professional
Engineering in Electrical Engineering are expected to be competent in this regard, the foregoing
notwithstanding, but most electrical engineers have no need of the license for their work.)
Safety is often seen as one of a group of related disciplines: quality, reliability, availability,
maintainability and safety. (Availability is sometimes not mentioned, on the principle that it is a
simple function of reliability and maintainability.) These issues tend to determine the value of any
work, and deficits in any of these areas are considered to result in a cost, beyond the cost of
addressing the area in the first place; good management is then expected to minimize total cost.
Program Review
A review of the current safety program is undertaken to assess those activities and program elements
used by the client to manage the safety function. Information obtained in the Program Review will
be used in other activities to determine to what extent the safety program is being administered in
the field. Specifically, this will be determined through the Safety Perception Survey, Employee
Interviews/Site Visits, and Incident Analyses.
Safety Perception Survey

Customized for each client’s specific needs, a Safety Perception Survey is utilized to analyze 21
categories of the safety function of a client. Each category is measured for management, supervision
and hourly employees. Results of the Safety Perception Survey are interpreted, prioritized and
presented to the client through graphics and easy-to-understand narrative. The initial Safety
Perception Survey’s greatest benefit is to serve as a baseline for future surveys. The client has the
option of repeating the survey periodically to assess the impact of corrective efforts and to verify
the continued success of the safety function.
Employee Interviews/Site Visits

Safety Perception Surveys are unmatched in their ability to quantify a client’s safety function by
providing a measurable glimpse of the “big picture”. However, interviews and site visits are just as
useful in assessing the client’s climate and can be used to gather useful “specifics” from
management, supervision, and hourly employees.
Interviewers visit jobsites and perform quick, informal interviews of employees. Interview notes are
then summated into declarative statements from which findings and recommendations are

developed. Anonymity of interviewees is guaranteed, ensuring honest, enlightening feedback for

the client.
Effective steps to implement safety procedures
Weighing equipment intended for use in hazardous areas must comply with extensive regulations,
feature approved protection methods and be installed and maintained correctly to ensure safe
operations. With our free guide, learn how you can ensure the safety of your workers, plant and
products.
Every year in the news there seems to be a major incident resulting from an accident in a hazardous
area. Most of these unfortunate incidents could have been prevented with a measure of safety
competence, better planning and the right equipment. While well-meaning companies can make
mistakes, in hazardous areas, those mistakes can come at a high price.
Learn to Avoid Safety Incidents

The key to avoiding these safety incidents lies in preparation, regulatory-standards knowledge and
careful selection of the right equipment for hazardous-zone operation. Identifying the right
equipment that can deliver both workplace safety and accurate measurements can be a challenging
task for manufacturers. However, it is essential for a safe and reliable operation that limits potential
danger to employees and capital.
Compliant Equipment, Correct Installation

Our guide “Competence for Hazardous-Area Safety” explains how to avoid dangerous situations
in hazardous areas with compliant equipment, and it offers a comprehensive explanation of
standards and regulations. It also explains how to correctly install and maintain equipment in
hazardous areas and offers examples of hazardous-area weighing systems.
Improve your safety competence by reviewing

Explosion Protection Basics
An explosive atmosphere is a mixture of air and combustible material in form of gases, vapors, mists
or dusts. Learn how to avoid sufficient energy output for ignition to avoid dangerous combustion
and the chain-reactions they can precipitate.
International Standards and Regulations

Increasing numbers of accidents in processing industries are highlighting the importance for
comprehensive, harmonized safety regulations. Learn about technical approval requirements.

Hazardous-Area Classification
Area classification is the method of analyzing and classifying the environment where explosive
atmospheres may occur to facilitate proper electrical equipment selection and allow preparation of
safety procedures. Learn the various categorization methods and how to apply them.
Electrical-Equipment Protection
The basic safety concept of ignition protection is to eliminate the simultaneous existence of
possible ignition sources. The method of equipment protection will depend on the degree of safety
needed for your hazardous area. Equipment markings are also covered so you can identify
equipment with appropriate safety features.
Installation and Maintenance

Learn how often your equipment must be inspected to ensure safety in your hazardous area.
Weighing in Hazardous Areas

Weighing is one of the most basic and important process variables in a vast majority of
manufacturing processes. However, it can be one of the most challenging parameters to control.
Learn the specifics of ensuring accuracy while also ensuring you have competence in safety.
Safety in Petrochemical Industry

The worker safety is dependent on worker behaviour and human factors.
Stay Alert
 The more awake a worker is, the less likely he or she is to get hurt.
 If you are unsure how to operate equipment orperform a task, ask your supervisor
 Make sure you know in advance the correct, safe way to do the work safety.
Wear the right clothes
 Wear protective clothing and equipment asrequired.
Use the right tools
 If you need a hammer, get a hammer.
 It may be handier to use a pair of pliers,wrench, screw driver or even your fist.
 But you will have only yourself to blame if youbreak your fingers.
Use lifting devices & learn how to lift
Dont be a prankster
 Practical jokes and horseplay can bedangerous around machinery
 If you feel the urge to play, resist it until afterwork.

Be tidy
 Good housekeeping reduces hazards in theworkplace or your home.
 Always put away tools when they are not inuse.
Reporting is important
 Never fail to report accidents
 Defective equipment.
 Unsafe conditions.
Get first aid immediately
 Neglect of the injury may lead to seriousinfection, even permanent injury.
 Keep the floors clean, pick up scraps, wipe upspills.
 A slip or trip can be fatal.
Back your safety program
 If you have an idea you believe will reduceaccidents, tell your supervisor about it
 Set an example by obeying safety rules.
 Cooperate with your safety committee.
Aviod shortcuts & never take a chance
 Be punctual at your Work Place
Safety and health programs

If your employees are exposed to hazardous chemicals in the workplace.
Develop the safety and health programs for your Industry
 An Accident Prevention Program (APP)
 A Personal Protective Equipment (PPE)Program
 A Hazardous Chemicals Communication Program
If your employees use respirators to do their work.
 A Hearing Loss Prevention Program- Sample plan for preventing hearing loss
 A Fall Protection Work Plan
 A Respiratory Protection program
Make sure your accident prevention program is effective in practice
Develop, supervise, implement and enforce safety and healthy training programs that are effective
in practice.
Develop a written accident prevention program.
To establish, supervise and enforce an accident prevention program that is effective
in practice.

UNIT IV
ACCIDENTS
Accident costs
The realization that it pays to prevent accidents and the injuries they bring should be the
driving force behind the safety movement. Estimation of accident cost will let us know the
importance of safety activities.
There are two types costs involved in industrial accidents.
(i). Direct Costs.: Only 25% of the total accident cost.
(ii). Indirect Costs.75% of the total accident cost pertinent to the victims, management and society
which are invariably omitted out of ignorance while computing costs of accident.
Direct costs.
(i). Payment by way of compensation to the accident victims.
(ii). Medical expenses incurred by the management for the injured in the accident.
Indirect costs.
Indirect costs can again be classified into three subclasses.
(i). Employer Related.
(ii). Employee Related.
(iii). Government-Society Related.
Employer Related
(i). Cost incurred in the inquiry and preparing of investigation reports.
(ii). Cost of time lost by other personnel, than those involved in the accident who stop work
(a). Out of curiosity. (b). Out of sympathy. (c). To assist injured person.
(iii). Loss/Damage of machinery and its components or material,
(iv). Cost involved in recovery and salvage of damaged equipment and cleaning of accident spot.
(v). Overheads incurred during the downtime after the accident.
(vi). Loss of expertise and skill of the victims.
(vii). Payment to the injured persons when they are not able to give their full contribution.
(viii). Expenses of recruiting new employee and the cost of his training.
(ix). Loss due to low production due to new inexperienced worker.
(x). Loss of public confidence, prestige and hence revenue.
Exployee related.
(i). Loss of payment to the injured persons.
(ii). Degradation of morale among workers.
(iii). Cost of subsequent injuries that occurs in consequence of the excitement or weakened morale
due to original accident.
(iv). Exodus of skilled people to other factories due to accidents.
(v). Loss of future earnings if the injury affects the moral advancement in his career.
Society – Government related:
(i). Escalation in the price of the products due to production loss which will change the consumer
priority.
(ii). Consequent reduction in Prices at the cost of quality which affects the consumers.
(iii). Loss to the government by way of reduced tax collection.
(iv). Resulting in industrial unrest and the interference of the government.
(v). Finally leading to the retention and lockout leading to the disturbance in the equilibrium of the
society.
Prevention methods of accidents.

Accidents do not happen but they are caused. A cloud of flammable vapor can not explode until
there is some means of ignition. An injury invariably results form a sequence of factors. The
sequences of factors to an injury are:
(i). Social environment
(ii). Fault of a person.
(iii). Unsafe act or unsafe condition.
(iv). Accident,
(v). Injury.
It is easiest and most effective to remove the central cause that is unsafe act or unsafe
condition.
Unsafe acts
The unsafe acts or conditions that are normally encountered in industries are as follows.
(i). Working on moving or dangerous equipments.
(ii). Operating equipments without authority.
(iii). Failing to shut off or secure the equipment.
(iv). Making safety devices inoperative.
(v). Taking unsafe position.
(vi). Using unsafe equipment or the unsafe use of hangers.
(vii). Working at unsafe speeds.
(viii). Distracting and abusive actions
Hazardous arrangements
a). Unsafely stored or piled materials or tools.
b). Crowded work spaces.
c). Narrow or blocked aisles.

d). Overloaded floors, platforms or vehicles.
e). Unsafe processes.
Improper Guarding:
a). Unguarded.
b). Inadequately guarded.
c). Lack of support.
Equipment defects
a). Rough and Sharp guarded.
b). Poorly designed or constructed.
c). Not strong enough
e). Worn or cracked.
Remedial measures of accidents

In any accident one must venture to find and remove root cause. There are two different
ways of approaching this problem, which are well explained by two theories.
(i). Unimode or domino theory.
(ii). The theory of multiple causes.
The Unimode or domino theory just gives an immediate solution, but it is not the end of it.
The theories of multiple causation give all possible causes and sub causes for a particular accident
and removes it permanently.
For example let us consider a common accident, wherein a man falls off from a step ladder.
If the accident is investigated using the domino theory one would identify as follows. Unsafe Act
Climbing on a defective ladder.
Unsafe Condition: A defective ladder.
Correction: Change the ladder.
In terms of multiple causation one go in search of all the surrounding factors that led to the accident.
(i). Why was the defective ladder not found in normal inspection.
(ii). Why did the supervisor allow its use.
(iii). Did not the injured employee know that he should not use it.
(iv). Was the worker was properly trained.
(v). Did the supervisor examined the job first
As a result one will find the following corrections.

Corrections
i). An Improved inspection procedure.
ii). Improved training.
iii). A better definition of responsibilities.
iv), Pro-Job planning by supervisor.
Narrow interpretation of the domino theory would lead us only to accident symptoms but
not causes. If we deal only at the symptomatic level we will end up removing the symptoms leaving
the path free for further accidents.
Fault tree analysis

Fault tree analysis (FTA) is a top down, deductive failure analysis in which an undesired state of a
system is analyzed using boolean logic to combine a series of lower-level events. This analysis
method is mainly used in the field of safety engineering and Reliability engineering to determine
the probability of a safety accident or a particular system level (functional) failure.
In Aerospace the more general term "system Failure Condition" is used for the "undesired state" /
Top event of the fault tree. These conditions are classified by the severity of their effects. The most
severe conditions require the most extensive fault tree analysis. These "system Failure Conditions"
and their classification are often previously determined in the functional Hazard analysis.
FTA can be used to:
 understand the logic leading to the top event / undesired state.
 show compliance with the (input) system safety / reliability requirements.
 prioritize the contributors leading to the top event - Creating the Critical
Equipment/Parts/Events lists for different importance measures.
 monitor and control the safety performance of the complex system (e.g. Is it still safe to fly
an Aircraft if fuel valve x is not "working"? For how long is it allowed to fly with this valve
stuck closed?).
 minimize and optimize resources.
 assist in designing a system. The FTA can be used as a design tool that helps to create (output
/ lower level) requirements.
 function as a diagnostic tool to identify and correct causes of the top event. It can help with
the creation of diagnostic manuals / processes.

Methodology
Any sufficiently complex system is subject to failure as a result of one or more subsystems
failing. The likelihood of failure, however, can often be reduced through improved system
design. Fault tree analysis maps the relationship between faults, subsystems, and redundant
safety design elements by creating a logic diagram of the overall system.
The undesired outcome is taken as the root ('top event') of a tree of logic. For instance the
undesired outcome of a metal stamping press operation is a human appendage being
stamped. Working backward from this top event we might determine there are two ways this
could happen: during normal operation or during maintenance operation. This condition is a
logical OR. Considering the branch of occurring during normal operation perhaps we
determine there are two ways this could happen: the press cycles and harms the operator or
the press cycles and harms another person. This is another logical OR. We can make a design
improvement by requiring the operator to press two buttons to cycle the machine—this is a
safety feature in the form of a logical AND. The button may have an intrinsic failure rate—
this becomes a fault stimulus we can analyze. When fault trees are labeled with actual
numbers for failure probabilities, computer programs can calculate failure probabilities from
fault trees. When a specific event is found to have more than one effect event, i.e. it has
impact on several subsystems, it is called a common cause or common mode. Graphically
speaking, it means this event will appear at several locations in the tree. Common causes
introduce dependency relations between events. The probability computations of a tree
which contains some common causes are much more complicated than regular trees where
all events are considered as independent. Not all software tools available on the market
provide such capability.
The tree is usually written out using conventional logic gate symbols. A cut set is a
combination of events, typically component failures, causing the top event. If no event can
be removed from a cut set without causing the top event, then it is called a minimal cut set.

Some industries use both fault trees and event trees (see Probabilistic Risk Assessment). An
event tree starts from an undesired initiator (loss of critical supply, component failure etc.)
and follows possible further system events through to a series of final consequences. As each
new event is considered, a new node on the tree is added with a split of probabilities of taking
either branch. The probabilities of a range of 'top events' arising from the initial event can
then be seen.
Classic programs include the Electric Power Research Institute's (EPRI) CAFTA software,
which is used by many of the US nuclear power plants and by a majority of US and
international aerospace manufacturers, and the Idaho National Laboratory's SAPHIRE,
which is used by the U.S. Government to evaluate the safety and reliability of nuclear
reactors, the Space Shuttle, and the International Space Station. Outside the US, the software
RiskSpectrum is a popular tool for fault tree and event tree analysis, and is licensed for use
at almost half of the world's nuclear power plants for probabilistic safety assessment.
Professional-grade free software is also widely available; SCRAM is an open-source tool
that implements the Open-PSA Model Exchange Format open standard for probabilistic
safety assessment applications.
Methods of fire prevention and fire protection

Fire is a chemical reaction in which a combustible material combines with oxygen in the
atmosphere to give out heat and flame. The chemical change is called oxidation, and the process is
referred as ‘combustion’.
Rate of combustion varies from substance to substance and is described as slow, rapid or
spontaneous.
(i). Slow combustion is accompanied by slow evaluation of heat but not light. Eg: Cotton waste
burning.
(ii). Rapid Combustion is accompanied by rapid evolution of heat and appreciable amount of light.
Eg: Petroleum Products.
(iii). Spontaneous combustion is due to result of heat by the absorption of the atmospheric oxygen
at ordinary temperature and due to chemical reaction. Eg: Coal, paint, Phosphorous in contact with
wood
Fire Fighting, Detection and Alarm System:

Fire-fighting systems include:
1. Water sprays system (sprinkler system):
Generally used for offices, stores, turbine- generators, transformer and boiler front areas.

2. CO2 system:
These are used in enclosed areas, switchgear room, cable tunnels, and gas turbine/engine cells.
3. Dry chemical powder (DCP) system:
Dry chemical powder (DCP) system, used for control room, offices, electrical plant etc.
4. Foam system:
Foam system, used for fuel-oil storage tank protection.
5. Halon System:
This is used for computer room, cable tunnels, control-relay room and other light current auxiliary
system rooms.
6. Hydrant system:
This is used for general use throughout the plant.
7. Water Hose-reels:
Used in offices, stores, and workshop corridors etc.
Total Fire Protection System includes:

1. Fire Detection systems.
2. Fire Alarm systems.
3. Fire Alarm and Control Panel.
4. Fire Hydrant System.
Smoke indicates presence of fire. Flame, light and heat confirm the presence of fire. Fire must be
detected rapidly and it should be quenched before it grows. Fire is detected by the fire detection
system comprising fire detectors.
The fire detectors are located in various zones of the plant, substations and are connected to the fire
alarm and fire control panel located in the control room and to the automatic fire fighting system
distributed in the plant.
The detection of smoke/fire, sounding of alarm and initiating the fire extinguishing action can be
achieved by various methods. Fire detector system initiates fire alarm system. The operation of a
fire detector is immediately indicated and buzzer is sounded on the respective zone window of the
panel. This initiate operation of automatic fire fighting system in the affected zone.
Accident proneness
Accident-proneness, also known as clumsiness, is the conception that some people might have
predisposition, or that they might be more likely to suffer accidents, such as car crashes and
industrial injuries, than other people. It may be used as a reason to deny any insurance on such
individuals.

Statistical evidence clearly demonstrates that different individuals can have different rates of
accidents from one another; for example, young male drivers are the group at highest risk for being
involved in car accidents. There also seems to be substantial variation in personal accident rates
between individuals.
However, a number of studies have cast doubt on whether accident-proneness actually exists as a
distinct, persistent and independently verifiable physiological or psychological syndrome. Although
substantial research has been devoted to this subject, there still seems to be no conclusive evidence
either for or against the existence of accident proneness in this sense.
Nature and causes

The exact nature and causes of accident-proneness, assuming that it exists as a distinct entity, are
unknown. Factors which have been considered as associated with accident-proneness have included
absent-mindedness, carelessness, impulsivity, predisposition to risk-taking, and unconscious desires
to create accidents as a way of achieving secondary gains.
Safe working environments

Following important provisions for safety are provided in the act.
1. Fencing of machinery: All moving parts, flywheels, Head race and trail race of water turbine,
electric generator, motor, transmission machinery and other machines are to be fenced.
2. Work on or near moving machinery: This has to be done by trained adult with tight fitting clothing
3. All the devices are to be provided with cut off power supply mode during emergencies.
4. Casing of machinery: For all the machineries wherever possible suitable casing has to be provided
for bolts, key or any revolving shaft etc.
5. Hoists and lifts: It should be of good mechanical construction and maintained. Should be
thoroughly examined regularly.
6. Lifting machines, chains, ropes and lifting tackles: All these are to be of good construction and
of adequate strength. Properly maintained and thoroughly examined at least once in a year.
7. Revolving machinery: A notice has to be attached to all grinders, the safe working peripheral
speeds.
8. Excessive weights: No worker in any factory is allowed to lift, carry or move any load so heavy
as to likely cause him injury.
9. Protection of eyes: Welding, cutting of metals , fettling, rivet cutting and other operations
involving risk of injury to eyes are to be given with screens or goggles.

10. Precautions against dangerous fumes: No person is allowed to enter dangerous places like tank,
pipe, pit etc., where fumes are likely to be present. Electric light above 24 watts should not be
permitted in such area. Workers after removing fumes with breathing apparatus should enter the
place.
11. Precautions against fire:
(i). All factories are to be provided with emergency escape whose doors are not be locked or
fastened.
(ii). All these escape ways are to be marked with in local language.
(iii). Effective means of giving warning in case of fire to every person shall be provided.
(iv). Suitable type of ire preventing equipments are to be installed at all sensitive places.
The classes of fire

There are six classes of fire: Class A, Class B, Class C, Class D, ‘Electrical’, and Class F.
– Class A fires – combustible materials: caused by flammable solids, such as wood,

paper, and fabric
– Class B fires – flammable liquids: such as petrol, turpentine or paint
– Class C fires – flammable gases: like hydrogen, butane or methane
– Class D fires – combustible metals: chemicals such as magnesium, aluminum or potassium
– Electrical fires – electrical equipment: once the electrical item is removed, the fire changes
class
– Class F fires – cooking oils: typically a chip-pan fire
Following fire-fighting arrangements should be made:
(a) Fire extinguishers and fire buckets, painted red, be provided at all fire hazardous locations. The
extinguishers should be inspected, serviced and maintained in accordance with manufacturer’s
instructions.
(b) In isolated locations (away from the cities), it will be necessary to provide for and install
complete fire-fighting facilities including provision for fire tenders commensurate with the
numbers, size and importance of equipment’s, buildings or supplies to be protected.
(c) Since portable hand extinguishers have limited capacity, full reliance should never be placed on
them. Water in ample quantity and under adequate pressure should always be available for fire
fighting
(d) Fire exit and fire alarm arrangements should be provided at all locations featuring hazards.
(e) All staff should be conversant with the use of all types of fire extinguishing apparatuses.
Demonstrations and training in fire-fighting should be conducted at sufficient intervals.

Fire Protection
Following precautions should be taken to avoid fire hazards on all oxy-acetylene cutting and
welding:
(a) Keep hose and cylinder valves free from grease and oil.
(b) Keep cylinders away from stoves, furnaces and other sources of heat.
(c) Only ‘Gas Lighter’ should be used to light the torch.
(d) Avoid use of oxy acetylene flame in confined spaces.
(e) For testing of leakages, use only soap water and watch for bubbles.
(f) Valve protection caps should be in place when cylinders are not in use.
2. Gas cylinders should be kept upright in approved safe place where they cannot be knocked over,
and well separated from furnaces and combustion materials. Loaded and empty cylinder should be
kept in separate places.
3. Oxygen cylinders should not be stored in close proximity to acetylene cylinders. In no
circumstances oxygen or acetylene cylinders should be stored under direct rays of Sun or in places
where excessive rise of temperature is likely to occur.
Foam Extinguishers:
These are of two types
(а) Foam (chemical) type
These have two containers, one inside the other. Outer container is filled to an indicated level with
an aqueous solution of sodium bicarbonate, while the inner container is filled with a solution of
aluminium sulphate in water. When the extinguisher is actuated by inversion, the two solutions are
mixed and produce the foam and a gas which acts as an expellant.
Foam Extinguishers

Foam extinguishers are most common type of fire extinguisher for Class B fires, but also work on
Class A fires as they are water-based.
Label Colour:
– Cream
Use for:
– Organic materials such as:
Paper and cardboard
Fabrics and textiles
Wood and coal
Plus:
– Flammable liquids, like paint and petrol
Do not use for:
Kitchen fires
Fires involving electrical equipment
Flammable metals
How foam extinguishers work:
As with water extinguishers, foam extinguishers have a cooling effect on the fuel. On burning
liquids, the foaming agent creates a barrier between the flame and the fuel, extinguishing the fire.
Types of premises/business who may need Foam extinguishers:
Buildings constructed of wood or other organic materials
Premises where there are organic materials to be found such as:
Offices
Schools
Hospitals
Residential properties
Warehouses
Buildings where flammable liquids are stored
In fact most buildings need either water or foam extinguishers
Where to locate foam extinguishers:

By the exits on a floor where a Class A or Class B fire risk has been identified
(b) Foam (mechanical) type
This is similar to earlier one, except that this has no inner container. The foam is produced from a
foam compound and water. The foam compound is stored in a sealed plastic bag which is ruptured
on the release of carbon dioxide from a cartridge. The water and the foam compound are mixed and

expelled by the gas. This extinguisher type also consists of two containers- the outer one is filled
with water, whereas the central one has carbon dioxide charge and foam solution.
The central container has a plunger mechanism at the top which when depressed releases the
carbon dioxide and allows foam and water to mix.The foam and water comes out of the nozzle,
creating mechanical foam. This extinguisher is operated in upright position.
(c) Carbon Dioxide Extinguishers

A steel cylinder filled with liquid carbon dioxide to approximately two-thirds of its capacity. A
special discharge horn is fitted to direct the gas on to the fire. CO2 is a gas at ordinary temperature
but when compressed for storage in cylinders, it liquefies. The liquid vapourises when released.

Overview:
CO2 extinguishers are predominantly used for electrical fire risks and are usually the main fire
extinguisher type provided in computer server rooms. They also put out Class B fires (flammable
liquids, such as paint and petroleum).
Label Colour:
– Black
Use for:
– Flammable liquids, like paint and petrol
– Electrical fires
Do not use for:
– Kitchen fires – especially chip-pan fires
– Combustible materials like paper, wood or textiles
– Flammable metals
How CO2 extinguishers work:
CO2 extinguishers suffocate fires by displacing the oxygen the fire needs to burn.
Types of premises/business who may need CO2 extinguishers:
– Premises with electrical equipment, such as:
o Offices
o Kitchens
o Construction sites
o Server rooms
All work vehicles should also carry a smaller 2kg CO2 extinguisher.
Where to locate CO2 extinguishers:
– Place near to the source of the fire risk and/or near the fire exits.
(d) Dry Powder Extinguishers:

These are also known as dry chemical extinguishers and are filled with a free-flowing non-toxic,
non-conductive dry power. Sodium bicarbonate is generally used for the purpose. The expellant gas
is stored either in the extinguisher body or in a cartridge.
Overview:
Standard dry powder extinguishers are also called ‘ABC’ extinguishers because they tackle class A,
B and C fires, however they are not recommended for use in enclosed spaces. This is because the
powder can be easily inhaled, and also the residue is very difficult to clean up after. ABC powder
extinguishers can also be used on some electrical fires. Specialist dry powder extinguishers are used
for flammable metals.
Label Colour:
– Blue
Use for:
Organic materials such as:
Paper and cardboard
Wood and coal
Plus:
Flammable liquids, like paint and petrol
Plus:
Flammable gases, like liquid petroleum gas (LPG) and acetylene
Plus:
Fires involving electrical equipment up to 1000v
Specialist dry powder extinguishers are only used on flammable metals, such as titanium and
magnesium.
Do not use for:
Fires involving cooking oil
Fires involving electrical equipment over 1000v
or in enclosed spaces, such as offices or residential properties
How dry powder extinguishers work:
Dry powder extinguishers smother fires by forming a barrier between the fuel and the source of
oxygen.
Types of premises/business who may need Dry Powder extinguishers:
Businesses using flammable gases for chemical processes
Premises where welding and flame cutting takes place
Garage forecourts
Liquid petroleum gas (LPG) dispensing plants
Premises with large, commercial boiler rooms
Where to locate Dry Powder extinguishers:
Place dry powder extinguishers near to the source of the fire risk.
Specialist Dry Powder extinguishers – what’s the difference?:
Specialist dry powder extinguishers work in the same way as standard dry powder extinguishers
but are for use with flammable metals only. There are 2 types of specialist dry powder
extinguishers – ‘L2’ which only tackles lithium fires, and ‘M28’, for all other flammable metal
fires.

e. Water Extinguishers
Overview:
Water extinguishers are the most common fire extinguisher type for class A fire risk. Most
premises will require either water or foam extinguishers.
Label Colour:
Bright Red
Use for:
Paper and cardboard
Wood and coal
Do not use for:

Fires involving electrical equipment
Kitchen fires
Flammable gas and liquids
How water extinguishers work:

The water has a cooling effect on the fuel, causing it to burn much more slowly until the flames
are eventually extinguished.
Types of premises/business who may need water extinguishers:

Buildings constructed of wood or other organic materials

Premises where there are organic materials to be found such as:

Offices
Schools
Hospitals
Residential properties
Warehouses
In fact most buildings need either water or foam extinguishers.
Where to locate water extinguishers:
– By the exits on a floor where a Class A fire risk has been identified
Water spray extinguishers – what’s the difference?:
Water spray extinguishers are equipped with a spray nozzle, rather than a jet nozzle, meaning a
greater surface area can be covered more quickly and the fire put out more rapidly.
Water mist extinguishers – what’s the difference?:
Water mist extinguishers have a different type of nozzle again which releases microscopic water
particles. These particles ‘suffocate’ the fire and also create a wall of mist between the fire and the
person using the extinguisher, reducing the feeling of heat.
f. Wet chemical extinguishers
are designed for use on Class F fires, involving cooking oils and
fats. They can also be used on Class A fires although it is more usual to have a foam or water
extinguisher for this type of fire risk.
Label Colour:
Yellow
Use for:
Cooking oil/fat fires
Paper and cardboard
Wood and coal
Do not use for:
– Flammable liquid or gas fires
– Electrical fires
– Flammable metals

How wet chemical extinguishers work:

Wet chemical extinguishers create a layer of foam on the surface of the burning oil or fat,
preventing oxygen from fuelling the fire any further. The spray also has a cooling effect.
Types of premises/business who may need wet chemical extinguishers:
– Commercial kitchens
– Canteens
Where to locate wet chemical extinguishers:
– Place near to the source of the fire risk.
g. SODA ACID EXTINGUISHER:
The soda acid extinguisher is used to fight Class A Fires and can be found in accommodation area
of the ship.Sodium bicarbonate (soda) and sulphuric acid are the prime components of the
extinguisher. They combine to form a chemical reaction to produce carbon dioxide gas, which is
used to smother the fire.

The arrangement of the extinguishers comprises of a container which holds the sodium bicarbonate
solution. A small glass bottle (phial) containing sulphuric acid is placed below a plunger mechanism,
which is covered by a safety glass along with a screw and cap at the top.
When the plunger is struck hard, the glass bottle breaks, resulting in mixing of acid and soda. A
chemical reaction takes place which produces carbon dioxide gas.
The carbon dioxide gas pressurises the space above the liquid (used for extinguishing fire) and
forces it out through the internal pipe of the nozzle.
SAFETY AT WORKPLACE: A CASE STUDY

Alarming rise in cases of workplace casualties
India ranks second when it comes to workplace accidents and illnesses. In fact, the International
Labour Organisation (ILO) reports that globally, every 15 seconds, 153 workers meet with an
accident at the workplace.
Apart from that, on an average everyday around 6300 people, worldwide, die from occupational
accidents or work-related diseases.
From these staggering statistics, one can identify that human loss has been immense due to unsafe
work environments.
To classify these incidents, there are primarily three types of hazards, workplace fatal, non-fatal and
physical injuries, and occupational diseases. Out of which workplace accidents take the top spot.
The Tragic Incident of Dombivali Factory Blast
In May 2016, the chemical factory owned by Probace enterprises exploded at Dombivali East in
Mumbai MIDC area. The incident caused the death of 12 people and injured around 201. The impact
of the explosion affected the people at the nearby residents and shops.
The mysterious blast resulted in the shattering of glasses and rooftops in a two-kilometre radius
from the factory. Resulting in many reported cases of trauma victims, the incident noted prominent
injuries due to the cuts from the shattered glass pieces.
With the cause for the accident still being investigated, the loss of people remains uncompensated.
The injuries and deaths left people with deep scars both physically and financially.
Framework for Safety in Indian Workplace
In the past 50 years, India has witnessed an immense growth in the manufacturing, industrial and
technological fields. With the upscale in business, the number of dangerous incidents in workplace
is bound to increase unless stricter, more refined laws and implementations are followed.
Although the Indian Constitution contains a system for occupational health and safety, it only
applies to certain restricted industries. It still keeps a huge part of the workforce outside the scope.
According to international studies, many workers employed in smaller factories and industries in

India are not provided with any legal and healthcare protection in the instance of an accident on the
job.
Ways to Prevent and Protect Against Workplace Hazards
The rising workplace accidents can be mitigated by consciously taking measures. Some of the safety
pre-requisites are as follows:
 Employee responsibility of being alert and aware of volatile surroundings
 Proper safety equipment for operating tools and heavy instruments
 Reduction in stress and distraction in workplace through appropriate and timely breaks
 Proper and regular maintenance checks on heavy machinery
 Organising safety classes in workplace
 Precautionary measures through healthcare aid and insurance policies for workers
 Ease of accessibility to emergency exits and paths in case immediate evacuation is required
 Coverage for risks in special environments involving chemical and other combustible
processes
 Accountability through reports sent to higher authorities even of the smallest inconsistency
concerning safety
While accidents by definition cannot be avoided, proper precaution can save lives and savings of
the people. Safeguarding the interests of the employees, employers can protect their workforce with
the appropriate insurance plans that cover accidents and diseases at the work place.
The most common types of accidents in the workplace

The most common types of non-fatal work accidents as follows:
 manual handling injuries (20%);
 slips and trips (18%);
 falling object accidents (9%);
 moving machinery accidents (7%);
 falls from height (7%);
 physical assault (7%)
 Workplace Injury Claims
Workplace Injury Claims
There is no exhaustive list of injuries that can be caused as a result of a workplace accident. It
depends on the type of work you were doing, the place you were doing it in and the force with which
the accident happened.
Many of the injuries suffered by workers are similar to those suffered by people in general day to
day life, including:
 Back injuries
 Head injuries
 Knee injuries
 Shoulder injuries
 Skin conditions
 Amputations
 Head and brain injury
 Spinal injury
But there are some injuries that are more likely to occur in the workplace. These include:
 Burns and scalds
 Crushing
 Cutting or severing
 Sharps injuries or puncture wounds
 High-pressure fluid injection
 Asphyxiation
 Drowning
 Electrical injuries
Industrial Diseases
Industrial diseases are injuries or sicknesses resulting from exposure over a period of time to an
occupational hazard in the workplace.
The ‘occupational hazard’ will vary according to the type of work being carried out, but it could be
a harmful substance, such as dust or fumes, a harmful activity, such as using a vibrating tool of some
sort, or a harmful environment, such as one that is very loud.
Typically, workers are exposed to the harmful substance or working conditions over a period of
time, with the result that it has a serious impact on their body and general health.
There are many different types of industrial disease, but some of the most well-known relate to
asbestos. You’ll find more information on this in our asbestos-related diseases section. Other
examples of industrial diseases include:
 Dermatitis
 Work related upper limb disorders
 Industrial Deafness
 Respiratory Disease
 Occupational Asthma

Dermatitis
Skin diseases are a common work-related illness. In fact, the latest Government figures estimate
that over 35,000 new cases are diagnosed each year.
Many of these cases turn out to be a condition called contact dermatitis, which is caused by
prolonged exposure to substances that dry out the skin. These substances can include detergents,
solvents, cements or even water.
Employers have a legal duty to provide protection against prolonged exposure to substances that
could cause dermatitis and to provide information on any risks involved. If they do not, and you
develop dermatitis as a result, you could be entitled to claim compensation.
Work Related Upper Limb Disorders
Work related upper limb disorders (WRULDs) are a common problem in the workplace. As the
name suggests, upper limb disorders refer to a number of symptoms affecting the upper limbs –
including the neck, shoulders, wrists, hands and arms – as well as the tendons, ligaments, soft-
tissues, muscles, and nerves that support them.
While not all WRULDs upper limb disorders are originally caused by work, the majority are
typically linked to activity in the workplace (and often made worse by it). In fact, according to the
Health and Safety Executive, musculoskeletal disorders accounted for 44% of all work related
illnesses and 40% of all missed working days in 2014/15.
They include conditions that do not have a specific medical diagnosis and result in gradually
developing symptoms such as pain, swelling, or difficulty in movement. Such conditions are
generally known as Repetitive Strain Injuries (RSIs) and are commonly caused, as the name
suggests, by constant movement and overuse of the tendons and muscles.
Industrial Deafness
Occupational exposure to noise is a significant cause of hearing impairment and disability.
In the early 80s approximately 600,000 workers in the British manufacturing industry were exposed
to substantial levels of noise and, more recently, 11% of employed men and 6% of employed women
from a large community survey reported that they had to raise their voice to be heard in the
workplace.
Another 3% of men and 2% of women claimed they left work with temporary deafness and ringing
in their ears every day.
Respiratory diseases
Exposure to harmful substances and processes in the workplace can casue a range of lung and
respiratory diseases.

According to the Health and Safety Executive, in 2017 41,000 people, who had worked in the
preceding 12 months, had "breathing or lung problems" they felt had been caused or made worse by
their work.
And of all people who had ever worked, an estimated 147,000 were suffering from "breathing or
lung problems".
The Labour Force Survey (LFS) estimates that around18,000 new cases of respiratory diseases are
being reported each year.
Respiratory disease is a general term covering a number of conditions that can develop as a result
of exposure to hazardous substances in the workplace.
Occupational Asthma
It is difficult to say how many cases of occupational asthma occur each year – the Health and Safety
Executive thinks that its data sources substantially underestimate the number of people who are
suffering from the condition, and the number of people who begin to suffer from it each year.
Even so, the latest estimates suggest that there were anything between 8,600 and 13,000 people
suffering from occupational asthma over the last three years.
If you have developed asthma and this has been caused or exacerbated by your work then you may
be able to recover compensation as a result.
You might also help to prevent someone else from developing the condition.
CASE STUDY:
BHOPAL TRAGEDY
If we see the history of worst chemical disasters, in industries the first thing that comes to our
memory is one at Bhopal
On the night of Dec. 2nd and 3rd, 1984, a Union Carbide plant in Bhopal, began leaking. due to run-
away reactions, temperature and pressure rise and the safety valve lifted to the atmosphere. About
25-27 tons of the deadly gas methyl isocyanate spread through the city of Bhopal.
Half a million people were exposed to the gas. Protective systems that should have prevented or
minimized discharge were out of service. Refrigeration system to cool the reactor was down.
Scrubbing system to absorb the released vapour was not immediately available. Flare system to burn
vapours getting past the scrubber was out of service.
Lessons we learned form Bhopal Tragedy
1)Reduce inventory of hazardous material (MIC)
2)Keep all the safety related equipment in order
3)Keep residential areas away from the plant
4) Proper Management
Flixborough Disaster – A CASE SYUDY.

On 1st June 1974 the Nypro (UK) site at Flixborough was severely damaged by a large explosion.
Twenty-eight workers were killed and a further 36 suffered injuries. Offsite consequences resulted
in fifty-three reported injuries. Property in the surrounding area was damaged to a varying degree.
A 20 inch bypass system ruptured, which may have been caused by a fire on a nearby 8 inch pipe.
This resulted in the escape of a large quantity of cyclohexane. The cyclohexane formed a flammable
mixture and subsequently found a source of ignition. At about 16:53 hours there was a massive
vapour cloud explosion, which caused extensive damage and started numerous fires on the site.
Eighteen fatalities occurred in the control room as a result of the windows shattering and the collapse
of the roof. No one escaped from the control room.
The fires burned for several days and after ten days those that still raged were hampering the rescue
work.
Mangalore Chemicals and Fertilizers Limited
There was a chemical accident in the Urea Plant at M/s. Mangalore Chemicals and Fertilizers
Limited, Panambur, Mangalore on 9.2.2000. An 8" dia high-pressure pipeline housing a weldolet
was connected between autoclave (urea reactor) of 108MT capacity and the stripper to carry
ammonium carbamate (Urea Solution). The pressure of pipe line was of the order of 141kg/cm2 and
the temperature of 180 C. The Solution had contained 29% of ammonia, 18% carbon di oxide and
32% of urea..
On 9th February 2000, a substantial quantity of ammonium carbamate solution leakage was noticed
at the weldolet joint of the pipeline. A maintenance manager along with two operators, an engineer
and two contract workmen were trying to plug the leakage by providing a proper clamping. In the
process, the weldolet joint gave way resulting in sudden release of pressurized hot ammonium
carbamate solution. As a result, the personnel on the job were exposed to hot solution and toxic gas.
Consequent to which, 8 persons were affected amongst them 2 died on the spot and the other two at
the hospital amounting to death of 4 persons including the maintenance manager and an engineer.
Investigation conducted by the department under the guidance of an expert committee revealed that
the weldolet used in the high pressure pipe line had high carbon content which is not suggested for
that kind of a process, maintenance Repair works was undertaken on line even after noticing the
hazardous solution which amounts of non implementation of shutting down procedures. Further the
high-pressure pipeline was not subjected to hydrostatic test, ultrasonic tests and examinations as
required under relevant provisions of law for its soundness. The personnel who were on the job were
not wearing any personal protective equipment in addition to non-adherence to work to permit
system.

The expert committee investigated made the following recommendations to prevent any incident in
future.
The pipeline, connected equipment and the accessories must be subjected to hydrostatic test as
required under the relevant provision of law;
Weldolet must be subjected to 100% examination to detect corrosion and the soundness;
Maintenance/repair works shall not be undertaken on line, it shall be done only as per standard
maintenance procedure drawn up before hand;
Permit to work system shall be strictly adhered to along with suitable personal protective equipment;
The on site emergency plan rehearsals shall be put to rigorous tests and practiced by updating the
weaknesses noticed from time to time;
The personnel including the contract workmen shall be put to rigorous training in handling chemical
emergencies particularly to bring a change in their attitudinal behaviour of over confidence.
National Fertilisers Limited (NFL) at Panipat.

Liquid ammonia burst out at the high pressure of 23 kg per sq cm, vaporising within seconds
to form suffocating clouds of deadly gas. This hit and choked to death eleven persons and
injured ten even as their colleagues sprung into action to diffuse the gas with water sprays.
Liquid ammonia hit workers Coughing and choking, with lungs bursting, scrambled for fresh
air.
It is a Freak accident? This was the first major incident in any of the NFL plants. When working
on the ammonia pipelines. It was admitted to down to earth that for such work "Need to take extra
precautions to ensure that workers other than those doing the hazardous task, are not present in the
vicinity,"
The Chlorine Gas Leak at Jamshedpur

People of Jamshedpur were caught unaware when they were exposed to a dense, pale green, pungent
and poisonous gas, Chlorine. This gas had leaked from an unused cylinder lying in the Tata Motor’s
water treatment plant for the past 10 years. By the next day, around 150 to 200 people had been
hospitalised. The affected people also included company employees and their family members. So
far no deaths have been reported. Later, in a statement, Tata Motors claimed that the chlorine leak
has been plugged and about 60 to 70 residents who reported breathing difficulty were admitted to
the Tata Motors hospital in Jamshedpur. The Chief Minister of Jharkahnd, Madhu Koda, alleged
that negligence by Tata Motors had led to the leakage of chlorine gas.
.As we know Chlorine gas has strong oxidising properties. Its toxicity irritates the respiratory
system. Severe exposure to the gas may cause pulmonary edema within 30 to 60 minutes and die´.
There is no available prophylactic or post exposure therapy for chlorine.
SPIC ammonia unit shut due to leakage problem

Southern Petrochemical Industries Corporation (SPIC) at Tuticorin has been shut down due to a
leakage in the pipeline. When the repair works were going on, a fatal accident occurred on October
1, company sources told Business Line.
Sources said that after the southern grid failure last month, technical problems arose in SPIC's plant,
causing a leakage in the pipeline. The plant has been shut down since September 27.
While trying to do the repair work, Mr Thiraviyaraj, Joint Manager (Operations) slipped and fell.
The gas mask he was wearing came off and he died of asphyxiation, it is learnt.
It is understood that it would take at least another 10 days to restart the plant.
None of the senior officials of the company was available for comment, and therefore, no estimate
of the value of loss in production is readily available.
Only last year, the Tuticorin plant of SPIC had been shut down between May 1 and June 22 for a
"routine turnaround maintenance", which caused a loss of production of 1.03 lakh tonnes of urea.
UNIT V
HEALTH HAZARDS AND LEGAL ASPECTS
Health hazards
Under factories act following operations are considered to be hazardous to health.
1). Electroplating-using electrolyte containing Chromic acid and other chromium compounds.
2). Manufacture and use of lead or certain lead compounds.
3). Generation of gas from dangerous petroleum.
4). Manufacture of chromic acid and bichormates of sodium, potassium and ammonia.
5). Use of acids, alkalis and other corrosive substances.
6). Use of acetone, Tetrachloro ethane, and other toxic and flammable solvents.
7). Manufacture and use of nitro and amino compounds.
8). Manufacture and use of Carbon sulphide and hydrogen sulphide.
9). Manufacture of Pesticides.
10). Compression of Oxygen and hydrogen produced by electrolytic process.
Occupational diseases
Importantly following diseases are associated with the chemical industry.
1). Poisoning due to lead and its compounds, Phosphorus, Mercury, Manganese, Arsenic, Carbon
disulphide, Benzene and its homologous including nitro and amino compounds, Halogens or
halogen derivatives and hydrocarbons.
2). Manifestations of chrome ulceration, anthrax, silicosis, Toxic jaundice, Toxic anemia.
3). Primary cancer of the skin due to radioactive substances, X-rays or radium.
4). Pathological manifestations due to radioactive substances.

For the prevention of occupational diseases the degree of interest on the part of
executives and workers sufficient to initiate and maintain preventive
and control methods are very important. Then one has to go search of all necessary facts and finally
corrective action has to be taken based on these facts.
The problem is further complicated by such factors as the susceptibility of the individual,
allergies and physical resistance or immunity.
Occupational hazards and legal aspects

Important following diseases are associated with the chemical industry.
1. Poisoning due to lead and its compounds, phosphorous, mercury, manganese,
arsenic, carbon disulphide, benzene and its homologous including nitro and amino
compounds, halogens derivatives and hydrocarbons.
2. Manifestations of chrome ulceration, anthrax, silicosis, toxic jaundice, toxic
anaemia.
3. Primary cancer of the skin due to radioactive substances, x-rays or radium.
4. Pathological manifestations due to radioactive substances.
For the prevention of occupational diseases the degree of interest on the part of executives and
workers sufficient to initiate and maintain preventive and control methods are very important. Then
one has to go search of all necessary facts and finally corrective action has to be taken based on
these facts.
The problem is further complicated by such factors as the susceptibility of the individual, allergies
and physical resistance or immunity.
Remedial measures of occupational hazards

1. Elimination of the injurious substances or sources.
2. Reduction in the original amounts or volumes or frequency of use of
the injurious substances.
3. Strict control of injurious substances at point of origin.
4. Provisions for washing, cloths changing and or taking lunch away
from unsafe areas.
5. Removal of injurious or substances after use.
6. Isolation and guarding of the injurious substances or sources.
7. Provisions of personnel protection devices.
8. Control of unsafe, personal acts through instruction.

9. Periodic physical examination and enforcement of rules for personal

hygiene.
Control measures of hazardous chemicals.

1). The hazardous chemicals can be substituted.
Ex: Use of C6H5CH3 instead of C6H6
CHCl3 instead of CCl4
Chalk instead of talc.
2). Segregation
(a). Segregation by time:
The hazardous operations can be conducted when the minimum numbers of workers are present.
(b). By placing hazardous operation at one end of a workshop in a separate room or in a separate
building minimizes the number of workers at risk.
3). Providing complete enclosures:
Hazardous operations can be completely enclosed with the operators operating for outside
the enclosures.
Safety organizations
The following organizations are playing an important role in safety propagation.
National safety council

This was set up on 4th march 1966., with the headquarters at Bombay by the ministry of
labor Government of India as a non profit making, non political, voluntary organization.
The main objective of the council is to generate, develop and sustain a voluntary movement
at the national level to promote awareness of safety, health and environment. The aims are to
eliminate human suffering, loss of production and damage to material and establishment. It has
subsidiary chapters in various states.
The activities of the council are
(i). Screening of films on safety
(ii). Publication of Industrial safety chronicle.
(iii). Issue of safety posters, Booklets on safety.
(iv). Conducting training programmes on safety.
(v). Consultancy services to member factories regarding safety problems.

It arranges National level essay, poster and slogan competitions and gives prizes and certificates
to encourage a spirit of competitiveness and creative thinking.
It maintains liaison with international agencies like

(i). International labor organization.
(ii). World safety council, Australia.
(iii). British safety council. UK
(iv). National fire protection association. (USA).
--to facilitate useful exchange of information .
4th march will be celebrated as national safety day.
Loss prevention association.

This is also a non-profit organization set up in 1978 promoting safety through education,
training and consultancy. LPA’s activities mainly concern losses due to fire, damages to cargo and
road accidents.
The main objectives are.,
(i). To publicize causes and magnitude of losses and create awareness of the need for loss
prevention.
(ii). To provide education and training.
(iii). To provide consultancy and advisory services.
(iv). To build and maintain data bank on loss prevention.
The association brings out publication on various aspects of fire prevention and conducts
training programmes, seminars and conferences on different aspects of safety and loss prevention.
Bureau of Indian Standards

Unsafe conditions do exist in industries due to process limitations. This is the area where we need
personal protective equipments. If personal protective equipments are not made up to the required
standard, it would not give the desired safety effects. The bureau of Indian standards plays a vital
role in standardization and controlling the equality of these personal protective equipments.
Till date about 450 specifications have been published with safety aspects.
A safety cell is functioning exclusively for safety standards and this cell in coordination with
other cells stipulates the necessary safety standards for the industries. Before issuing ISI mark based
on quality, safety aspects are also taken into consideration. Hence the ISI mark not only guarantees
the quality but also the safety.

Role of government
Parliamentary legislations
Following legislations were made by the government for making good industrial relations and to
take care of safety of workers.
1). The poison’s act – 1919
2). THE FACTORIES ACT – 1948
3). The mines act – 1952
4). The atomic energy act – 1962
5). The insecticides act –1968
6). The Pollution control act – 1981
7). The explosives act – 1984
8). The environmental protection act – 1986.
Labor welfare legilslations

1). WORKMEN COMPENSATION ACT – 1923.
2). Payment of wages act – 1936.
3). EMPLOYEES STATE INSURANCE ACT – 1948.
4). Minimum wages act – 1948.
5). Factories act – 1948.
6). Employees Provident funds act – 1972.
7). Payment of bonus act – 1965.
8). Payment of Gratuity act – 1972.
Role of trade union in promoting industrial safety

Each worker being poor and ignorant about the existing legislations is unable to fight against the
injustice done to him. As a group they can settle terms with the employers in a better way. Such
associations formed by workers are known as Trade Unions.
Trade Union is an association or union of workers engaged in a particular trade and formed
chiefly with the object of helping the members in times of distress and getting their grievances
settled and legitimate a rights established.
They can register their union with Registrar of trade unions.
Rights and Liabilities

(i). They can collect membership fees and fix up notices regarding meetings.
(ii). They can use general funds for specific purposes.

(iii). They can conduct strike by peaceful methods.

By using the last right, Trade unions can always demand safe working environments form
the management. A better environment and good sanitary surroundings, supply of pure water and
fresh air, sufficient medical aid, always promote industrial safety altogether.
Factories Act
The factories act, which regulates the safety, Health and welfare, was enacted in 1948. But
amendments were made to the act in 1954, 1976 and 1987. These amendments were based on the
potential hazards associated with chemical industry.
Definitions
Adult: Above 18. Adolescent: Between 15 and 18.
Child: Below 15. (iv). Calendar Year:12 months from Jan 1.
Young Person: Either child or Adolescent.
Week: 7 Days form midnight on Saturday.
Power: Electrical or other form of energy, which is mechanically transmitted and is not generated
by human or animal agency.
Prime Mover: Any engine, motor or other appliance, which generates or otherwise provides power.
Transmission Machinery: Any shaft, wheel, drum, pulley, coupling, clutch, driving belt or any other
device by which the motion of a prime mover is transmitted to or received by any machinery.
Manufacturing Process: Making, altering, repairing, ornamenting, finishing, packing, Oiling,
washing, Cleaning, breaking up, demolishing, treating or adopting any article or substance with a
view to its use, sale, transport delivery or disposal.
Worker: A person employed directly or through any other agency whether for wages or not in any
manufacturing process or in cleaning any part of the machinery or premises or used for
manufacturing process or in nay other kind of work incidental to or Connected with the
manufacturing process.
Factory: (i). Wherein 10 or more workers are working or were working on nay day of the preceding
12 months and in any part of which a manufacturing process is being carried on with the aid or
power.
(ii). 20 or more workers are working or were working on any day of the preceding 12 months and
in any part of which a manufacturing process is being carried out with out the aid of power.
Occupier

The person who has ultimate control over the affairs of the factory and where the said affairs are
entrusted to a managing agent such agent shall be deemed to be occupier of the factory.
Licence and Registration

The act specifies that before a factory can be started:
(a). Previous permission for the site of the factory construction or extension has to be obtained from
the chief inspector.
(b). The factory Inspector should have approved Plans and specifications.
(c). The factory has to be registered and the license fees has to be paid.
Inspecting Staff
The act permits the state government:
(a). To appoint chief Inspector and other Inspectors to supervise the conditions in factories and to
see that the provisions of the acts are practiced.
(b). To appoint certifying surgeons to examine medically the young persons, to examine the
conditions in factory to find out whether any process or action in manufacturing is harmful to cause
any injury to the health of workers.
Health Standards and Rules
The act prescribes the following provisions for maintaining the health of the worker and
reducing the possibilities of injuries to their body.
1. Cleanliness: Every factory should be kept clean and free form gases arising from drains. Walls
are to be whitewashed or color washed once in 14 months.
2. Ventilation Temperature: Adequate ventilation has to be secured and maintained by the
circulation of fresh air in the workroom. Temperature should be kept as low as practical. Hot parts
of the machinery shall be insulated.
3. Overcrowding: No room in the factory should be overcrowded. 14.2 sq meters space should be
provided to each worker.
4. Lighting: Sufficient and suitable lighting whether natural or artificial or both shall be maintained
at he working place or passages.
5. Drinking Water: Drinking water should be made available to all workers, at some points marked
with “DRINKING WATER” boldly in local language. Such points should be 6 meter away form
any source of contamination like washing place, urinals etc.
6. Bath rooms: Sufficient numbers of bathrooms are to be provided if the work involves dirt.

7. Latrines and urinals: Sufficient number of separate enclosed accommodation for male and female
workers is to provide. One latrine for 20 females and one for 50 male workers are to be provided.
8. Spittoons: Sufficient numbers of spittoons are to be provided at convenient places. These are to
be washed regularly and kept clean.
Employees' State Insurance (abbreviated as ESI) is a self-financing social security and health
insurance scheme for Indian workers. This fund is managed by the Employees' State
Insurance Corporation (ESIC) according to rules and regulations stipulated there in the ESI
Act 1948.
List of laws & regulations Relating to Safety and Health of Workers
1. The Factories Act 1948 (Amended 1987) – An Act to consolidate and amend the law
regulating labor in factories
 State Factories rules of respective States
2. The Mines Act 1955 (Amended 1984) – An Act to amend and consolidate the law relating
to the regulation of labour and safety in mines.
 The mines Rules 1955 (amended in 1989)
 The Coal Mines Regulation 1957
 The Metallic –ferrous Mines Regulation, 1961
 The Mines Vocational Rules 1966
 The Oil Mines Regulations 1984 amended 1996)
 The Mines Rescue Rules 1985
3. The Dock Workers (Safety, Health & Welfare) act 1986)
An Act to give effect to the convention concerning the protection against accidents
of workers employed in loading and unloading ships.
 The Dock Workers (Safety, Health & Welfare) Regulations 1989.
4. The Motors Transport Workers Act 1961 – An act to provide for the welfare of transport
workers and to regulate he conditions of their work
 The Motors Transport Workers Rules 1964
5. The Plantation Labour Act 1951 and Rules there under
6. The explosives Act 1984 (amended 1983) – An Act to regulate the Manufacture, Possession,
Use, sale, Transport, Import and Export of Explosives.
 The Explosive Rules 1983 (amended 2002)
 The Static and Mobile Pressure Vessels (unfired) Rules 1981 (amended 2002)
 The Gas Cylinder Rules 2004 (replaces the Gas Cylinders Rules 1981)
7. The Petroleum Act 1934 – An act to consolidate and amend the law relating the import,
transport, storage, production, refining and blending of petroleum.

 The Petroleum Rules 2002 (replaces the Petroleum Rules 1976)

 The Calcium Carbide Rules 1987
 The Cinematograph Rules 1948
8. The Inflammable Substances Act 1952 – An Act to declare certain substances to be
dangerously inflammable and to provide of the regulation of their import, transport, storage
and production by applying thereto the Petroleum Act 1934, and the Rules there under and
for certain matters connected with such regulation.
9. The electricity Act, 2003 (replaces The Indian Electricity Act, 1910)- An Act to
consolidate the laws relating to generation, transmission, distribution, trading and use of
electricity and generally for taking measures conducie to development of electricity industry,
promoting competition therein, protecting interest of consumers and supply of electricity to
all areas, rationalization of electricity tariff, ensuring transparent policies regarding
subsidies, promotion of efficient and environmentally benign policies, constitution of
Central Electricity Authority, Regulatory Commissions and establishment of Appellate
Tribunal and for matters connected therewith or incidental thereto.
 The Indian Electricity Rules, 1956.
10. The Indian Boilers Act, 1923 (amended 1960) – An Act to consolidate and amend
the law relating to steam boilers.
 The Indian Boilers Regulations 1950 (amended 1997)
 Boilers Rules of respective States
11. The Environment Protection Act, 1986 (amended 1991) – An Act to provide for the
protection and improvement of environment and matters connected therewith.
 The Environment Protection Rules, 1986 (amended 2004)
 The Manufacture Storage and Import of Hazardous Chemicals Rules, 1989
(amended 2000)
 The Rules for Manufacture, Use, Import, Export and Storage of Hazardous Micro
Organisms, Genetically Engineered Organisms or Cells, 1989.
 The Hazardous wastes (Management and Handling) Rules, 1989 (amended 2003)
 The Environmental Clearance of Projects Notification, 1994.
 The Chemical Accidents (Emergency Planning, Preparedness and Response)
Rules, 1996.
 The Bio-Medical Waste (Management &Handling) Rules, 1998 (amended 2003)
 The Environmental (sitting for Industrial Project) Rules, 1999
 The Recycled Plastics Manufactures and Usage Rules, 1999 (amended 2003)
 The Noise Pollution (Regulation & Control) Rules, 2000 (amended 2002)

 The Ozone Depleting Substances (Regulation & Control) Rules, 2000

 The Municipal Solid Wastes (Management & Handling) Rules, 2000
 The Batteries (Management & Handling) Rules, 2001.
12. The Water (Prevention & Control of Pollution) Act, 1974 (amended 1998) – An
Act to provide for the prevention and control of water pollution and the maintaining or
restoring of wholesomeness of water, for the establishment, with a view to carrying out the
purposes aforesaid, of Boards for the prevention and control of water pollution, for
conferring on and assigning to such Boards powers and functions relating there to and for
matters connected therewith.
 The Water (Prevention & Control of Pollution) Rules, 1975.
13. The Water (Prevention & Control of Pollution) Cess Act, 1977 (amended 2003) – An
Act to provide for the levy and collection of a cess on water consumed by persons carrying
on certain industries and by local authorities, with a view to augment the resources of the
Central Board and the State Boards for the resources of the Central Board and the State
Boards for the prevention and control of water pollution constituted under the Water
(Prevention & Control of Pollution) Act, 1974.
 The Water (Prevention & Control of Pollution) Cess Rules, 1978 (amended
1992)
14. The Air (Prevention & Control of Pollution) Act 1981 (amended 1987) – An Act to
provide for prevention, control and abatement of air pollution, for the establishment, with a
view to carrying out the aforesaid purposes, of Boards for conferring on and assigning to
such Boards powers and functions relating thereto and for matters connected therewith
 The Air (Prevention & Control of Pollution) Rules 1982
15. The Public Liability Insurance Act 1991 (amended 1992) – An act to provide for public
liability insurance for the persons affected by accident occurring while handling any
hazardous substance and for matters connected therewith or incidental thereto.
 The Public Liability Insurance Rules 1991 (amended 1993)
16. The Motors Vehicles act 1988 (amended 1994)- An Act to consolidate and amend the law
relating to motor vehicles
 The Central Motor Vehicles Rules 1989 (amended 2001) and Motor Vehicles
Rules of respective Sates
i. To provide for regulation of trade and commerce in production supply,
distribution and us of product of any industry manufacturing dangerous
machine.

ii. To the welfare of the labourers operating any such machine and for payment
of compensation for death or bodily injury suffered by any labourer operating
such a machine.
 The Atomic Energy (Factories ) Rules, 1996.
 The Building and Other Construction Workers (Regulation of Employment &
Conditions of Service) Central Rules, 1998.
17. The Dangerous Machines (Regulation) Act 1983 – enacted
18. The atomic energy act 1962 (amended 1987) – An Act to provide for the development,
control and use of atomic energy for the welfare of the people of India and for other peaceful
purposes and for matters connected therewith.
19. The building and Other Construction Workers (Regulation of Employment &
Conditions of Service) Act,1996 – An Act to regulate the Employment and conditions of
service of building and other construction workers and to provide for their safety, health and
welfare measures and for other matters connected therewith or incidental thereto.
20. The Indian Ports Act, 1908 (amended 2000) – An Act to consolidate the Enactments
relating to Ports and Ports-charges.
 The Drugs & Cosmetics Rules, 1995.
 The Insecticides Rules, 1991 (amended 1999)
21. The Drugs & Cosmetics Act, 1995 – An Act to regulate the import, manufacture,
distribution and sale of drugs and cosmetics
22. The Shops and Commercial Establishments Acts enacted by respective State
Governments.
23. The Insecticides Act, 1968 (amended 2000) – An Act to regulate the import, manufacture,
sale, transport, distribution and use of insecticide with a view to prevent risk to human beings
or animals, and for matters connected therewith.
24. The Energy Conservation Act, 2001 – An Act to provide for efficient use of energy and
its conservation and for matters connected therewith or incidental thereto.

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CH6703 Chemical Process Plant Safety 2019-2020

Safety and health requirement in chemical industry

Facts of Safety & Health in a Chemical Industry

Hazards Of Pressure Vessels

Psychological behaviour based safety

 Common goals – Both employee and managerial involvement in the process

St.Joseph’s College of Engineering 2 Department of Chemical Engineering

Elements of safety programme

Social environmental set up.

St.Joseph’s College of Engineering 3 Department of Chemical Engineering

Aspects to be looked upon carefully for setting up a chemical industry

St.Joseph’s College of Engineering 4 Department of Chemical Engineering

Safety design criteria for chemical plants

Trade union in industrial safety

St.Joseph’s College of Engineering 5 Department of Chemical Engineering

Rights and Liabilities

Industrial Health Hazards

St.Joseph’s College of Engineering 6 Department of Chemical Engineering

This training should include the following:

Safety Efforts by Government:

St.Joseph’s College of Engineering 7 Department of Chemical Engineering

St.Joseph’s College of Engineering 8 Department of Chemical Engineering

In any safety programme, following are essential

St.Joseph’s College of Engineering 9 Department of Chemical Engineering

 Maintain adequate first-aid facilities.

Safety programme is carried out in following three phases:

Factors Affecting Industrial Safety

St.Joseph’s College of Engineering 10 Department of Chemical Engineering

Economic and social benefits

System view and efficiency approach

St.Joseph’s College of Engineering 11 Department of Chemical Engineering

St.Joseph’s College of Engineering 12 Department of Chemical Engineering

Cost of illness analysis

Management control methods

Financial appraisal method

Value-based health promotion methods

Protect your staff

Reduce absences and sick leave

Productivity and profits

Save insurance and legal costs

Importance of Communication skill training

The ability to speak precisely

St.Joseph’s College of Engineering 17 Department of Chemical Engineering

A better rapport with customers

Control measures to industrial hazards

Providing complete enclosures

St.Joseph’s College of Engineering 18 Department of Chemical Engineering

Benefits of doing a Job Safety Analysis

Sequence of Events Potential Accidents or Hazards Preventive Measures

Remove spare and tool kit

Pry off hub cap and loosen lug bolts (nuts)

St.Joseph’s College of Engineering 21 Department of Chemical Engineering

How do I "identify potential hazards"?

 Can any body part get caught in or between objects?

 Can the worker make harmful contact with moving objects?

And so on..... a) ...

Determination of preventive measures:

St.Joseph’s College of Engineering 23 Department of Chemical Engineering

 Modify or change equipment or tools