Chapter 3

Importance of Plant layout

for Industrial Safety
Introduction
Plant layout is often a compromise between a number of
factors such as:
• The need to keep distances for transfer of materials between
plant/storage units to a minimum to reduce costs and risks
• The geographical limitations of the site
• Interaction with existing or planned facilities on site such as existing
roadways, drainage and utilities routing
• Interaction with other plants on site
• The need for plant operability and maintainability
• The need to locate hazardous materials facilities as far as possible from
site boundaries and people living in the local neighborhood
• The need to prevent confinement where release of flammable
substances may occur
• The need to provide access for emergency services
• The need to provide emergency escape routes for on-site personnel
• The need to provide acceptable working conditions for operators
Plant Layout vs Safety
The most important objective of plant layout as far as
industrial safety aspects are concerned are those to :
 Prevent, limit and/or mitigate escalation of adjacent
events (domino)
 Ensure safety within on-site occupied buildings
 Control access of unauthorized personnel
 Facilitate access for emergency services

The most important factors to be considered by a plant layout

designer for industrial safety are :

 Inherent Safety  Positioning of Occupied Building

 Domino effects  Aggregation / trapping of flammable
– Fire Vapor
– Explosion
– Toxic gas release
Inherent Safety
 Major principle in Inherent Safety is to remove the hazard
altogether
 Best Method – reduce the inventory of hazardous substances
such that a major hazard is no longer presented

Possible Methods

 Intensification to reduce inventories

 Substitution of hazardous substances by less hazardous
alternatives
 Simpler systems/processes to reduce potential loss of
containment or possibility of errors causing a hazardous event
 Fail-safe design e.g. valve position on failure
Domino Effects
 Ensure consequences of loss of containment and chances of
escalation are minimized
 Domino may be by fire, explosion or toxic gas cloud causing
loss of control of operations in another location

Fire

 Can Spread in four ways – Direct Burning, Convection,

Radiation and Conduction
 Spread of fire could be prevented by vertical and horizontal
compartmentation using fire-resisting walls and floors
 Venting out the flammable vapor via ducts & drains to prevent
the spread of fire
 Distances between plant items are sufficient to prevent
overheating of adjacent plants
 Providing fire fighting equipments & water pipe lines
 Established control system to detect the fire event in hazardous
area
Domino Effects
Explosion
Explosion propagation may be directly by pressure waves or indirectly by
missiles.

 Arranging separation distances such that damage to adjacent

plants will not occur even in the worst case
 Provision of barriers e.g. blast walls for reactors, pressure
vessels, hazard materials storage
 Protecting plant against damage e.g. provision of thicker walls
on vessels
 Directing explosion relief vents away from vulnerable areas e.g.
other plants or buildings, roadways near site boundaries.

Explosion propagation by missiles requires a proper risk analysis and disaster

management
Domino Effects
Toxic gas releases
Toxic gas releases may cause domino effects by rendering adjacent plants
inoperable and injuring operators.

 Provision of automatic control systems using inherently safer

principles
 Centralized Control room to prevent even the slightest leakage
of the toxic gas
 Providing proper draft system for ventilating the toxic gas
release
 Inert gas supply lines to dilute the toxic gas concentration
 Provision for cut down of the feed responsible for toxic gas
release
 Siting of the plant away from the public living place
 Emergency exits & PPE in the hazard prone area
 Positioning of Occupied Buildings

 Distance between occupied buildings and plant buildings will

be governed by the need to reduce the dangers of explosion,
fire and toxicity

 Evacuation routes should not be blocked by poor plant

layout

 Personnel with more general site responsibilities should

usually be housed in buildings sited in a non-hazard area
near the main entrance

 Siting of occupied buildings outside the main fence

 Aggregation/Trapping of Flammable Vapor

 Buildings should be designed so that all parts of the building

are well ventilated by natural or forced ventilation

 Flammable storages should be sited in the open air so that

minor leaks or thermal outbreathing can be dissipated by
natural ventilation

 Maintenance procedures should include the displacement

of vapors from hazardous areas before work begins

 Provision of ducts or pipes to route the escape of the

flammable vapor to the ambient

 Avoiding ignition sources around the flammable storages

 General points of Consideration

 Locating all high-volume storage of flammable / toxic

material, outside the process areas

 Locating hazardous plant away from main roadways through

the site

 Fitting remote-actuated isolation valves where high

inventories of hazardous materials may be released into
vulnerable areas

 Provision of ditches, dykes, embankments, sloping terrain to

contain and control releases and limit the safety and
environmental effects

 Process Plants and Occupied buildings to be separated far

enough distance
 General points of Consideration

 Siting of plants in the open air to ensure rapid dispersion of

minor releases of flammable gases and vapors

 Hazardous area classification for flammable gases, vapors and

dusts to designate areas where ignition sources should be
eliminated.

Risk management techniques should be used to identify control measures that

can be adopted to reduce the hazardous consequences
 Case Studies
Case studies illustrating the importance of Plant Layout

a) BASF Warehouse Fire (9/10/1995)

b) Flixborough (Nypro UK) Explosion (1/6/1974)
c) Hickson and Welch Ltd Fire (22/9/1992)
d) Mexico City - Pemex LPG Terminal (19/11/1984)
e) Pasadena - Phillips 66 (23/10/1989)
 Mumbai Blast November 26-29, 2008
• November 26 (Wednesday)
9:20 pm Firing near Chhatrapati Shivaji Terminus.
Terrorists hijack a police jeep near Metro Cinema
9: 48 pm Firing outside Leopold café at Colaba in South Mumbai
9:57 pm firing near Hotel Trident
9:59 pm firing at Cama hospital, near CST
10.03 pm Firing outside the Taj Mahal Hotel in south Mumbai.
10:50 pm firing near the Times of India building
10:51 pm firing outside the Municipal Corporation of Greater Mumbai
headquarters, Gate 2, opposite CST
11:00 pm Blast in a van in Vile Parle in North Mumbai
11:00 pm Mumbai police Anti- Terrorist squad (ATS) Chief Hemant Karkare
killed in a fire fight with terrorists in Cama Hospital.
11:10 pm two blasts at Napean Sea road in South Mumbai
12.00 am: The top floor of the famous hotel catches fire after a bomb
explosion.
12:29 am: shooting at the State Bank of India
12:30 am: shooting at Vidhan Bhawan
 November 27th (Thursday)

2.30 am: Maharashtra DGP A N Roy says no more hostages in Taj .

7:30 am: NSG commandoes enter the Taj to evacuate people.
9.30 am: Senior Army officer says 10 -12 terrorists still hiding in the two hotels and the
Nariman House.
12.13 pm: Anti-mine squad from Pune also rushin g to Mumbai.
12.55 pm: A day after the terror attack on the historic Chhatrapati Shivaji Terminus
which left over hundred killed, services on the Central Railways were
restored to normal.
1.50 pm: 200 more NSG commandos rushed to Mumbai.
2.40 pm: More NSG commandos reach Taj.
2.40 pm: Firing resumes in Taj.
2.43 pm: Grenade blast heard from Nariman House.
4.13 pm: Jewish priest Gabriel among hostages held at Nariman House. 13
4.24 pm: Terrorists holed up in Room No 473 of Taj Hotel.
4.25 pm: A terrorist reportedly killed in Taj hotel. Commandos began entering into
the rooms of the hotel.
4.40 pm: 30 hostages freed from Trident; ano ther 35 people still trapped inside the
hotel.
4.55 pm: Navy spokesman Capt Manohar Nambiar said MV Alpha located.
6.00 pm: 14 more people evacuated from the Oberoi, 50 more commandoes enter
the Taj.
11: 30 pm : Security forces surround the Nariman House with reports of fresh firing.
November 28 (Friday)
• Early morning: NSG commando Major Sandeep Unnikrishnan killed in the operation at Taj.
• 12.05 am: seven hostages freed from Nariman.
• 2.25 am: Fresh firing begins between NSG and the holed up terrorists in Nariman house.
Reports of an Israeli team being flown in to assist in operations.
• 5.00: Third blast heard at Nariman House. National Security Guard (NSG) commandos take
positions.
• 5.55 am: Police asks media to stop live telecast of happening s at the Taj.
• 6.55 am: One terrorist reportedly spotted at the third floor of Taj.
• 7.40 am: One more helicopter drops commandoes on top of Nariman House.
• 8.05 am: NSG brings more commandos from Delhi.
• 10.12 am: Evacuations underway in two floors of Trident -Oberoi hotel.
• 10.35 am: At least 35-45 more hostages, majority of them foreigners, rescued from Trident-
Oberoi hotel.
• 11:26 am: Six foreigners among 35 -45 people rescued from Trident.
• 1.00 pm: Six more teams of Rapid Action Force (RAF) are on way to Taj.
• 1.24 pm: At least 148 hostages, majority of them foreigners, rescued from Trident.
• 2.00 pm: Operation complete in Oberoi Trident, NSG takes control.
• 3.50 pm: Nine blasts rock Taj.
• 4.11 pm: 30 bodies recovered from Trident.
• 4.22 pm: Six hostages rescued from Taj.
• 4.44 pm: Three explosions at Taj .
• 7.40 pm: Two terrorists killed in Nariman House.
• 7.55 pm: Operation on at the third floor of Nariman House.
• 9.06 pm: DG NSG says "Nariman House cleared and secured ."
November 29 (Saturday)

12.01 am: NSG moves into lobby of Taj; Director General (DG) NSG J K
Dutt says operation will end tonight.
3.50 am: Intense gunfire on first floor of Taj.
6.04 am: Five large explosions heard from inside the Taj.
7.45 pm: Fire breaks out on lower floors of Taj.
12.00 pm: NSG confirms all terrorists killed at Taj.
4.30 pm: Indian government announces death toll of 183, inclu ding 22
foreigners.
9.00 pm: 22 bodies, including that of the fourth terrorist, recovered in
Taj by NSG commandos.
Case Studies
BASF Warehouse Fire (9/10/1995)

Chain of Events
04:00 hrs – Fire alarm sounded in ICI’s Wilton Site Emergency
Services Control Centre, alerting of a fire in the BASF
warehouse which was used for storing polypropylene finished
products
Case Studies
BASF Warehouse Fire (9/10/1995)
Chain of Events
05:00 hrs – Major emergency on the site was declared due to fire
and the full on-site emergency plan initiated

05:30 hrs – Police alerted the public situated down wind of the
fire to stay indoors and to close windows. The "Redcar" trunk
road was closed and employees of adjacent companies, including
those on-site, were advised not to report to work

11:30 hrs – Fire was brought down completely

16:30 hrs – No loss of life reported. Infrastructure damage was

estimated to be around $ 3.67 million
Case Studies
BASF Warehouse Fire (9/10/1995)
Causes
The warehouse facility met the building regulations and was equipped
with a range of fire safety features.
This included fire doors, operated both by fusible links and smoke
detection, which failed to close during the fire.

The fact was that the warehouse did not become completely smoke
logged, as smoke was vented through the roof. Hence, the smoke failed to
activate the detectors, which would have closed the doors.

No direct root causes for the fire was determined. However, investigations
revealed that the probable cause was a fluorescent light fitting overheating,
causing the ignition of its Perspex refectory which dropped flaming molten
plastic onto stored product below. The warehouse lighting was in continuous
use.
 Chapter 3

Industrial Safety –
Effective Steps to Implement Safety
Procedures
Introduction
The OSHA Health and Safety Act 1983
 a duty of care principle for all employers to ensure the health, safety
& welfare of employees and others in the workplace

 an obligation for employers to establish that all reasonably

practicable measures have been taken to control risks against all
possible injuries arising from the workplace

 people in control of workplaces must ensure the health and safety of

people who use the premises as a place of work

 the employer's "duty of care" applies to all people in the workplace,

including visitors, contractors and others

 a general obligation on employer to ensure that their processes &

products are not a risk to health and safety to all type of workers

 a general obligation on employees to take care of others and

cooperate with employers in matters of health and safety
Effective implementation – A six point approach
The aim of the OSHA Health and Safety Act is:
 defining an employer's duty of care
 develop a code of safety standard & practices
 stressing workplace participation and consultation by employers and
employees

Overall objective – Effective implementation of safety procedures & policy

by the employer

A six point approach is recommended by OSHA for effective implementation

of safety procedures & policy

1. Develop a safety policy and related programs for it

2. Set up a consultation mechanism with employees
3. Establish a training strategy
4. Workplace assessment process
5. Develop and implement risk control
6. Promote, maintain and review the safety policy & program
Note: These points are not necessarily in order because all workplaces are
different
Develop a safety policy & related programs for it
What to include in a safety policy:
 Shows commitment of management 1
 Ensures accountability at all levels
 Encourages co-operation
 Clearly understood by employees
It’s important to review and update the policies regularly

How to start:
 Draft a simple statement of the organization's commitment to safety
 Discuss with employees for further development of the policy
- Employees will be more committed to the policy if they're involved in
its development
 Finalize the policy after discussion with all stalk holders

The policy should outline the responsibility and accountability of management

and supervisors as well as other employees

If required, Contractors could be considered when developing a safety policy

Develop a safety policy & related programs for it
How to develop a safety program:
 Planned, coordinated activity - better to involve all the people 1
 Identify the hazards before listing the objectives
 Risk identification & assessment
 Development of controls & implementation
- Control strategy may involve redesigning the work system
Consultation is an important step in the development of a safety program
Safety program may detail new ways, if appropriate, to perform tasks; includes
information & training given to managers, supervisors and employees
The safety program should have a timetable for implementation and list of the
people responsible for the program
Monitor each program so that problems are dealt with as they arise
Let people know
 Advertise the policy and its related programs by promoting it in
meetings, seminars, newsletter, notice boards and other information
sources
 Include the policy in the company's induction program
Consultation mechanism with employees 2
A consultation process could include:
 establishing a workplace safety committee comprising of employer,
floor supervisors and employees

 having meetings, workshops, suggestion boxes, and surveys to let

employees know regarding the safety policy & program

 providing general safety information such as explaining the ‘OSHA

Health and Safety Act 1983’ and its implications to the organization

 making sure the input of all employees is valued

 ensuring management shows strong commitment to the workplace

safety committee

 involving employees in the identification & assessment of hazards,

and the development of control strategies and evaluation of
controls
Set up a training strategy 3
Information, instruction and supervision are the essential components for an
effective training strategy

Everyone in the organization, from senior management level to shop floor

staff, should receive training with respect to safety policy & procedure

Safety trainings does not just involve specific hazard training - it is part of all
workplace training

Workplace Health and safety concepts should be included in:

 induction training
 supervisor and management training
 on-the-job training (including Maintenance & troubleshooting)
 work procedures and skills training
 emergency procedure training
 first aid training
Set up a training strategy 3
An effective training program can be developed through:
 analyzing work tasks and assessing the knowledge or skill level required
for these tasks

 Imparting the required skill sets for the safety & hazard control

 understanding the domino effect of hazard propagation (if any) &

including them in the safety programs

 including the concept of safe systems available at work place in the

safety trainings

 analyzing the emergency situations and incorporating the emergency

procedures in trainings

 including safety principles in employee induction programs

 evaluating the effectiveness of training program by workplace monitoring

 on-the-job training of employees including apprentices

Workplace assessment 4
Safety audit
• Systematic and periodic inspection of the workplace to evaluate the
effectiveness of the organisation's health and safety system
• The audit may be conducted by a safety consultant or workplace
professionals such as safety officers
• An audit usually contains a written report for management and is usually
referred to local OSHA committee
Workplace inspections
• These are regular inspections of the workplace by managers, supervisors
& safety committee members to determine the safety level by observation
• Inspections involve consultation with supervisors and employees and a
report to management and/or the safety committee

Accident investigations
• Workplaces should have a set of procedures for investigating and
reporting on accidents (and near miss) to identify the hazards / safety
procedure failure that contributed to the incident
• Accidents that involve “Causalities” or "lost time" should be reported to
the Workcover Authority Report (WAR).
Workplace assessment 4
Consultation
• Employees are often more aware of hazards and the possible ways of
controlling them, than management
• Consulting employees can improve the assessment process as well as
improving cooperation with control measures eventually put in place

Injury and illness records

• Workplaces are required to keep records of injuries and illness
• Many workplaces also generate reports and statistics based on workers'
compensation claims
• Workplace injury and disease recording standard has to be done as a
Code of practice for ensuring Occupational health & Safety

Complaints
• Many workplace hazards are brought to the attention of a supervisor or
manager through a complaint being made by an employee
• Complaints should be taken seriously and passed to the appropriate
person for prompt action, not left to create an industrial problem
Develop & Implement risk control 5
Engineering controls
1. DESIGN - Try to ensure that hazards are 'designed out' when new
materials, equipment & work systems are being planned for workplace
2. REMOVE the hazard or substitute less hazardous materials, equipment
or substances
3. ADOPT A SAFER PROCESS - Alteration of tools, equipment or work
systems can often make the process or work much safer
4. ENCLOSE OR ISOLATE THE HAZARD through the use of guards or
filters and remote handling techniques
5. PROVIDE EFFECTIVE VENTILATION through local or general exhaust
ventilation systems to dilute any leakage of toxic substances
Administrative controls
6. ESTABLISH appropriate ADMINISTRATIVE PROCEDURES such as:
 job rotation to reduce exposure or boredom; or timing the job so that
fewer workers are exposed
 routine maintenance and housekeeping procedures
 training on hazards and correct work procedures
Personal Protective Equipment
7. PROVIDE suitable and properly maintained PERSONAL PROTECTIVE
EQUIPMENT and training in its use.
Promote, Maintain and review safety policy & program
Strategies for maintaining & reviewing the safety policy & program would 6
include:
 communicating with people in the workplace about safety policy &
program including the success of control strategies

 making sure that safety concepts are integrated into all management
procedures e.g.: planning, budgeting, performance objectives

 evaluating the success of the control strategies, such as an injury review,

accidents and "near miss" reports & records

 evaluating and reviewing the quality of training programs

 seek advice from employees to check whether they feel the control
strategies are working and whether there are any problems with it.
e.g.: check whether the control strategies have created new problems of
their own

 strong commitment to safety policy & program from all people

 Chapter 3

Personnel Protective Equipment &

Industrial Safety
Personal Protective Equipment

• Definition: Devices used to protect an

employee from injury or illness resulting from
contact with chemical , radiological, physical,
electrical, mechanical, or other workplace
hazards (OSHA)

• The need for PPE and the type of PPE used

is based on hazard present; each situation
must be evaluated independently
 When PPE is used?
• PPE is used as a last resort
• The use of PPE signifies that the hazard
could not be controlled by other methods,
such as:
– administrative controls (i.e., shift rotation)
– engineering or industrial hygiene controls
 Presence of PPE means…
• The use of PPE signals that the hazard
still exists in the workplace
• Unprotected individuals in the same area
will be exposed
• Failure of PPE means that the worker will
be exposed
• PPE can be combined with other controls
So, what PPE is like???
 Types of PPE
• Head protection
• Eye and Face protection
• Hearing protection
• Respiratory protection
• Arm and Hand protection
• Foot and Leg protection
• Protective clothing
Head Protection
Hard Hats work by dissipating
force
Eye Protection
 Eye Protection
• Common Uses:
– Impact Protection
– Chemical Hazards
– Radiation Protection
• welder’s goggles
• laser goggles
• UV
• Infrared
 Eye Protection - Selection
• Visitor specs are only appropriate for non-
employees with no true exposure to
hazards
• Safety glasses are used to protect the
eyes from flying objects (no face
protection)
• Chemical splash goggles protect against
fluids by sealing tightly against the face
• Face shields provide highest level of
protection
Face Shield - the highest level
of face protection
Hearing Protection
 Hearing Protection Basics
• Noise induced hearing loss can occur with
exposures > 90 dB

• A hearing conservation program becomes

a requirement at exposures >85 dB

• Higher levels of noise exposure have

shorter allowable exposure times
 Noise levels versus Duration
Sound Level (dB) Exposure (hours)
90 8
92 6
95 4
100 2
105 1
110 0.5
115 0.25
 Hearing Protection
• Rule of Thumb - if you cannot carry on a
conversation in a normal tone of voice with
someone at arm’s length, you are likely
near 90 dB
 Hearing Protection - Types
• Ear Plugs - less expensive, disposable,
good ones have fairly high NRRs -
sometimes difficult to tell if employees are
wearing them

• Ear Muffs - more expensive, more durable,

typically higher NRRs than plugs, Can be
used together in very high noise areas
Arm and Hand Protection
 Gloves - Typical Uses
• Chemical protection
• Biohazard protection
• Abrasion protection
• Friction protection
• Protection from extremes of heat and cold
 Hand Gloves

• No glove is good against all hazards.

Hence selection of glove depends on
the need.
• Gloves have a finite lifespan and must
be periodically replaced
• When wearing gloves, examine them for
signs of tears, cracks, holes and dry rot
• Hands should always be washed after
removing gloves
Handwashing and gloves
Foot and Leg Protection
 Protective Footwear
• Steel-toed footwear, preferably with
metatarsal guards, is used to protect feet
from crushing injuries caused by heavy
objects

• Rubber boots are often used to protect

feet from exposure to liquids
Other Protective Clothing
 Other Protective Clothing
• Used to protect normal clothes from
hazards in the workplace

• Often hazard specific

• To be considered effective, protective

clothing must prevent the contaminant
from reaching the clothing or skin of the
wearer!
Respiratory Protection
 Respiratory Protection
• Protects users by removing harmful
materials that may enter the body via the
lungs

• Inhalation is one of the quickest, most

efficient ways to introduce lethal levels of
hazardous materials into the body
 Respirators - types
• Air Purifying Respirators (APR)
– Half-face
– Full Face

• Powered Air Purifying Respirators (PAPR)

• Self Contained Breathing Apparatus

(SCBA)
 Respirators
• Does not include:
– surgical masks
– dust masks

• N-95 respirators are a special class of

respiratory protection primarily used in the
health care field
 Respirators – Who can use?
• Employees should not wear a respirator
unless they have been medically cleared
to do so!

• This clearance may take the form of a

questionnaire, physical examination,
pulmonary function testing, chest X-Ray,
or a combination of the above
 Why?
• Respirators put additional resistance
against the respiratory system of the
wearer

• Persons with undiagnosed respiratory

system or cardiovascular problems could
trigger a serious medical problem
(respiratory distress, asthma, heart attack,
etc.) by using a respirator
Respirators are incompatible
with facial hair
 Facial hair…
• The respirator cannot form a tight seal against the
cheeks and chin, resulting in air leaks which can allow
airborne contaminants to be inhaled

• Specially designed PAPR hoods can be used for

employees with facial hair

• Small amounts of facial hair that fit inside the

respirator face piece are acceptable
 PPE Usage
• PPE is required to carry out the work in a
safe manner
• Supervisors are responsible for ensuring
that PPE is available and worn
• Employees are responsible for wearing &
maintaining PPE, and reporting worn or
defective PPE to their supervisor
 Recap
• PPE is hazard specific; the hazards of
each workplace and task must be
evaluated
• PPE is used as a last resort when the
hazard cannot be controlled by other
methods
• Supervisors are responsible to ensure it is
available and worn; Employees must wear
and maintain their PPE
 Recap
• PPE is only considered effective if it
prevents the contaminant from reaching
the wearer
• Respirators should not be worn by
employees unless they have been
medically cleared to do so
Dressed for Success!
 Chapter 3

Occupational health & Safety

 OCCUPATIONAL HEALTH
• The modern definition of Occupational
Health (WHO) is:

“The promotion and maintenance of the

highest degree of physical, mental and social
well-being of workers in all occupations –
total health of all at work”
 OCCUPATIONAL HAZARD:
``Source or situation with a potential for
harm in terms of injury or ill health,
damage to property, damage to the
workplace environment, or a combination
of these``
Safety and Health Legislations :
THE FACTORIES ACT,1948
11 Chapters
120 Sections
3 Schedules
Chapter- III - Covers Health
Chapter- IV - Covers Safety
Chapter- Iva - Provision-related-to
Hazardous Processes
Chapter- V - Welfare
Chapter- VI - Working hrs-adults
Chapter- IX - Special provisions
- Dangerous operations
- Notifications
OCCUPATIONAL HEALTH HAZARDS

TYPES OF OCCUPATIONAL HEALTH HAZARDS

A. Physical
B. Chemical
C. Biological
D. Mechanical
E. Psychosocial
PHYSICAL HAZARDS

Temperature - Heat / Cold

Illumination
Noise
Vibration
Radiation
Atmospheric pressure
DISEASES DUE TO PHYSICAL AGENTS
Heat –
Heat hyperpyrexia (raise in temp of body- children),
Heat Exhaustion,
Heat Syncope (sudden arrest),
Heat Cramps,
burns,
Prickly heat

Cold –
Frost bite

Light –
Occupational Cataract
DISEASES DUE TO PHYSICAL AGENTS
Atmospheric-pressure –
Caisson disease (A condition caused by long-term whole body
decompression ),
Air embolism (Bubbles of air in the heart
or vascular system )

Noise – Occupational deafness

Radiation – Cancer,
Leukemia,
Aplastic anemia (disorder in which the bone
marrow greatly decreases or stops production of
blood cells. )

Pancytopenia (reduction in RBC, WBC, Platelets)

Electricity –
Burns,
Shocks
 Heat Illness

• Predisposing Factors
– Physical activity disturbance
– Extremes of age, poor physical condition, fatigue
– Excessive clothing
– Dehydration
– Cardiovascular disease
– Skin disorders
– Obesity
– Drug consumption
 Heat Stroke

SYMPTOMS PREVENTION
– True emergency Awareness
– Any neurological finding Adaptation of behavioral and
and elevated temperature physical activity
may still be sweating
–Clothing
initially
–Activity
– Syncope (temparory loss of
conciousness)
Appropriate hydration
– History is critical Education
 Frost Bite
SYMPTOMS
Caused by freezing conditions which cut off circulation,
usually in extremities (hands, feet, ears, nose), which
may be permanently affected. Frost-bitten areas are
cold, pale or marbled-looking, solid to the touch, and
painless (until circulation is restored).

TREATMENT
Giving warm drinks, and covering with blankets.
Warm the injured part with body heat only-put a hand under an
armpit, for example.
Do not rub the skin or apply direct heat to the injured area.
CHEMICAL HAZARDS

• Routes of entry - Inhalation, Ingestion, skin

absorption. (inhalation is the main route of
entry)
• Chemical agents can be classified into-
1) Metals - Lead, TEL, As, Hg, Cd, Ni , Co
etc. 2) Aromatic Hydrocarbons - Benzene,
Toluene 3) Aliphatic Hydrocarbons - Methyl
alcohol 4) Gases –
* Irritant gases : Ammonia, SO2, Cl2,
* Systemic poison : CS2
 TLV CONCEPT

The Threshold Limit Value - Time Weighted Average

(TLV-TWA) : ``Time-weighted average concentration
for a normal 8-hour working day and a 40-hour working
week, to which nearly all workers may be repeatedly
exposed day after day, without adverse effect``

The Threshold Limit Value - Short Term Exposure Limit

(TLV-STEL) is defined as a 15-minute, time-weighted
average which should not be exceeded at any time
During a working day, even if the 8-hour time-weighted
average is within the TLV``
 DUSTS (Pneumoconiosis)

Inorganic Dust
Coal Dust - Anthracosis(a chronic lung disease characterized by the deposit of coal dust in the
lungs)

Silica - Silicosis
Asbestos - Asbestosis

Organic Dusts
Cane Fiber - Bagassosis (Bronchi gets affected)
Cotton dust - Byssinosis (In Textile industries)
Tobacco - Tobaccosis, Lung Cancer
Grain Dust - Farmer’s Lungs
 Biological Hazards

Bacteria - Tetanus, Tuberculosis, Anthrax,

Virus - Hepatitis, AIDS

Protozoal & Parasitic

- Malaria, Hookworms, tapeworms

Fungi - Tinea - infections, ornithosis,

etc.
 MECHANICAL HAZARDS
Injuries- Cuts,abrasions,concussions ,etc.
Ergonomic Disorders-
Musculo-skeletal disorders (MSDs),
Cumulative-trauma-Disorders (CTDs) etc.

Ergonomics: ``Adjustment of Man & Machine``/

Application of human biological sciences with engineering science
to achieve optimum mutual adjustment of man & his work, the benefit
being measured in terms of human efficiency and well being

Tool / machine design to fit to work. Ergo tools/ ergofriendly tools : Tools
which reduce the stresses or problems resulting in CTD’s / MSD’s.)
Manual Handling - Back Injuries
All forces which come down the
spine compresses discs and as
a result of continuous
squeezing they can rupture and
bulge causing severe pain.

Most back injuries are built over

along period of time by
repetitive pounding on discs
caused by improper methods.
After sometime some minor lift
can produce such rupture
Manual Handling - Back Injuries
*CONTROL any risk by reducing
necessity for manual handling by using
alternative means of handling

*consider the load; size, awkward shape,

etc

*consider need for mechanical or manual

assistance

*position legs apart - one foot level with

the load

*keep back straight, look up

 VISION & LIGHTING

*NO GLAIR

*Optical Illusion

*Use screen filters to reduce glare

*Screen intensity needs to be adjusted

*Frequent breaks from the screen to reduce

stress on eyes
PSYCHOSOCIAL HAZARDS
 Lack of job satisfaction, insecurity, poor
interpersonal relations, work pressure,
ambiguity, etc.

 Psychological & behavioral changes –

hostility, aggressiveness, anxiety,
depression, alcoholism, drug addiction,
sickness absenteeism.

 Psychosomatic disorders- Hypertension,

headache, body-ache, peptic ulcers, asthma,
diabetes, heart disorders, etc.
TYPE OF CONTROL MEASURES

Engineering
(Best Engg. Control is to reduce exposure)

Administrative / Legal.
(Emphasis given to reduce the exposure)

Medical
(required to monitor effectiveness of Engg. Controls)
 Chapter 3

Industrial Safety – Importance of

Equipment Selection &
Maintenance
Importance…
• Assure the Quality & Quantity of the product
• Minimize equipment breakdown
• Lower repair costs
• Prevent delays in meeting the demand
• Maintain productivity
• Minimize the accidents & causalities during working
• Maintains the stipulated working time
• Ensures continuous operation of the plant

On a broader side, Selection & Maintenance of equipments

plays a critical role with economics & safety of the industry
Equipment Management
• As per Indian factory Act, 1948, the various steps
involved in equipment management

– Selection
– Acquisition
– Installation
– Calibration / Validation
– Maintenance
– Troubleshooting
– Service and repair
– Retiring equipment / disposition
Selection Criteria
Safety factors involved with selection
• Meeting of requirement – match equipment with service
provided

• Performance characteristics (Efficiency, Volume handling,

Time consumption, etc…)

• Facility requirements (electrical, HVAC)

• Supply of Spares

• Ease of operation (training, fatigue, errors)

Selection Criteria
Economic factors
• Cost (purchase, maintenance, replacement)

• Warranty

• Availability of manufacturer technical support

• Service Contracts

A balance of both set of factors (Safety & Economics) has to

be taken up during the selection of the equipment
Installation
• Pre installation safety considerations:
– verify physical requirements have been met
 Safety checks, electrical, space, ventilation, water
supply, ambient temperature, etc.
– confirm responsibility for installation

• Installation safety considerations:

– verify package contents
– do not attempt to use prior to proper installation
– If required, ensure the equipment is installed by the
manufacturer
Installation (Contd…)
• Post installation

– Establish inventory record

– Define conditions

– Develop and implement protocols for calibration,

performance verification, and operating procedures

– Establish maintenance program

– Provide training for all operators

Replacement – Maintenance Program
• Preventive maintenance (PM) is a schedule of planned
maintenance actions aimed at the prevention of breakdowns
and failures.

• The primary goal of preventive maintenance (PM) is to

prevent the failure of equipment before it actually occurs.
Maintenance Program
• Some advantages of a PM system include:
– Reduced production downtime
– Conservation of assets and increased life
expectancy of assets (both machine and human)
– Ensuring all equipment safety features are
functioning properly
– Reduced cost of repairs by reducing secondary failures
– Quality products
– Identification of equipment with excessive maintenance
costs
– Improved safety and quality conditions.
Maintenance Program
Need for a PM system
• A PM system aligns with a safety management program to:
– Prevent injuries caused by malfunctioning equipment
– Increase automation
– Reduce losses due to production delays
– Improve quality
– Just-in-time manufacturing
– Provides a more organized work environment.
Maintenance Program
Three keys for successful PM system:
–Scheduling: Should be automated to the maximum extent
possible
–Execution: Should be done before an actual break down
occurs
–Quality: Should have a formal process for checking the
quality of repairs.

• PM focus should be on:

– Cleaning
– Lubrication and inspection
– Correcting deficiencies
– Operation of safety devices.
• Parts replacement should be minimal & done only when
evidence clearly indicates wear-out characteristics.
Maintenance Program
• Things to be considered after completing a maintenance
operations:

– Ensure equipment meets manufacturer’s specification

– Review job hazard analysis (JHA) to ensure equipment
alterations or equipment maintenance did not introduce
new hazards not included on the JHA
– Conduct machine checks to ensure all feature, especially
safety devices, are functioning properly
– Ensure employees are aware of any changes to
equipment and/or operating procedures.
Implementing a Maintenance Program
• Assign responsibility
- Oversight of all laboratory equipment
- Individual responsibilities
• Develop written policies and procedures
• Train staff
• Keep records

• For each piece of equipment:

 Establish routine maintenance plan
 Establish required function checks
 Develop a list of spare parts
Implementing a Maintenance Program
• Develop written procedures for all equipment

– Concise step-by-step instructions for performing

maintenance and function checks

– Include guide for troubleshooting

• Establish maintenance records to track:

– function checks and routine maintenance

– Calibration

– manufacturer’s service
Retiring Equipment / Disposition
• When?
– When experts indicate not repairable
– Outdated, will replace with new equipment

• Why?
– Prevent quality & quantity loss
– Free up valuable space
– Hazardous

• How?
– Salvage any useable parts
– Follow safety disposal procedures
Implementing better Equipment Management
• Assign responsibilities for all activities

• Train all employees in a particular process on their

responsibilities, equipment management & maintenance

• Monitor equipment management activities by

– Routinely review all records

– Ensure all procedures are followed

– Update policy and procedures, when necessary