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Irjet V4i12102 PDF
Irjet V4i12102 PDF
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Abstract - Cement industry plays a vital role in safeguards provided, residual risk if any and the
infrastructure development in India. It is also associated with role to be played in them in the event of emergency.
few environmental impacts which may lead to health hazards To be ready for mutual aid if need is arise to help
when unnoticed. This study aims at identifying the major neighbouring unit. Normal jurisdiction of an OEP in
hazards in cement industry and provide guidelines for the own premises only, but looking to the time
management to reduce the risk associated and to maintain the factor in arriving the external help or off - site
health of the employees. In order to study the health issues I emergency plan agency, the jurisdiction must be
considered Chettinad Cement Corporation Ltd, Puliyur, Karur, extended outside the extent possible in case of
Tamilnadu. The required data are collected through direct emergency occurring outside.
investigation and interaction with workers. Not only the To inform authorities and mutual aid centres to
physical health issues but also the noise exposure levels and come for help.
ergonomics of workers are studied. Finally guidelines and To affect rescue and treatment of casualties. To
suggestions on how to control health problems and make a count injured.
better workplace to the employees are given to the To identify and list any death.
management. To inform and help relatives.
To secure the safe rehabilitation of affected areas
Key Words: Occupational health, Risk assessment, Major and to restore normalcy.
hazards, Safety measures, Ergonomics, etc. To provide authoritative information to the media.
To preserve records, equipment, etc., and to
1. INTRODUCTION organize investigation into the cause of emergency
and preventive measures to stop its recurrences.
To ensure safety of the workers before personnel re
Chettinad cement factory is one of the leading cement
- enter and resume work.
manufacturers in South India. They provide accurate blends
of quality materials including Portland cement and blended To work out a plan with all provisions to handle
cement etc., The Puliyur branch consist of more than 100 emergencies and to provide for emergency
employees and around 42 employee works per shift with a preparedness and the periodical rehearsal of the
total of 3 shifts per day. I have studied the incident reports plan.
of past few years and also the process involved in the
manufacturing of cement. Thus from the collected data the 3. METHODOLOGY
following analysis and inferences were made which would
help to mitigate occurrence of accidents or health issues to The philosophy and methodology of study is as follows:
the employees. The risk assessment study involves
identification of hazards, their effects, exposure limits of Provide the information required to identify major
workers to chemicals/hazards, surveillance of worker’s hazard installations;
occupational health and safety etc. Carry out hazard assessment;
Report to the authorities on the results of the
2. OBJECTIVE OF THE STUDY hazard assessment;
Set up an emergency plan;
The main objectives of the Risk Assessment Studies are as Take measures to improve plant safety.
given below:
In order to fulfill the above responsibility, the Management
To define and assess emergencies, including risk must be aware of the nature of the hazard, of the events that
impact assessment. cause accidents and of the potential consequences of such
To control and contain incidents. accidents. This means that in order to control a major hazard
To safeguard employees and people in vicinity. successfully, the Management must have answers to the
To minimize damage to property and environment. following questions:
To inform the employees, the general public and the
authority about the hazards / risk assessed,
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 534
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 535
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
Health hazards associated with the occupation are called 7.1 Sources:
occupational hazards. In Cement industry the major sources
Grinding mills, Compressors, Fans, Blowers, Material
of emission are:
handlers, Crushers and DG sets
1. Raw material handling: Total Dust or Suspended
Particulate Matter. 7.2 Effects:
2. Raw Mill Section: Total Dust or Suspended Hearing impairment, Hypertension, Ischemic heart disease,
Particulate Matter. Annoyance, Sleep disturbance
3. Cement Grinding Unit: Total Dust or Suspended
Particulate Matter. 7.3 Attenuation and Conservation:
All precautions would be taken to avoid foreseeable accident Tools for assessing noise levels A successful noise control
like spillage, fire and explosion hazards and to minimize the program that focuses on engineering control of noise
effect of any such accident and to combat the emergency at requires the institution of a hearing conservation plan and
site level in case of emergency. Some of the preventive safety the use of proper monitoring equipment, surveys, maps, and
measures to minimize the risk of accident with respect to modeling.
Technical Safety, Organizational Safety and Personal Safety
are listed below: A thorough hearing conservation plan should be established
where noise exposure exceeds a 85-dBA time weighted
The factory will take all reasonably practicable average for eight hours. A good program consists of the
measures to minimize the risk of such accident in following components:
compliance with the legal obligation under the
relevant safety. • Noise measurement and analysis
All building plans and installations are as per • Engineering control of noise sources where feasible
relevant acts and duly approved by competent • Administrative controls and personal protection
government authorities. where noise control is not feasible
Process and Equipment will be designed by • Audiometric testing
qualified and experienced professionals and • Employee training and education
fabricated to applicable national / international • Record keeping
codes with stage wise inspection. • Evaluation
Safety features such as fire extinguisher and
suitable Personal Protective Equipment (PPE) shall 7.4 Control Measures:
be provided. Regular operations and testing of fire
extinguishers shall be carried out. • Introducing good acoustic design for the new
Periodic inspection and testing of pressure vessels, production line
equipment, machineries and equipment handling • Adopting proper scheduling of construction
substances. activities
Training of workers and Staff for fire fighting, work • Scheduling noisy activities during the daytime
permit system, first aid, safe handling of materials periods
and integrating safety, in all activities. • Operating well-maintained mechanical equipment
Accident / Incident reporting system and on-site
information of employees about the same for better • Ensuring that equipment that may be intermittent
awareness. in use should be shut down between work periods
or should be throttled down to a minimum
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 536
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
• Installing rubber coating in dumpers and entry unavoidable, but discomfort that persists from day to day or
chutes interferes with activities of work or daily living should not be
• Using personnel protection gear such as earplugs, considered an acceptable outcome of work.
muffs, etc.
• Developing a greenbelt around the quarry area 8.3 Control Strategies:
• Controlling air-flow generated noise by adopting
adequate sizing of inlet/outlet ducts The incidence and severity of MSDs are best controlled by an
integrated ergonomics program. Major program elements
7.5 Administrative or work practice controls to offset include:
heat effects:
Recognition of the problem,
• Provide accurate verbal and written instructions, Evaluation of suspected jobs for possible risk
annual training programs, and other information factors.
about heat stress Identification and evaluation of causative
• Acclimatize workers by exposing them to work in a factors,
hot environment for progressively longer periods. Involvement of workers as fully informed active
• Replace fluids by providing cool water or any cool participants, and
liquid (except alcoholic and caffeinated beverages) Appropriate health care for workers who have
to workers and encourage them to drink small developed musculoskeletal disorders.
amounts frequently, e.g., one cup every 20 minutes.
Ample supplies of liquids should be placed close to General programmatic controls should be implemented
the work area. when risk of MSDs is recognized. These include:
• Personal monitoring can be done by checking the
heart rate, recovery heart rate, and oral Education of workers, supervisors, engineers, and
temperature. managers;
Early reporting of symptoms by workers; and
8. ERGONOMICS Ongoing surveillance and evaluation of injury,
health and medical data, Job-specific controls are
Ergonomics is the term applied to the field that studies and directed to individual jobs associated with MSDs.
designs the human-machine interface to prevent illness and These include engineering controls and
injury and to improve work performance. It attempts to administrative controls. Personal protection may he
ensure that jobs and work tasks are designed to be appropriate under some limited circumstances.
compatible with the capabilities of the workers.
8.4 Control Measures:
8.1 Source:
Among engineering controls to eliminate or reduce risk
Some physical agents play an important role in ergonomics factors from the job, the following may be considered:
such as Force, Acceleration and Thermal factors. Force is an
"important causal agent in injuries from lifting. Other Using work, methods engineering, e.g., time
Important ergonomic considerations include work duration, study, motion analysis, to eliminate
repetition, contact stresses, postures, and psychosocial unnecessary motions and exertions.
issues. Using mechanical assists to eliminate or reduce
exertions required to hold tools and work
8.2 Work-Related Musculoskeletal Disorders: objects.
Selecting for designing tools that reduce force
Work-related musculoskeletal disorders (MSDs) are an requirements, reduce holding time, and
important occupational health problem that can be managed improve postures.
using an ergonomics health and safety program. The term Providing user-adjustable workstations that
musculoskeletal disorders refers to chronic muscle, tendon, reduce reaching and improve postures.
and nerve disorders caused by repetitive exertions, rapid Implementing quality control and maintenance
motions, high forces, contact stresses, extreme postures, programs that reduce unnecessary forces and
vibration, and/or low temperatures. Other commonly used exertions, especially associated with non-value
terms for work-related musculoskeletal disorders include added work.
cumulative trauma disorders (CTDs), repetitive motion
illnesses (RMIs), and repetitive strain injuries (RSIs). Some Administrative controls reduce risk through reduction of
of these disorders fit established diagnostic criteria such as exposure time and sharing the exposure among a larger
carpal tunnel syndrome or tendinitis. Other musculoskeletal group of workers. Examples include:
disorders may be manifested by nonspecific pain. Some
transient discomfort is normal consequence of work and is
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 537
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 04 Issue: 12 | Dec-2017 www.irjet.net p-ISSN: 2395-0072
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10. CONCLUSIONS
© 2017, IRJET | Impact Factor value: 6.171 | ISO 9001:2008 Certified Journal | Page 538