Plant & equipment safety Appraisal & Control Techniques

(a) Plant safety observation & inspection. (b) Safety sampling & survey.
(c) Job safety analysis. (d) Safety inventory system. (e) Product safety.
(f) Permit to work system. (g) Safety tag system. (h) Total loss control system.
Accident major or minor, injury to man or to material or to both
Hazard – danger – risk – near miss.
Reportable accident: - Disability more than 48hrs non reportable accident
Non reportable accident: - Disability less than 48hrs
1 man day = 8 working hrs
Severity of accident:- More the man days loosed in less number of accidents
Frequency rate: - More number of accidents in less time.
Severity rate: – Gravity or seriousness of injury.
Working at height is a hazard while probability of falling from height is a risk.

JOB SAFETY ANALYSIS

A job safety analysis (for job hazard analysis) is a procedure to make a job safety
by:-
(i) Identifying the hazard or potential accidents associated with each step of the job.
(ii) Developing a solution for each hazard that will either eliminate or control the exposer
Some job steps may help no hazard associated with them but other job steps may be
accompany by one or more hazard. Some hazards are conditions, some are actions. All
are potential causes of accidents. (Unsafe conditions or unsafe acts are the causes of
accidents to happen.)
Once job hazard are identified proper solutions can be developed, like
(Standard operating practice & standard maintenance practice etc)
Some solutions may be physical changes that control the hazard such as placing a
guard over exposed moving machine parts. Others may be job procedures that eliminate
or minimize the hazard such as safe piling of materials. Job safety analysis is also half
full in discovery of eliminations or safe guarding of motion, positions and actions that are
hazardous. It adds the determination of equipment and tools needed for safety.
A detail analysis of each step in the operation of any job helps to decide what
personal characteristics such as age, health, physic, skill, height, weight and reaction time
are necessary in selecting the operative for the job.
It also helps to give proper instruction to the selected employees on the various
steps of operation in the job so that he/she may do his/her job better, faster and more
safely with minimum supervision and follow up.
TECHNIC OF JOB SAFETY ANALYSIS:
The four (4) basic steps in job safety analysis are:
1. Selecting the job: - The most hazardous and those with the worst accidents should
be taken first. The following are suggested as guiding factors for selecting the job
(a) Frequency of accident: - The greater the number of accident associated with the
job, the greater its priority claim for job safety analysis.
(b) Production of disabling injuries: - Every job that has produced disabling injuries
should be analyzed.
 (c) Severity potential: - Some jobs may have no history of accidents but might have
the potential of savior injury.
(d) New jobs created by changes in equipment or process:- Job safety analysis should
be made on every new job.
(e) Number of employees at risk: - If more number of people are engaged with a job
having potentiality of risk.
Thrust area: - where numbers of accidents are more.
Total injury: - Any accident minor or major repotted to plant first aid or referred to
hospital are called total injury.
Disable cases: - Any injury makes a workman disable for more than 48 hrs. (To be
reported to statutory body)
2. Break the job down into successive steps: - The job should be broken down in to
basic steps. The steps must not be too general but covering all major process points. Each
step should describe what is being done. Steps should be given in the order of occurrence.
3. Identify the hazard and potential accidents: - Each step should be analyzed for
hazard and potential accidents. The purpose is to identify all the hazards by observation
and knowledge of the hazard, wither produced by the environment or connected with job
procedure.
4. Develop ways to eliminate the hazard and prevent the potential accidents: - The
principal solutions are
(a) Find an entirely different way/procedure to do the job.
(b) Change the physical condition that creates the hazard.
(c) Revise the job procedure if required.
(d) Reduced the frequency of the job by correcting the unsafe condition.
ADVANTAGE OF JOB SAFETY ANALYSIS

1. It maps out all the details of a operation so that it gets it gets the supervisor
directly in tough with minute details of all the job as no other procedure can do.
2. It is quick, simple, factual and objective so that it makes the supervisor to use his
imagination in determining wither each element of the job is necessary and ether
each element of the job done in the safe way.
3. It permits a ready comparison of the undesirable method and the propose new
method demonstrating the types of hazard and the number of steps involved in
each.
4. It presents the picture of the effect on production with safety improvements.
5. It is an aid for showing the management that a properly designed safety feature
does not hinder production output and therefore can assists in convincing
management the benefits to be gained by improving the safety.
6. It permits the engineer to make out and improve ways for increasing the
production of an operation. It brings to light what we call the continue appearance
of normal faction.
7. It facilitates the analysis of the safety potential of a job before an accident can
happen. This is purely a safety working system.
8. It assists in through investigation of those methods which have involved accidents
but in which cases are hidden.
9. It brings the supervisor and his workman close together on the subject of safe
operation in way that no other procedure or technique can do.
10. The greatest importance of the evidence provides to support the safety engineers
to obtain disputed contention that improving a shops safety and increase the
productivity.
11. Job safety analysis helps in identifying hazard and make out safe practices. The
technique is help full in preparing special safe procedures, codes for various
operations in machines. Listing of hazard will help to draw a code of safe
practices

MECHANICAL & PHISICAL HAZARDA IN METAL LATHES: -

There are four steps to define the mechanical & physical hazards in Metal Lathes: -
(1) Power transmit ion: - Lathes may be driven
by individual motor or from a line shaft comprising belt and pulley. There may be
gears and head stock.

(2) Power of operation: -

(a) Contact with projection of face plates and chucks.
(b) Contact with lathe dogs (especially project set screws)
(c) Filling right handed, especially near dog or chuck or using the hand instead of a
stick to hold emery cloth.
(d) Callipering or gauging the job while the machine is in operation.
(e) Accidental contact with the tool
(f) Attempting to clean chips while the machine is in motion.

(3) Chips: -
(a) Continuous spiral – with some types of metal, continuous spiral chips are
produced which frequently causes injuries to hand, arms & face.
(b) Flying particles – With some types of metals, some particles are thrown off which
constitutes a hazard to eyes of the operator and others.
(4) Other Hazards: -
(a) Chuck keys left on chuck sockets.
(b) Tools, work stock etc are kept on walk way.
(c) Strains from lifting heavy work/job chucks etc.

PLANT SAFETY INSPECTION

Plant safety inspection: - Plant safety inspection which is a method of discovering
potential accident risk is one of the oldest of accident prevention techniques. When an
employee was caught in-between a pair of gear wheels, naturally preventive action
was confined not only to the particular dangerous unit which cause the unfortunate
incident, but to other similar units also. The plant safety inspection became an
important tool in accident prevention right from the early days. Developments of the
statutory regulations covering safety and the inspections by the factory inspectorate
have given stimulation in a plant inspection and guarding program.
Just a inspection is an important function in quality control of the product
manufactured, plant safety inspection plays a vital role in accident prevention. Its
purpose is to find and remove hazards in jobs before an accident occurs. It may not be
possible to locate and remove all the unsafe conditions or unsafe practices in the
entire plant in one stroke but the ultimate aim is to make all the operations safe and
efficient.
Plant safety inspection is some times wrongly interpreted as being coffined only
to detection of unsafe physical or mechanical conditions. This is probably in view of
the emphasis on statutory requirement alone. As unsafe action is a causative factor in
all accidents and it may not be possible to make the physical conditions safe and full
proof in all circumstances. It is very important that unsafe actions and work practices
are also carefully noted during plant safety inspection. Properly carried out
inspections contributes to safety by its incidental benefits. The safety officer, plant
superintendent (sectional in charge) or other supervisory personal making the
inspection could achieve the purpose of inspection better by consulting the persons
concerned in the shop and thus enlisting their cooperation. Consultation with the
employees besides reveling the practical aspects of the problem often brings out
useful suggestions from the employees. Such consultation and implementation
suggestion is a sure way of creating employees interest in safety.
A system of discovering the hazards in various jobs and taking prompt corrective
measures to eliminate those serves indirectly to demonstrate management’s interest in
safety to employees and there by motivate them. The employees in turn are
encouraged to report the hazards in their jobs.
RESPONSIBILITY FOR INSPECTION: -
Obviously safety inspection can not be done by any individual or agency. The
responsibility should be shared by all those those concerned with in the plant. It is
important that all personal at the various levels should clearly understand and their
responsibilities and functions so that management’s objectives in this respect are
implemented through their co coordinated effort.
SAFETY OFFICER: -
Industries of a fairly large size normally have a safety department with one or more
qualified safety officers. But in smaller units, safety is normally under the charge of a
senior person or or under the personnel department or under the operation
department. Though safety inspection will have to be carried out by all levels of
personal, the safety officer and his assistant have a special responsibility in this
respect. The inspection made by the members of the safety department could bring
out many unsafe conditions and actions which are not reported by those in charges of
the department concerned. Bring slowly concerned with safety they have sufficient
time for caring out these inspections. Further, the critical eye of these specialists
easily detects the accident potential in the various jobs or process.

LINE MANAGEMENT: - Safety brings principally a Line management function

persons from the line management should themselves take the main responsibility for
plant inspection.
(a) Senior Plant Management: - Senior plant management should make it
obvious that they are keen in on safety. They must create interest, stimulate
and maintain safety in all levels.
For example: - While going round the dept. the action on the part of a plant
superintendent who notices an unsafe condition or unsafe action which is contrary to
the approval practice, to stop and point it out to the supervisor will go a long way in
educating all those under him. Indeed it is the senior plant management who has to set
the role in accident prevention.
In addition to the type of inspections maintained above, the senior plant
management should periodically make throw safety inspections of the plant or the
section in their charge to locate all hazard conditions and practices.
(b) First Line Supervisor: - The duties of a supervisor require that he should
continuously look out for hazardous conditions and unsafe practices on the
part of the man in his section. In addition to this he should make periodic
special inspections of machinery at regular intervals to see that all the
hazards have been properly safe guarded and safe procedures are being
followed.
(c) Engineering & Maintenance Engineer: - Supervisory both of senior and
first line levels of the above dept. could make effective contribution to
safety by making frequent safety inspection and taking necessary steps for
maintaining the plant and equipments in safe conditions.
(d) Workers: - It is workers who ultimately carry out the various operations
using the machinery and equipments. Since they come into close contact
with the machinery, equipment, tools and other parts of the plant during
working, they can easily detect the defects associated with these. They
should be encouraged to report defects or hazardous conditions which can
cause accidents to them or to others.
TYPES OF INSPECTION: -
Safety inspection can be of the following type.
1. Periodic inspection
2. Intermittent inspection
3. Continuous inspection
4. Special inspection
1. Periodic inspection: - These inspections are well planed and made at regular
intervals. Machineries, equipments, tools and all parts of the plant should be
inspected periodically. The periodicity should be decided according to the
requirements while making periodical general inspection. Effects should be made
to cover the entire plant. For periodic inspection of pressure vessels, cranes,
hoists, elevators chains, ropes etc a prearranged schedule as required by law or
statutory body should be followed and these should be carried out by competent
person. All concerned person should be notified well in advance of such
inspections for necessary arrangements.
2. Interment ant or (Surprise) inspection: - These are unarranged and
unannounced inspections made an irregular interval. These may be made by
safety supervisors safety committee and may cover a particular department or a
section or a piece of equipment or small work areas.
3. Continues inspection: - In a system of continues inspection some selected
employees spent their time observing certain equipment/s, operation or
maintenance. In some factories Continues inspection of tools are done by stores
 people. Continues system of inspection on personnel protective equipments
to keep them in good shape is especially desirable.

4. Special Inspection: - Special inspections are those which are occasionally made
to locate hazards which are suspected to be present in certain situations or
processes.
Example: - (I) Inspections during especial campaigns, such as fire prevention week,
west elimination week, safety week etc.
(II) Inspections of new building/s, installations of new processes etc.
(III) Health survey to determine the extent of the suspected hazard and
necessary preventive measures.
(IV) Inspection of hand tools scaffolding, PPEs, point of operation guards
lighting facility, general ventilation, equipments, excavation &
construction work.

INSPECTION PROCEDURE: -
The persons making inspection should be familiar with the equipment, tools, the
processes and operations. They should have adequate knowledge of hazards
associated with these. They should also be familiar with the company rules and
policies and also the various status dealing with safety and health. The inspection
should be equipped with data based on a detailed analysis of previous accidents on
the plant. An inspection check list often proves to be very handy and will eliminate
the chances of over looking some of the sources of the accidents. Detailed check list
could be drawn of for individual plants or sections.
The inspection should be systematic, thorough and cover all the operations,
equipments, tools and parts of plant so that no hazard is over looked. The inspector
should not depend on his memory and make complete notes of the unsafe conditions
and practices which are discovered at the time of inspection. All data should be
recorded and this can be used at the time of writing the inspection report.
The implementation of the suggestions arising out of inspection is to be carried out by
the various departments concern with production, maintenance etc and therefore it is
important that recommendations are discussed where ever necessary with the
concerned persons.
REPORTING AND FOLLO UP: -
The inspection report should be clear and concise with enough explanation to make it
understandable. Copies of recommendation should be sent to concerned persons for
implementation. Progress should be reported to the management at regular intervals.
Periodic check should be made until they have been completed.

PREPARATION OF CHECK LIST FOR CHECKING BY THE SAFETY

INSPECTOR/SAFETY OFFICER/SAFETY COMMITTEE MAMBERS: -
OBJECTIVE OF SAFETY: -
The success of any organization depends upon the effective utilization of available
resource in terms of mane, machine, material and method etc. actually the effort of
good workman ship needs knowledge and skill for safe and efficient production. The
safe working environment and procedure helps an employee to apply his full capacity
 to accomplish his assigned task in safe way. To obtain the above we need the
following: -

1. To integrate safe practice and methods into operational requirements.

2. To provide safe work environment, proper & adequate tools, PPEs which are
required during the work.

Safety is not an ornamental approach. It is a state of keeping one and all safe at all
conditions. It should be the top priority and foremost concern of all industrial work
environments. Mostly safety is the primary and statutory requirement of the top
management of any organization or factory. Hence the main objectives of safety can be
summarized as follows: -
!. Identification: - To identify the risk which can lead to injury or more that
in a unsatisfactory condition at work place.
2 Analysis: - Analysis and determine the nature of risk and problem, how
ultimately it effects the workers. It also analyses what measures needs to
be taken.
3 Follow up: - Follow up procedure which ensures that measures have been
taken to properly carry out the job. It is basically SOP & SMP. (Standard
Operative Procedure & Standard Maintenance Procedure)
PLANT SAFETY OBSERVATION: -
As per ILO (International Labor Organization) 0.18 million workers die and 100 million
workers suffer from non fatal injury every year in the world. Hence it is necessary to
enforce safety at all work places to reduce accidents and injuries. Safety is subjected to
man, machine, material and the environment. Each of these factors is concerned with
accidents due to any circumstances. Equipments are concerned with both safe and unsafe
operations where as men concern with work with positive, negative or mutual attitude.
Materials are concerned with toxic, explosive, inflammable, corrosive and reactive
properties. Finally environment is concern with dusty, noisy and heat etc.
OBJECTIVE OF PLANT SAFETY OBSERVATION: -
In ancient days industrial work was not concerned with safety. The production and
quality was given highest priority then safety. Then in the middle age the society paid
equal importance to safety and production, but in present industrial scenario safety is
being paid most attention then the production.
In general the objective of plant safety observation are as follows: -
1. To prevent accident at every step and control hazards during maintenance and
operation.
2. Publicity, propaganda, education and training of safety polices and day to day
activities.
3. Environmental control and co ordination of occupational health activities.
4. To promote co operation between management and employees in enforcing and
taking measures to ensure the health and the safety standards of the employees.
5. To compliment effective system of the management to establish standards, codes,
regulations with a view to eliminate risk and hazard in work.
6. To chive proper awareness among the managerial and supervisors of the shop
floor for enforcing safety measures.
 WORK PERMIT SYSTEM
Introduction: -
Serious accidents often resulting in fatalities have accrued and continue to accrue
repeatedly while performing certain type of jobs under certain conditions. Therefore to
control and prevent the repetitive accident occurrences, some positive measures of safe
guard and controlling are necessary. As a result, the “work permit system” is drawn. The
work permit system proved to be one of the most satisfactory methods of ensuring
positive controls over hazardous operations performed in unfavorable conditions.
Moreover the system helps to affect greater controls on execution of jobs, maintenance
and repair workers performed simultaneously on the same equipment by different
sections under separate supervision.
WHAT IS A WORK PERMIT: -
Work permit is essentially a document that, categorically spells out the task, equipment
involve, its location, personnel’s involve, time limitation, precautionary measures to be
taken together with likely hazards to be encountered if any.
USEFULLNESS OF WORK PERMIT: -
Work permit provides written information on the hazards connected with the job to be
formed. It spells out suitable remedial measures to be adopted to encounter the hazardous
condition that are prevailing or that can be encountered while performing the job. It also
stipulates various conditions and limitations on the part of persons actually required to
perform the job. It indicates the various types of personnel protective equipments to be
used at different stages of work.
It serves as a predetermined check list for various safety precautions to be taken. It also
serves as media of information to all concern in advance. It provides a written record of
the operation including the personnel who are involved in authoring and caring out the
operations. The permit system requires for caring out various tests and safeguards.
In a nut sheet, the work permit system offers one of the best methods to meat all the
conditions required for making a hazardous operation safe and easy to perform.
TYPES OF PERMIT: -
Depending on the type of industry and the hazardous operation carried out, various types
of permits have been developed to suit the individual industry. However the most
commonly used permits are: -
(A) Fire permit/Hot work permit.
(Any work involving open flame in the more hazardous area or equipment
caring hazardous materials)
(B) Safe entry permit/Vessel entry permit/Confined space permit.
(C) Excavation permit
(D) Electrical work permit
(E) Acid/Alkali/Chemical work permit
(F) Safe work permit/Work at height permit
Permits are used by supervisors having proprietary responsibility of areas and
equipments. It is generally issued on the name of a supervisor who is to carry out the
required job under the known hazard condition.

WHAT SHOULD A PERMIT TO WORK CONTAIN: -

A permit to work contains written information/s and instruction/s pertaining to hazards
that are to be avoided in a particular operation. It indicates that all hazards have been
considered in advance and foreseeable appropriate precautionary measures have been
taken. People responsible to execute a job defined in the permit are to review them from
the point of compliance. In other wards, a permit is a written consent of the plant in
charge that guarantees proper and safe conditions where personnel can work safely by
complying with the instructions of the permit. Similarly it also indicate that the people
executing the job have reviewed the permit and accepted responsibilities adhering to the
instructions and limitations stipulated. Thus a permit finally becomes a document of
consent by both parties such as the plant in charge and job executer.
1. Fire/Hot Work Permit: - Fire/hot work permits are issued to authorize to work
with open flames or other work like grinding, chiseling etc, which release sparks
in such areas and equipments where hot work under normal condition is
considered to be dangerous. Usually a hot/fire permit will be necessary to carry
out hot work in, on or around: -
(a) No smoking areas.
(b) Equipments and pipelines with hydrocarbon crevice.
(c) Rubber lined equipments.
(d) Equipments and pipelines with acid crevice.
It will be the responsibility of the operating department for making the area or
equipment (where hot work is intended to be carried out) free from fire hazard
and explosion. Therefore, before a hot work permit is issued, generally the
following points are given auto most consideration: -
(a) The equipment/ area and the surrounding must be tested to determine the
explosive range. This can be achieved by an explosive meter or taking air
samples and testing at laboratory. In case of presence of explosive mixture in
the air no hot work will be permitted till such time the area is made free of
explosive content by cleaning, ventilating, purging etc.
(b) All pits, sumps openings, pumps etc in the vicinity are must be covered with fire
proof materials to prevent sparks entering and causing explosion and fire.
(c) The area and the surrounding are sufficiently wetted to facilitate extinguishment
of sparks, hot slages etc as they fall.
(d) Adequate first aid fire fighting to be kept readily available for use in case of
need.
In the crew caring out the repair the repair work do not know how to operate
the fire fighting equipment, hence man with fire fighting knowledge are to be
made available at the work spot during the repair work.
2. Safe Entry/Vessel Entry Permit: - (Confined Space Permit) Under the
provision of Factory Act no person shall be permitted to enter in to a space
classified as a confined space, unless and until all measures have been taken to
 make the equipment/vessel adequately safe for working. The act also stipulates
that a written certificate has to be given by the competent person stating that the
space is made free of all hazards and is fit for persons entering. Usually the
supervisor having the control over the equipment/vessel to issue a safe enter
permit and authorize entry and work in on and around a confined space. Before
issuing such a permit, it will be his responsibility: -
(a) To isolate the equipment/vessel from all source so that no energy or stock or
harmful substance can get introduced.
(b) To drain, clean, wash and purge the equipment/vessel to make it free from
toxic gases and other harmful substances.
(c) To test the air inside the vessel to determine the presence of explosive
mixture, oxygen content etc. Incase of presence of explosive mixture or
deficiency of oxygen, it should be further ventilated till such time the
explosive mixture is removed or the oxygen content increased to a minimum
level of at least 16% (safe level is 19%)
CAUTION: -
(1) To increase the oxygen in air in coffined space using oxygen from a cylinder
shall never be attempted. In case of deficiency in oxygen which can not be
improved up on an entry in to the vessel/equipment should be strictly
restricted by the uses of adequate birthing apparatus and uses of birthing
apparatus should also be restricted to self contend birthing apparatus or a
supplied air line respirator.
(2) As far as practicable two openings on the equipment/vessel should be kept
open for cross ventilation. After ensuring all the above points the operating
supervisor should prepare adequate number of safe entry permits and display
at each point of entry. If any other precautions to be taken for entry should be
clearly specified on the permit. Persons entering in to the equipment/vessel
that has been declared as safe to enter by executing safe entry permit, must
read the safe entry permit carefully and strictly obey and comply with all the
instructions detailed there on the safe entry permit. Where reading by the
concern becomes a problem suitable singes may be used.
Vibration as a health hazard: - Operators who operate pneumatic tools such as
fettling, rebating hammers and also those who operate heavy duty vehicles often
experience the effect of vibration which is transmitted to them by those tools. Vibration
may be of two types: -
1. Whole body vibration: - In which vibration effects are felt on the entire
body through supporting surfaces such as, vehicle seat etc. Workers
working near the blowers in a power plant turbine hall and those who
working and dealing with dumper and dozer are exposed to such
vibration.
2. Segmental or local vibration: - In which a portion of the body exposed to
vibration. Vibration in this case is mainly transmitted by hands and arms.
As in the case of workers using drills, pneumatic hammers etc. Also
workers working in Foundry, Patten making, Fettling, Ramming, Forging
shop and mines etc.
Health hazards: - Exposure to vibration not only irritates and damages body tissues but
also affects central nervous system.

Exposure to high level whole body vibration may result in: -

 Frequent and violent headache.
 Reduces work performance.
 Increases physical weakness.
 Back pain
 Change in bone structure.
 Damage to internal organs.
 Loss of hearing.
 Increase in O2 consumption.
 Increase heart rate.
Exposure to segmental or local vibration may result in: -
 Hand arm vibration syndrome.
 Persistence numbness & tingling of fingers.
 Swelling of fingers.
 Whitening/blanching of fingers.
 Tied ness and muscular pain in hands after work.
 Lake of sleep. (sleep less ness)
 Excessive sweating of palms.
 Change in bones of elbow joints.
Health & Safety Measures to be taken: -
 Tools which are light to handle & have reduced vibration level to be used.
 Old & excessive vibrating machine pats to be replaced.
 Inspection, adjustment and oiling of machines & equipments to be done
regularly.
 All the machine parts to be suitably tightened.
 Use of automated & remote control machines to be introduced.
 Always self massage of arms, legs and warm up of body is necessary before
starting of work.
 Use of personal protective equipments like hand gloves & ear muff is must.
 Short rest brakes in between work schedule to limit exposure to vibration to be
followed. Rest to be taken at quite surroundings.
 All work sites should be equipped with hot water tapes & hot drinks.
 Where ever possible inter departmental rotation of workers exposed to vibration
may be done.
 Workers to be trained and instructed in adopting working methods which will
minimize the effect of vibration.
 Regular medical examination to be done.