Professional Documents
Culture Documents
OBJECTIVES
•Summarize basics of industrial safety
OE5092 •Describe fundamentals of maintenance
engineering
INDUSTRIAL SAFETY
•Explain wear and corrosion
Dr. K. Kamalanand •Illustrate fault tracing
•Identify preventive and periodic maintenance
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Industrial Accident
Industrial Injury
• Accident is an unexpected event in the course • An industrial injury is defined as “a personal
of employment which is neither anticipated injury to an employee which has been caused
nor designed to occur. by an accident or an occupational disease and
• An accident is an unplanned and uncontrolled which arises out of or in the course of
event in which an action or reaction of an employment and which could entitle such
object, a substance, a person, or a radiation employee to compensation under Workers’
results in personal injury.
Compensation Act, 1923”.
• It is important to note that self-inflicted
injuries cannot be regarded as accidents.
Types of Accidents
• Accidents may be of different types depending upon the
severity, durability and degree of the injury.
• An accident causing death or permanent or prolonged
disability to the injured employee is called ‘major accident.
• A cut that does not render the employee disabled is termed
as ‘minor’ acci-dent.
• When an employee gets injury with external signs of it, it is
external injury.
• Injury without showing external signs such as a fractured
bone is called an internal one.
• When an injury renders an injured employee disabled for a
short period, say, a day or a week, it is a temporary accident.
• On the contrary, making injured employee disabled for ever is
called permanent accident. Disability caused by accident may
be partial or total, fatal or non-fatal.
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3. Other Causes? • Safety experts identify that there are some high danger zones in
an industry. These are, for example, hand lift trucks, wheel-
barrows, gears and pulleys, saws and hand rails, chisels and screw
drivers, electric drop lights, etc., where about one-third of
industrial accidents occur.
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Hazard means: Failing to take the necessary precautions can lead to:
• any potential or actual threat to the wellbeing of people, • injury or death
machinery or environment
• fire or property damage
Risk minimization
• Ensure rotating shafts, belts, and pulleys are • Tools
covered by guards, lids, or covers. – Careless use of tools or use of tools in poor
• Check devices attached to a rotor before use condition can cause injuries to the hands, eyes,
head, and limbs.
to ensure that they are tightly fastened.
• Wear eye protection when using uncovered, • Cutting Tools (Scalpels, Razor Blades)
rapidly rotating parts – By design, these instruments are very sharp.
Careless use can quickly result in deep cuts.
• Have a safety shield available.
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Electric current
Effect
(contact for 1s)
What are the levels of effect of current? Below 1 mA Not perceptible
1 mA Threshold of feeling, tingling
Slight shock. Not painful. Average individual can let
AC current (mA) Effect on human body 5 mA
go. Involuntary reaction can lead to indirect injuries
1 Slight tingling sensation
6-25 mA
Painful shocks. Loss of muscle control
(women)
2-9 Small shock
Freezing current, "can't let go". The person may be
10-24 Muscles contract causing you to freeze
thrown away from the power source. Individual cannot
25-74 Respiratory muscles can become 9 to 30 mA (men)
let go. Strong involuntary reaction can lead to
paralysed; pain; exit burns often visible
involuntary injuries
75-300 Usually fatal; ventricular fibrillation; entry &
exit wounds visible Extreme pain. Respiratory arrest. Muscles reactions.
50 to 150 mA
Possible Death.
>300 Death almost certain; if survive will have
badly burnt organs and probably require Fibrillation of the heart. Muscular contraction and
1 to 4.3 A
amputations nerve damage occur. Likely death.
10 A Cardiac arrest, severe burns. Death is probable
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Deep burns of skin, muscle and bone How do you respond to electrical incidents?
tissue caused by high voltage
If you come across a person receiving an electric shock:
• if possible, disconnect the electrical supply (switch?)
• assess the situation – never put yourself at risk
• take precautions to protect yourself and anyone else in the vicinity
• apply the first aid principles (e.g. DRSABCD)
• assess the injuries and move the casualty to a safe area if required
• administer first aid if trained
• seek urgent medical attention
What should you do in an electrical emergency? Can you protect yourself from electricity?
For low voltage electricity >50 V AC and 110 V DC • Don’t wear metal objects
• remove the source of electricity supply • Turn power off
• commence CPR if trained • Wear appropriate clothing
• call the emergency number on site • Don’t touch live parts
• Don’t install or repair electrical equipment
For high voltage electricity >1000 V
• Use qualified personnel
• call the emergency number for your site
• Clean and dry leads and plugs before use
• don’t go near the casualty
• Use PPE
• don’t touch the casualty or try to free them with anything
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Manufacturing process means any process for: - Hazardous Process means any process or activity in
i) Making, altering, repairing, ornamenting, finishing, relation to an industry specified in the First
packing, oiling, washing, cleaning, breaking up, Schedule where, unless special care is taken, raw
demolishing or otherwise treating or adapting any
article or substance with a view to its use, sale,
materials used therein or the intermediate or
transport, delivery or disposal or finished products, by- products, wastes or effluents
ii) Pumping oil, water, sewage or any other substance thereof would cause material impairment of the
or health of the persons engaged in or connected
iii) Generating, transforming or transmitting power or therewith, or results in the pollution of the general
iv) Composing types for printing, printing by letter environment, provided that the State Government
press, lithography, photogravure of other similar may, by notification in the Official Gazette, amend
process or book binding, the First Schedule by way of addition, omission or
v) Constructing, reconstructing, repairing, refitting, variation of any industry specified in the said
finishing or breaking up ships or vessels, Schedule.
vi) Preserving or storing any article in cold storage.
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Fatal Injury means injury resulting from industrial Average Daily Number of Workers Employed The
accident which caused death to the worker. average daily number of workers employed is
calculated by dividing the aggregate number of
Non-Fatal Injury means injury resulting from attendances on all the working days (that is,
industrial accident, which prevented injured worker mandays worked) by the number of working days in
from attending to work for a period of 48 hours or the year. Attendance on separate shifts (e.g.
more immediately following the injuries. nightand day shifts) should be counted separately.
Adult means a person who has completed his Days on which the factory was closed for whatever
eighteenth year of age. cause and days on which the manufacturing process
was not carried on should not be treated as working
Adolescent means a person who has completed his days. Partial attendance for less than half a shift on
fifteenth year of age but has not completed his a working day should be ignored, while attendance
eighteenth year. for half a shift or more on such day should be
Child means a person who has not completed his treated as full attendance
fifteenth year of age
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Lighting
This section states:
• Firstly, There should be proper lighting in all the
places of the factory from where the workers of
the factory pass.
• In every factory, effective provision shall, so far as
is practicable, be made for the prevention of
glare, either directly from a source of light or by
reflection from a smooth or polished surface;
• the formation of shadows to such an extent as to
cause eye-strain or the risk of accident to any
worker.
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• Red:
Fire protection equipment
Danger, high risk of injury or death
Safety Colour Codes Emergency stops and alarms
• Orange:
Moderate risk of injury
Guarding devices
• The American National Standards Institute has • Yellow:
Caution statements
established rules governing what specific Minor risk of injury
Materials handling equipment
colors mean. • Green:
Safety equipment or information
• Standardized rules can help people easily First aid equipment or location
• Blue:
recognize and understand the message being No immediate hazard
conveyed. • Trucks, rail cards and other containers must have placards attached indicating the
hazard level of the container’s contents.
• The meanings of various colors on these placards also are standardized:
• Red – combustible materials
Yellow – oxidizers
White – poison or toxic
Orange – explosives
Green – nonflammable gas
Red and white stripe – Flammable solid
Answers
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Scenario Identification
– Pre-incident situations (start-up, maintenance, shutdown)
– Ignition source
– Ignited material
– Flaming or smoldering combustion
– Fire spread and heat release rates of ignited material
– Fire spread to secondary combustibles
• Consequence Analysis
– Property damage or loss
– Personnel injury or fatality
– Interruption of operation continuity
– Explosion damage (i.e., surrounding community)
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Aluminum Plants 2
Petrochemical
10 726 – 967 Pemex, Mexico City
Plant
Garment Factory in
Factories 9 549 – 606
Bangladesh
Offshore Oil/Gas
2 203 Piper Alpha, North Sea
Platforms
Jennings, Oklahoma
Fireworks Facility 5 145
USA
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Storage Considerations
• Combustible materials
– Quantity (e.g., rolls, drums)
– Type (e.g., liquids, powders, gases)
– Mixed commodities
• Effective measures to protect against fires
– Suppression systems
• Water
• Dry-chemical
– Spacing of discharge points (e.g., sprinkler heads)
Toulouse
http://oliaklodvenitiens.files.wordpress.com/2011/09/azf002.jpg – Limit ignition sources
– Remove unnecessary combustibles
The following table illustrates the types of extinguishers, fire classes for which each is used and the
Fire Extinguishers limitations of each extinguisher.
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