Safety & Fire Measures

In
Industry
 What is the main aim of industry ?

?
Efficient and Safe Production with Profitability

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Philosophy of Accident Prevention

Why do we need SAFETY?

Why should we prevent accidents?

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 Why do we need SAFETY ?

The Reasons are…

1. Humanitarian
2. Economic
3. Legal

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1. Humanitarian

Suffering to the injured person

Loss of life or limb

Suffering family members of injured person

Bhopal Tragedy 2 & 3 Dec 1984

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Just one accident…

Just one accident can ruin all future plans!

Savings plans
House-building plans
Children’s education
Daughter’s marriage
Retirement plans

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2. Economic
1. Loss of production
2. Cost of medical treatment
3. Damage to property (equipment, building, materials)
4. Loss of trained manpower (disintegration of team)
5. Loss of morale
6. Loss of efficiency
7. Time lost by other employees
8. Disruption of production schedule
9. Cost of repair and/or replacement
10. Loss of order/penalty for delay
11. Cost of recruiting new employees
12. Cost of training new employees
13. Less output/accidents (new employees)
14.Loss of reputation and goodwill

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 Economic (Contd.)

Cost of an accident is very high

Direct costs (tangible)
Indirect costs (intangible)

Direct costs are only one-fifth of total cost

(Herbert William Heinrich, 1931) H.W. Heinrich
Other experts say it is much higher

Indirect costs are intangible and difficult to compute

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Direct and Indirect Costs…

Direct cost is like the tip of an iceberg

Major part of the iceberg is hidden (intangible).

Examples of direct costs:

Cost of medical treatment
Compensation paid
Damage to equipment, etc.

Examples of indirect costs:

Time lost by other employees
Loss of order to the company, etc.
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 WHAT DO ACCIDENTS COST YOU?
Unseen costs can
sink the ship! Direct – “Just the tip of the iceberg”
Insured Costs

Indirect – Uninsured, hidden Costs

Examples:
1. Time lost from work by injured employee. Unknown Costs–
2. Lost time by fellow employees. 1. Human tragedy
3. Loss of efficiency due to break-up of crew. 2. Morale
4. Lost time by supervisor. 3. Reputation
5. Training costs for new/replacement workers.
6. Damage to tools and equipment.
7. Time damaged equipment is out of service.
8. Loss of production for remainder of the day.
9. Damage from accident: fire, water, chemical, explosives, etc.
10. Failure to fill orders/meet deadlines.
11. Overhead costs while work was disrupted.
12. Other miscellaneous costs (Over 100 other items of cost may appear one or more times with every
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accident)
 Recouping Cost of Accident
Example:
• Loss due to an accident = Rs. 5,000
• Profit margin in product sale = 5%
• Amount of sale needed to
offset the loss of Rs. 5,000= (5,000 x 100) ÷ 5
= 1,00,000
• It means that additional sale of Rs. 1 lakh will be needed to offset a loss
of mere Rs. 5,000.

• But, in reality, most accident losses are much higher.

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3. Legal

Legal obligations for both management and workers as laid down

under various statutes (Acts, Rules, Notifications, etc.)
The Factories Act, 1948
The Maharashtra Factories Rules, 1963
The Environment (Protection) Act, 1986
The Environment (Protection) Rules, 1986
The Petroleum Act, 1934
The Petroleum Rules, 2002
The Gas Cylinder Rules, 2004, etc., etc.

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Science of Accident Prevention

Theorems propounded by H.W. Heinrich: H.W. Heinrich

1. Industrial injuries result only from accidents

2. Accidents are caused directly only by:

a) Unsafe acts of persons,
b) Exposure to Unsafe physical or mechanical conditions.

1. Unsafe acts and unsafe conditions are caused only by the faults of persons.
2. Faults of persons are created by environment or acquired by inheritance.

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Heinrich’s Domino Theory

The Five Factors of Accident Sequence

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Heinrich’s Domino Theory

The injury is caused by the action of the preceding factors

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 Heinrich’s Domino Theory

1931 First Scientific Approach to Accident Prevention – H.W. Heinrich

Social Environment Fault of Unsafe Act

and Ancestry Person (Personal or Accident Injury
Characteristics) Condition

Human Failure
Heinrich’s Domino Theory

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Important: Be Proactive

Aim at eliminating all physical hazards of environment and the unsafe

acts of persons BEFORE the occurrence of an accident.

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H.W. Heinrich’s Pyramid
• A unit of 330 incidents of the same kind
• Involving the same person
• Under the similar conditions

….. Shrinking the height by

establishing Inherently safer 0.3% 1 Lost-Time Injury
processes and practices
8.8% 29 Minor Injury Accident
Shrinking the base by 90.9% 300
eliminating Unsafe
No-Injury Accident
behaviors and ………
Unsafe Acts … 00,000?
Unsafe Conditions …000?

Which one of the 330 would be a lost-time accident?

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FIRE PREVENTION, PROTECTION,RISK MANAGEMENT

OBJECTIVE

ZERO
INCIDENT

Prevention is better than cure.

How Does a Fire Work?

Three components
Need all three components to start a fire
Overview

• Elements of Fire Prevention Planning

• Identifying fire hazards
• Prevention Strategy
• Related Training
Identified fire risks areas as per Business Continuity Plan
LPG storage and distribution network.
• CNG skid and distribution network.
• Paint shops.
• Main receiving stations (Transformer yards and sub stations).
• Hot work activities
• Combustible material storage areas ( Wood, Paper, Thermocoal, Plastic, Packing
material, Scrap Yard
• Petroleum class A and B storage ( e.g. Petrol, Diesel, Thinner, benzene, toluene etc).
• Oil and Paint storage.
• Furnaces, Heat treatment area.
• Main data server rooms.
• Warehouses.
• Chemical pumping areas, reactors
Fire Protection Management

•Hazard identification and risk assessment for all the facilities.

• Fire Safety audit, Testing ,Inspections, Patrolling Rounds , gaps found during
audit to be bridged .
•Maximum credible loss scenario (MCLS) and emergency planning
• Buildings are constructed as per Nation Building Code (NBC) 2016 part 4
(minimize the danger to life from fire, smoke, fumes or panic before building can be
evacuated).
•Good Housekeeping
•Preventive maintenance
•Safe Storage
Fire Protection Management

•Hot work permit system.

• Fire safety management standard roll out with standard procedures
• Awareness & Training : conduct for all employees
• Full day fire warden training for selected employees of each department.
• Building Fire plans are made and mock trials
•Opportunities for improvement observed during mock trials to be implemented.
Fire Protection System

• Two Types of Fire Protection System

Active Fire Protection (AFP): is a group of systems that require some amount of action in
order to work efficiently in the event of a fire.
fire extinguisher, Sprinkler System, Fire and smoke detection system, etc.

Passive Fire Protection (PFP): is a group of systems that compartmentalize a building through
the use of Fire-resistance rated walls and floors, Dampers , Fire doors keeping the fire from
spreading quickly and providing time to escape for people in the building.

Active and passive fire protection systems, although different, are important to a building's
overall fire safety. AFP uses systems that take action in putting out the fire, while PFP uses
systems that help prevent the spread of fire and smoke
 Precautions to be Taken

• Basic knowledge of fire

• encourages all employees to learn to effectively use
fire extinguishers.
• Note; Normally company does not advocate
employee fire fighting beyond incipient stage
• All should know how to prevent fire
OUR FIRST DUTY - LIVES SAVING
THEN PROPERTY SAVING
Standards followed for fire risk management & statutory requirements
Maharashtra Factory Rules 1963 and Factory Act 1948.
• Maharashtra fire prevention and life Safety Act 2006. Rule -2009.
• Petroleum act 1934 and rule 2002.
• Oil industries safety directives. (OISD)
• National Building Code 2016 Part – 4.
• IS 2190: for maintenance, testing and installation of fire extinguisher.
• IS 2189: for installation, testing of Fire alarm and detection system.
• IS 3844: for Hydrant system maintenance.
• IS 15301 : Installation of fire pumps.
• IS 15325: for High and medium velocity water spray system.
• NFPA standards.
 Fire Prevention

Prevention is better than cure.

Understand the following:
Nature of the hazardous goods loaded
Conditions that can cause a fire
Avoid conditions that have potential to cause a fire.
Ensure the extinguishers are in good condition.
Educate your Cleaner in fire prevention.

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