Terms used: Accident, Safety, Hazard, Safe, Safety devices, safety guard, security, precaution,

caution, appliance, slip, trip, fall

Ladders and scaffolding, unsafe acts, reason for accidents, MSDS (material safety data sheet),
OSHA, WHO
Lockout and tag out procedure. Safe material handling

Accident:

It is defined as any unplanned event that result in injury or ill health of people or damage or loss
of property, materials or the environment or loss of business opportunity.
Accident may occur due to
1. Human error caused due to UNSAFE practice, loaf of foresight, wrong
attitude etc.
2. Mechanical failure: Ten percent accidents caused due to plant
condition, equipment or tool failure
3. Acts of Nature: Two percent accidents occur due to weather, food or cyclone
4. Accident can be classified based on magnitude of danger of life and property
1. Minor 2. Moderate 3. Major 4. Disaster

 Accident classification based on principle cause and effect

i. Fire and explosion

ii. Electrical accident

iii. Chemical accident and explosives

iv. Accidents with machines, plants, tools

 v. Falling of objects on body

vi. Falling of persons in pits or from height

vii. Natural disasters

Why do accidents occur?

Accident occur due to the following factors

i. Lack of risk awareness

ii. Lack of knowledge on the activity being undertaken

iii. Lack of safety aspects in design

iv. Lack of commitment to safety

v. Lack of control

vi. Lack of education, training and motivation

vii. Lack of teamwork and safety culture

viii. Lack of discipline

ix. Failure to learn from past experiences of similar incidents

x. Lack of continuous efforts in training employees

xi. Failure to employ competent and well trained people

xii. No efforts to prevent hazards by employing safer designs or by adopting control methods.

Types and causes of accident:

i. Combustible material ignition by heat: it’s principle course is spark, flame electric spark,
flash over, insulation failure rapid energy conversions.

ii. Weak construction: overload, vibrations, and mechanical failures.

iii. Overstress: material failure, impact, over pressure, ageing part failure.

iv. Flash over’s or shocks, explosions in electrical equipment: encroachment in high field
zone, abnormal condition implants, over voltage, over heating of electrical
plants/equipment.

Classification of Accident based on different criteria.

a) According to causes of events:

1. Machine accident: Machines are responsible for a large number of accidents in industry.
Depending on the way harm is caused, accident from machines can be classified inn to
following groups.

 Contact: physical contact of the body with ay moving part or machine.

 Impact: parts of the body are violently hit by moving parts of machines.

 Traps: parts of body caning between morning parts which mostly lead to rushing
of body trapped.

 Ejection of particles: parts projection at very high velocity from the machine,
which cause serious injury when they hit the parts of moving body.

b) Non-Machine accident.

 Fall of person from a height which can be due to

i. Hack of firm foot hold or unsafe postures.

ii. Working on a machine at a height.

iii. Leaning on a ladder or from it to reach a distant object.

iv. Strike against the object.

v. Pushes on the other persons on the slop.

 Fall of persons which can be due to

 i. Tripping over obstacles on ground.
ii. Slipping due to oily or greasy substances.
iii. Running inside the shop, sudden fean or excitement.
c) According to length of recovery:
 Lost time accident: lost time accident are those I which worker loses a day or shift
in which accident occurred. These require payment compensation from employer
to employee.
 Home-case accident: In this type of accident, worker loses the remaining of the
shift on twin on which the accident has occurred.
 First aid cases: in this, workers receive first aid attention at plant a hospital and
then return to their job.

d) According to nature of injury:

 Fatal accidents: In which the worker or more are killed.

 Permanent disablement: which incapacitate an employee and make it
impossible for him to engage in any work, which was capable of performing at
the time of the accident.
 Temporary disablement: this reduces the earning capacity of an individual in
the employment.

Safety:

The condition or situation of being protected from danger, risk, loss, accidents or damage.

Safety is freedom from accidents? Or can be achieved by reduction of accidents? Or is it all

about compliance of legal requirements? Safety can be achieved by obeying all safety rules of
the work place. Failure to do so should result in strict action.

In an industry all injuries must be reported as soon as possible. No horseplay, alcohol, or drugs
should be allowed in work premises. All tools/equipment must be maintained in good condition.
For performing specific jobs only appropriate tools should be used. All guards must be kept in
place. No spliced electrical cords/wiring allowed. Only authorized personnel can operate forklift
vehicles. Seat belt use required of all drivers/passengers. Smoking during work should be strictly
prohibited and should be allowed to do in separate room.

The utilization of advisory groups (committees) empowers the greatest advantage to be acquired
from employee’s functional experience and information, and in addition facilitating shared trust
and certainty through the moves made to enhance Safety.

Regular communication channels can be reinforced by the establishment of safety committee is

to provide a formal mechanism for consultation among employees on safety matters the safety
committee should support but not be a substitute for, the communication among management
and employees for individual and line management responsibilities to safety.

Safety committee is should operate at different levels in an enterprise and consists of

1. Employees at various levels

2. Managers with the authority to implement the committee’s recommendations

3. Safety Specialists

4. Contractors

Requirements of a safety committee

1. Safety committee members should receive safety training and specialist advise as necessary

2. Safety representatives can be established at a plant level safety representatives, nominated by

employees, represent those employees in consultation with the management on matters relating
to safety. They should be given specific training related to their role.

3. Resources should be available to safety committee for undertaking its activities

4. Safety committee members should not lose any earnings from time spent in activities related
to safety committee

5. Management should act upon the recommendations of the safety committee, recognizing that
the ultimate responsibility for safety remains with the management.
Safety Networks and interface

Safety Interface

 Safety management and safety precautions are necessary at every stage ( design of plant
and equipment), manufacture of equipment and components , testing, dispatch, site
contractors work ( erection/testing/commissioning) Operation and Maintenance of
industrial plants / equipments.

Safety Act and it's provisions

 1. Factories act 1948 was passed to regulate labour employment in factories. This act is
labour welfare legislation in factories, intended for benefit of work law care is to force on
April 1st 1949.

2. The act contains provisions to health, safety, welfare, working hours and level of workers
and Employment of young persons in factories.

Its objectives are

1. To protect labor employed in factories from unduly long hours of manual labour or
bodily strain.

2. To provide for health and sanitary conditions.

3. To take precautions for the safety of workers.

4. To maintain effective supervision by the state government by appointment of inspecting

staff for factories

Employees state insurance act 1948

i. It was passed in 1948 in order to provide welfare facilities to industrial workers through
of agency.
ii. It is compulsory and contributory health insurance scheme.
iii. Employee’s state insurance scheme (ESIS) provides medical benefits I the form of
medical attendance, treatment, drugs, injections to insured person and to member of their
families.
iv. ESI act is applicable to all factors employing 20 or more workers.
v. Workers whose remuneration does not exceed rupees 3000/month are covered by the
scheme.
vi. Its amendment act came by 1989.
vii. ESIS is administered by employees state insurance corporation (ESIC)
viii. It has a governing body of 42 persons representing union and state government, the
parliament employees and employee’s organization and medical professional.
Benefits include
i. Sickness benefit, medical benefit, marketing benefits, displacement benefit, dependent’s
benefit, funeral benefit.
Workmen’s compensation ac:(1943)
i. It was passed in 1943 providing pavement for compensation of occupational diseases
arising out of and during course of employment resulting in death or disablement.
ii. The object of this act is to impose obligation on employers to pay compensation to
workers for accident arising out of and in the course of employment.
iii. This act prescribes separate scales of compensation for those employed in hazardous
occupation except those who are covered under ESI act 1948.
Summary of work by safety Department:
1. Developing and implementing “the company safety plan”
i. Formulating complete plan.
ii. Implementing the plan and co-coordinating the implementation work.
iii. Setting up safety regulation and enforcing.
2. Inspection to locate unsafe condition or safe regulations.
(a) Very unsafe (b) unsafe (c) safe.
3. Organizing first aid facilities.
4. Organizing worker’s insurance.
5. Organizing safety audit and implanting emendators.
6. Formulate safety procedures and documentation.
7. Formulating procedures of accident investigation, investigating injuries.
8. Ensuring corrective actions are taken to avoid recurrences.
9. Maintaining work injury and illness records.
10. Organizing worker’s compensation and resettlement.
11. Analyzing cases, records for clues to prevention of future injuries and illness.
12. Safety facility planning and follow up.
13. Making health studies to discover and correct unhealthy situations
14. Consulting with government agencies.
15. Acting as advisor to other department and top management on safety matter.
16. Publicizing safety requirement, procedures and importance.
 17. Supervising the procurement and distribution of personal protective equipment.
18. Checking companies’ competency with central, state and statutory local regulations on
safety and health.
19. Checking on or aiding in HRD in safety.

Safety Audit:
i. It is the process that identifies unsafe conditions and unsafe acts in the plant and
recommends safety improvement.
ii. Safety auditing is effective tool with safety management for identifying weak spots and
planning corrective actions.
There are three types of safety audit:
1. Walk through safety audit.
2. Intermediate safety audit.
3. Comprehensive safety audit.

Walk through safety audit:

a) Least expensive audit.

b) Evaluates unsafe conditions noticeable to naked eye.
c) During walk through the plant with keen observation from safety view.
d) These are tasked, discussed and commitment for their dissolving is taking from time
supervisors.
e) During construction phase walk through audits may be correct out for stories, civil works
and erection works, documentation commission works security requirement are also
audited.
f) During operation and maintenance safety auditors observe the process, unsafe acts and
unsafe conditions.
g) Audit reports and recommendation are submitted to plant manager and safety manager
for taking corrective actions to eliminate unsafe conditions. Team includes
1. Safety manager 2.safety consultant 3.insurance inspector
4. Electrical inspector 5.manger-civil/electron/commissioning/operation-maintenance.
 h) Entire plant, its stores, documents, procedures are requirement interview are conducted,
observations are noted, report is submitted.
Intermediate safety audit:
a) It involves more detailed study and review of plant design.
b) Detailed measurement of high risk zone are conducted.
c) Tests may be conduct’s on unsafe condition/equipments.
d) Intermediate audit identifies weakness in plant design, equipment and subsystems and
operation/maintenance procedures and improvements are suggested.
Comprehensive Safety Audit:
a) It is a full scale audit that evaluates safety factors in the plant on the basis of engineering,
analysis, testing, measurement, module analysis etc.
b) It consists of the following
i. Envelope audit: covers civil works, switchyard, electrical plant auxiliaries, stores,
offices, canteen, ventilation system, security arrangements lighting etc.
ii. Functional audit: this covers organizational weakness, training requirements
clarity of responsibilities and delegation and documentation.
iii. Safety facility audit: the unsafe condition and acts are tested, it reviews those
condition of high risk and existing safety facilities visa-versa recommended
safety facilities for high risk medium risk and low risk zones

Recommendation: Unsafe conditions are noted, corrective actions and improvements are
recommended. Unsafe condition and unsafe acts observed are subjected to ABC analysis(A:high
risk, B:moderate risk, C:low Risk)Attention is processed on A&B categories.

Management response: safety audit is a powerful tool available to the management to take
action in right directions.

Work permit system:

For performing any work in the plant by any person other than the operating personal of that
area, a duly authorized written permit should be obtained by the person executing the works
before commencement of the work. Permits should be in printed form, serially numbered and
different color code may be adopted for different types of permits. Permit insuring authority
should satisfy him that permit condition are met before issuing permit. It is also to be ensured
that permit conditions are maintained in course of execution of work.

After completion of job, permits should be returned to concerned department. Records are to be
maintains for a month time. Example of permit to work (PTW).

OFFICE OF XX ORGANISATION ,XXX PLANT ,XXX(PLACE)

PTW No:____________________Date:__________________ Key No:__________

Permission is here by given to permit to work_____________________________

Name:__________________________________________________________________
_

Organization:__________________________________________________

For work on:________________________________________

Plant:________________________________________________________

Zone:____________________________________________________

Equipment:_________________________________________________________

Purpose:____________________________________________________________

On Date:________________________________From Time_________HRS___________

Onwards Till Date:____________________________________________________

Injury and causes:
The equipment has been isolated, made eached, and can be worked upon safety.
Cause can be unsafe physical conditions and unsafe personal acts. Unsafe physical conditions are
Safety key No:_______________is being issued to above person. Above person should
due to presence of defects in conditions, error in design, faulty planning or mission of essential
return the safety key and work permit after work completion signature (Authoring party)
safety requirement for maintaining a relatively hazard free physical environment. Unsafe
CC=Manager(operation)____________________Dt____________________________
personal acts are those types of behaviors that lead to injuries due to listing of common unsafe
Acknowledgement:
acts (working Name/Sign_________Dt____________________
unsafely, removing of safety devices, operating at unsafe aped and failure to use
safe Received
attire etc).PTW No.Organisation:_______________________
An injury report should be prepared after occurrences as it is required by insurance depart
for settlement of compensation it should include.
a) Time of injury
b) Specific space
 c) Name of injured person identification(card) number
d) Location of injury (head and so on).
e) Severity of injury
f) Names of witness.
Unsafe Acts:
 Accident does not just happen:-Accident are the reality unsafe acts or unsafe condition.
 Unsafe acts which cause majority of accident includes the following:
i. Operating without authority or warning such as closing switches, operating values
without authority and proper line up.
ii. Operating or working unsafe such as driving too fast throwing tools or materials
at other workers etc.
iii. Making safety devices inoperative: such as using oversize furs, blocking safety
values etc.
iv. Using unsafe equipment or using equipment improperly such as using dull cutting
equipment, wrenches not designed for them etc.
v. Unsafe loading, placing or missing such as overloading cranes and witches,
carrying too heavy load, leaving object where they are likely to fall.
vi. Acquiring unsafe position or positive such as waiting under suspended loads.
vii. Working on dangerous equipment such as cleaning, oiling or adjusting moving
machinery.
viii. Distracting, teasing, starting such as practical jacking.
ix. Failure of use of personal protection equipment (PPE).
x. Use of ring dim fingers, carrying metallic pen.
xi. Use of loose instead of correct fit.

Unsafe Condition:

i. Accident due to pitfalls in trench, escalations.

ii. Fall of person from height due to negligence.
iii. Accident due to failure of cranes slings and ropes.
iv. Falling of object on human body.
v. Collapse of structures, wall and stars due to improper construction.
 vi. Electric shocks due to facility wiring.
vii. Equipment failure.
viii. Lightning strokes.
ix. Flashovers.
x. Unsafe equipment.
xi. Not providing case for rotating or moving machine parts.
xii. Not removing oil or water from the floor after spillage, thereby making the floor slippery.

Hazard: A Hazard is a potential source of harm or adverse health effect on a person or person.
The terms Hazard and Risk are often used interchangeably but this simple example explains the
difference between the two.

If there was a spill of water in a room then that water would present a slipping hazard to persons
passing through it. If access to that area was prevented by a physical barrier then the hazard
would remain though the risk would be minimized.

Risk: Risk is the likelihood that a person may be harmed or suffers adverse health effects if
exposed to a hazard. The level of risk is often categorized upon the potential harm or adverse
health effect that the hazard may cause the number of times persons are exposed and the number
of persons exposed. For example exposure to airborne asbestos fibers will always be classified as
high because a single exposure may cause potentially fatal lung disease, whereas the risk
associated with using a display screen for a short period could be considered to be very low as
the potential harm or adverse health effects are minimal.
Hazard Recognition:
It is aimed at the study of accident process and attempts to find accident symptoms. Hazard
index can be developed by recognizing the hazard and predicting it’s criticality in terms of
degree of injury, number of workers likely to be involved. A Hazard is any agent that can come
horn of damage to Life, health, property or the environment. An event that is calmed by
interaction with hazard is called incident. Identification of hazard is the first stop I performing a
risk assessment.
To identify hazard three basic question may be asked a) is there a source of harm!
b) who(or that) could be harmed! c) How could harm occur!
Broad catagoration of hazard.
1. Mechanical
2. Electrical
3. Fire and explosion
4. Toxic release
During the work activity could the following hazard exists (some specific example)
1. Slips or fall on the level
2. fall of person from a height
3. fall of cools or materials from height
4. Hazard associated with manual lifting/hand ling of tools
5. Hazard from plant and machinery associate assembly, commissioning operation,
maintenance etc.
6. Fire/explosion
7. Inhalation of toxic substances
8. Harmful energies(electrify/heat/noise etc)
9. Slippery/haven ground or levels.
Prepare action control plans
1. If possible eliminate hazards.
2. If it is not possible, take necessary preventive measures to reduce impact of hazard.
3. Take measures that protected everyone.
4. Strict implement of safety apparels.

Classification of hazards:

Type of hazards to which a worker is exposed is the basis of selection of the right type of
respiratory protective equipments. Hazards may be classified as under.
 Oxygen Deficiency: Atmosphere in confined space such as tanks, holds of the ships etc.
may container, that is having oxygen content much less than normal (25% by volume).
 This may be due to displacement or dilution of air by other gases or vapor or because loss
of oxygen due to decay of organic matter chemical, reaction, and natural oxidation over a
long period of line.
  Person breathing as the air less than 16 %of oxygen content may exhibit symptoms such
as increased rate of breathing acceleration of pulse rate to unconsciousness and death.
 Such oxygen deficiency can be detected as the flame of safety lamp will be extinguished
in such atmosphere. The protective equipment should provide normal air or oxygen.

Gaseous Contaminants: Toxic or inert gases toxic producer harmful effect, the inert gases
produces undesirable effects by displacing oxygen term gases include vapor of volatile
substance.

 Gaseous contaminants immediately dangerous to life: These are contaminants that could
endanger a personal life of in hated for a short time. Where it is not possible to determine
the extent of concentration or the kind of gas is not known as gases to be considered as
“immediately dangerous to life”.

 Gaseous contaminants not immediately dangerous to life: These are present in

concentration that could be breathed by a person for a short time without endangering his
life, but which may possible make an injury after a prolonged single exposure or repeated
short exposure.
 Particulate contaminants: (Dust, fumes, smoke, mist, fog)
 Toxic particulate contaminants: These when inhaled may crate chemical irritation
systematic poisoning on allergic reactions. Common among them are asbestos, coal
bursitis free silica.
i. Fibrosis Producing Dusts: they do not pass into blood but remain in lungs and
may cause pulmonary impairment.
ii. Nuisance Dusts: dissolve and pass directly to blood stream or may remain in
lungs either producing systematic or local effect.

Electrical Hazards

 Electricity is used for driver, heating, Melting illumination, and control/Protection. Large
consumers take LT supply from Supply Company where as small industries take LT
supply.
 Electric voltage above EOV is dangerous, hazard caused by electricity are tested below.
Incidence/condition Effect

Person touches live conductors Electric shock

Person touches faulted structure or any Electric shock

metal part

Person touches faulted equipment enclosure Electric shock

Person places ladder or metal rod hear live Electric shock, flashover fault
conductor

Person carries metal rod/tool in clearance Electric shock, flashover

zone.

Person touches Pre charged capacitor or Electric shock

conductor

Person using tool cuts in situation of live Electric shock, fault, fire
wire

Expulsion of porcelain enclosed equipment. Injury, fire-oil filled equipment destruction

Unearthed rotating equipment body Electric shock

Loose contacts leads to sparking, Melting equipment failure and faults

and faults

Faults in power cable due to Overhead cable burst fire

insulation failure, over voltage

Electron potential through used parts Leakages aren’t through watts metal walls,
metal parts.

Causes Preventive Measures

1. ->Live wire was exposed and -> Provide in saluting or earthed metallic
 accessible
->Person was allowed to enter in the
clearance zone
->person touched live conductor
->Conductor was isolated but hot
discharged.
2. Structure/equipment was not earthed
and earth fault was not detected by
protection system.
3. ->Person was allowed to take ladder
to switch yard.
->fence and lock was not provided
for switch yard.
->the person was not aware of the
danger because electricity in barber
is invisible
->supervisor asked person to place
ladder elsewhere.
4. Capacitor was not discharged after
connection
->capacitor was accessible
->person was not aware.
enclosure to conductor or use sleeve or
cable.
->enclose area by fence with lock.
->Switch off and earth before touching.
->install earthing system and earth the
structure./other metal bodies.
->improve protection
->provide fence, lock and permit system
for entry after making installation
‘DEAD’.
->place danger plate/caution notice.
->Train person for safety.
->enforce safety management.
-> Capacitor unit should have internal
discharge resistor parallel to terminal
leads.
-> Capacitor should be placed on structure
with ground clearance.
-> Person should be trained for
discharging.
5. Underground cable was without -> provide RCC stab over power cable.
protective RCC stab.
-> Place caution signs at regular intervals.
->Danger signs not provided.
-> Provide safety belt to climber.

-> Provide earthling to structure.

6. -> safety belt was not used. -> provide safety belt climber.
->structure became live due to
->provide earthling to structure.
flashover/induced current.

7. -> Rotating parts not provide with ->Provide cover

protective cover/fence.
->Provide fence.

8. ->Leakage through equipment ->improve protection system.

insulation not detected.
->earth equipment body.
->sparking/arcing in
equipment/connected parts ->person should wear safety shoes.

->person should avoid touching

equipment body.

9. ->Loose contact, sparing last ->Contact should be repaired during

strength, misalignment periodic maintenance.

10. ->Fault in power cable due to ->Replace/Repair cable

moisture, aeging of insulation, partial
->Remove root cause after investigation.
discharge, over healing, voltage
surge, mechanical weakness
11. ->Conductors melted, sparking ->Protection against over current, under
cause, burning of cable. Insulation voltage to detect cable faults and stop
and spreading of fire. power.
 ->Remove inflammable material from
vicinity.

Hazard Identification:
If Hazard is identified, chances of accidents can be minimized. Hazard is a workplace condition
which exists or can be caused in combination with other variable which has potential for
accident, serious injuries, and disease or property damage.

Hazard identification analysis is very careful study of all components of a work system in order
to detect problems, to understand problems and the relationship between the system and the
problem in order to eliminate the problems and its potential consequence.

There are several methods for problem identification, each having its own contribution for
specific task and hazard analysis, most commonly used methods are.
i. Preliminary hazard analysis as more information becomes available. It focuses on what
already know about the product, process or change to be made.
ii. Failure mode and effect analysis: It is adopted for safety analysis from reliability analysis
of complex system.
 System is broken down into all its components and systematic evaluation of how
components might fail, and what effects of their failure might be, is done.
 This analysis requires criticality rating for each failure mode depending on degree
of hazard posed by the failure.
iii. Hazard and operability Reviews: (HAZOP): Adopted widely chemical plants to identify
operating problems, HAZOP uses brain storming techniques, encouraging involvement
and innovation, and generate ideas for solutions.
iv. Fault tree analysis’ deductive reasoning technique which assumes an undesirable extent
and proceeds in a logical manner to examine extents or combination of events which
must precede the occurrence of the top event.
 It provides a graphic model that displays the various combinations of equipment
faults and /or failures that can cause the top event.
 v. Failure mode, effects and criticality Analysis (FMECA): It is an extending FMECA, it is
a bottom up, inductive analytical method which may be performed at either the functional
or piece par level.
 FMECA extends FMECA by including a criticality analysis which is used to chart
the probability of failure modes against the severity of their consequences.

Safety guards
Types of guards:

Fixed guard– provides a barrier between a person and the point of opera, power train or other
moving parts. These include fences, gates, and protective covers for blades, presses and all
moving parts.

Interlocked guard – when opened or removed disengage the machine’s power source. It cannot
be restarted until the guard is replaced.

Adjustable guard – provide a barrier that can be adjusted to many different operations, such as
varying sizes of stock.

Self-adjusting guard – barriers that move or self-adjust, according to the size or position of the
workplace. The guard returns to its resting position when no material is passing through.

Affix guards to the machine where possible or secure it elsewhere if for any reason attachment to
the machine is not possible. The guard shall be such that it does not offer an accident hazard in
itself. Point of operation is the area on a machine where work is actually performed upon the
material being processed. The point of operation of machines whose operation exposes an
employee to injury shall be guarded. The guarding device shall conform with any appropriate
standards. If no specific standard exists then the design and construction of the guard will
prevent the operator from having any part of his body in the danger zone during the operating
cycle

The following are some examples of machines requiring point of operation guarding:

i. Guillotine cutters
ii. Shears
iii. Alligator shears
 iv. Power presses
v. Milling machines
vi. Power saws
vii. Jointers
viii. Portable power tools
ix. Forming rolls and calendars
Revolving drums, barrels, and containers shall be guarded by an enclosure that is interlocked
with the drive mechanism so the barrel, drum or container cannot revolve unless the guard
enclosure is in place. When the periphery of the blades of a fan Is less than seven feet above the
floor or working level, the blades shall be guarded. The guard shall have openings not larger than
one-half inch.

Machines designed for a fixed location shall be securely anchored to prevent walking or moving.

Simple Rules to Maximize Worker Safety

1. Always be sure that moving mechanisms are clear of people and objects
2. Be sure that workers are not wearing any jewelry or loose clothing that could get snagged
in the machine
3. Keep an eye on overheard moving parts, like pulleys, for potential hazards
4. Check that guards are in place at all points where you could contact moving parts before
turning the machine on
5. Be aware of how to turn power on and off if you should have to do so quickly
6. Read the manufacturer’s instructions on how to operate the machine safely and correctly
7. Feed material into the machine with push sticks, not your hands
8. Take it easy. Rushing through a job is one of the major causes of accidents
9. Make sure maintenance is performed when required. If you think your equipment might
have missed its scheduled maintenance let your supervisor know.
10. Use lockout/tag out procedures when a machine needs repair or maintenance. Turn the
machine and the power to the machine off and tag it so that no one tries to use it.
TRIPS, SLIPS AND FALLS

Falls and slips from elevations, inclusive of those into pit, or on the same level occur in all
industries, in all occupations and in all work settings from the ironworker connecting steel
columns 200 feet in the air to the laborer washing windows from a suspended scaffold 60 feet
from the ground to the stock clerk retrieving goods from a shelf using a 4 foot step ladder.
One of the more serious and potentially deadly hazards are falls from elevators. however falls
and slips on the same level are equally injurious though not equally severe to result in facility,
fall prevention measures can be general, varied, specific or elaborate and the recognition,
planning and implementation of sound fall-prevention programme is the first step in reducing
falls in the workplace, when fall hazards are recognized, provisions to reduce the hazards can be
developed, implemented and reinforced on a timely basis to prevent death and injuries.
For the purpose of this section, falls from ladders and scaffolding or from building or other
structures and falls from one level to other will be discussed.
The management of a company can develop, implement and enforce a comprehensive written
fall protection programme. The programme should include, but not be limited to the following
points.
1. Addressing all the aspects of safety and hazards in the planning phase of projects
2. Identifying all fall hazards at the work-site
3. Training employees in the recognition and avoidance of unsafe conditions and the
regulations to control or eliminate the hazards applicable to their work environment. Fall
protection training is recommended to include classroom instruction supplemented by
hand-on training with equipment. Training should commence at the time of appointment
of new employees who will be exposed to fall hazards and continue periodically
thereafter. Workers can be involved in identifying task that creates fall hazards and
 methods used to eliminate these hazards. Employee participation and acceptance is
crucial to implementing an effective fall-protection programme, as is true for all training
programmers.
4. A job hazard analysis for each task to be performed.
5. Providing appropriate fall-protection equipment, training workers on its proper use,
enforcing its use under strict supervision and conducting a daily inspection.
6. Conduction scheduled and unscheduled safety inspections of the worksite.
7. Addressing
a. Environmental conditions,
b. Multi-lingual differences and
c. Alternative methods/equipment to perform assigned tasks
8. Establishment of medical and rescue programmes.
9. Encouraging workers to actively participate in workplace safety.

Fall protection equipment is very specific in its application, and great care should be taken in
choosing the correct system for the application intended in accordance with industry standards or
guidelines on specific worker needs. The manufacturer’s instructions for correct use and
maintenance have to be followed explicitly or injuries and fatalities can result. Compatibility of a
fall-protection system’s components is crucial. It should be realized that not all components are
interchangeable.
OSHA regulations require employers to provide workers who are exposed to fall hazards of over
6 feet (In India over 10 feet (3 meters)) with adequate fall protection, which may involve the
installation of either fall-prevention systems or personal fall-arrest systems.

Fall-protection programme
Ladders
Safety features that have been provided in some ladders are slip-resistant rungs or steps,
positioning feet that fully articulate and top and bottom stabilizers. Fixed ladders typically have a
glide-rail system through the middle that egresses while using a full body harness with a glide
lock attached to a chest D-Ring. Other fixed ladders have caging systems which are a less
effective tool for fall protection. Some important factors to be considered before using or
climbing a ladder are placement, securing or typing, climbing and descending style, angle of
inclination, three-point contact and tasks to be performed.
Factors that contribute to falls from ladders are ladder slips (from top or bottom), overreaching
slipping on rungs or steps, defective equipment and improper ladder selection from a given task.
Every worker should be knowledgeable of the following when using ladders.
Prior to using a ladder, workers should visually inspect it for structural damage, such as
split/bent side rails, broken or missing rings/steps/cleats, missing or damaged safety devices,
such as rung locks, lock spreaders or safety shoes/ feet/spurs/spikes, grease, dirt or other
contaminants that could cause slips or falls and paint or stickers (except warning labels) that
could hide possible defects.
Damaged ladders should be: tagged or marked for repair, replacement or destruction.

Climbing Guidelines

1. Wear slip-resistant footwear

2. Keep the area around the top and bottom of the ladder clear
3. Wear approved fall-protection equipment where applicable.
4. Never carry large objects while ascending or descending a ladder
5. Uses a host or pulley mechanism to move heavy, large/awkward objects up to the
working level or down to the ground.
6. Place the ladder and maintain three point contact ( Two hands and one foot or one hand
two feet on the ladder) at all times.
7. Do not load ladders beyond the maximum intended load for which they were built, nor
beyond the manufacturer's rated capacity. Use ladders only for the purpose for which
they were designed.

2.3 Portable Ladders

Classifications (1) Self-supporting ( step ladders ) and

(2) Non-self supporting (straight or extension ladders)

Important factors in choosing between the two is the bottom (working surface) and top support
conditions.
2.4 Fixed ladders
1. Should be used at a pitch no greater than 90 degree from the horizontal, as measured to
the rear of the ladder.
2. Each step or rung should be capable of supporting a single concentrated load of at least
250 lb (114 kg) applied in the middle of the step or rung.
3. The rungs or steps of fixed metal ladders should be corrugated, knurled, dimpled, and
coated with skid-resistant material.
4. Cages, wells, ladder-safety devices or self-retracting lifelines should be provided to fixed
ladders where the length of climb the equals or exceeds 24 ft.(8m)
CASE STUDY 1: Fall from Height

On the 13th of April 2017 one of the Facility Management Company employee fell from 3.5m
building when descending a ladder from the balcony working on site. The IP received multiple
Injuries including a broken foot and stitches to his head.

What Went Wrong?

1. Normal access to the roof was to enter the villa and access the 1st floor balcony where the team
would use a 8ft ladder with a stabiliser to access the roof. The resident complained that her child
was sleeping in the balcony room. As it was the last job before the weekend, the team took the
decision to access the balcony from outside the villa using a 16ft ladder. This was against
company standing instructions as the risk assessment had shown that the ladders cannot be
secured and there was a high probability that someone may fall.
2. The IP was not wearing his PPE correctly, his safety boot laces were tied but the backs had
been crushed and the IP had ‘Slipped’ them on. He was also not wearing a hard hat chin strap.

3. Behaviour: The team decided to knowingly deviate from the safe working method when they
knew they should have rescheduled the appointment.

Safety comes first, follow the rules, they are there for a good reason

ACTION REQUIRED

1. Business Safety Stand Down - Recommunicate the ban on the use of long ladders without
Ladder Stabilisers.
2. Review working at height risk assessments and method statements.
3. Re-train all those who work at height, this will include the use of Ladder Stabilisers.
4. Re-educate all employees on the PPE Requirements (This includes how to tie shoe laces).
5. IMS to complete cross-site Working at Height audits.
Case Study 2: Risk of Explosion from Maintenance Free Batteries

On the 30th March 2017 an emergency generator battery exploded during a routine Generator
test run.

1. The likely cause of the explosion was due to the batteries age, in environments where the
ambient temperature is over 250C, a maintenance free batteries life is reduced
significantly.
2. During normal operation & charging, maintenance free batteries produce an explosive
cocktail of hydrogen and oxygen which is held in the head space of the batteries above
the electrolyte, this builds up over time. Temperatures above 25oC produce more
hydrogen and increase the evaporation rate of the batteries electrolyte.
3. Maintenance free batteries are sealed and the built-up gas cannot be fully vented.
4. This gas can be then be ignited by a spark from a damaged battery, corroded or loose
connections or from damaged plates within the batteries.

ACTION REQUIRED

1. In climates over 250C, it is recommended to change maintenance free batteries every 2

years.
2. During maintenance inspections, check that batteries terminals are clean and the
connectors are firmly secured.
3. Check the electrolyte level indicator and check for signs of battery damage.
4. Where excess gas has built up, the battery may visibly ‘bulge’. Replace these batteries
immediately.
5. When starting machinery that uses maintenance free batteries, make sure everyone is
shielded from the battery or stands a safe distance away.
6. Always wear safety glasses when working on or near maintenance free batteries.
CASE STUDY 3: ELECTRICAL NEAR MISS

After obtaining the appropriate authorisation, an Electrical Supervisor entered a switch room
each door of the live electrical panels had a notice on it which said, “Test Before You Touch”.
The supervisor complied with this, and using his test meter checked all 3 bus-bars, one of which
registered 415 volts. Touching the live bus-bar would have resulted in severe burns/shock and
death.

The investigation revealed that there was a malfunction within the bus-bar feeder switch
panel in that the outer switch handle did not correspond to the position of the inner (actual)
switch which was in fact “on”. (The outer switch was locked in the “off” position). The two
switches were joined by a rod which, in this case, appears to have been too short to properly join
the two switches together. This is being taken up with the switch panel supplier. Refer to
Diagram 1 below to check whether it was safe for another contractor to work there, in
accordance with procedures. In the room were three banks of exposed bus-bars. Their covers had
not been fixed in position over the bus-bars due to cabling work associated with their installation
not being completed.

Action Required:

1. The “Test before you Touch” poster must be displayed in all electrical switch rooms
where there is potentially live apparatus.
2. All switches must be checked to ensure that the inner and outer switches are linked and
that the external handle can be felt to activate the inner switch.
3. This must be done before energizing of any part of the panel takes place.
4. The circumstances of this incident along with the importance of the advice in the “test
before you touch” poster are discussed with anyone working with electricity on sites,
particularly testing and commission teams.
 5. CASE STUDY 4: CHEMICAL BURN FROM DRAIN REPAIR

A maintenance team was asked to help clear a blocked sink on site

1. The team had to cut the sink drainage PVC pipe to remove the blockage
2. On cutting the pipe, the liquid trapped inside the pipe splashed onto the technicians arm
causing minor burns
What Went Wrong?

1. Noticed initially there was a commercially available drain unblocker was used to try and
clear the pipe.
2. The IP was unaware of the risk so failed to wear appropriate PPE e.g. Rubber Gloves
3. Always question and verify and ensure you understand all the issues at hand and the
actions previously take.
4. If a chemical has been used, make sure you understand all the relevant safety details of
the chemical by reading the label or get a copy of the MSDS.
5. If in doubt, wear PPE to be sure of your safety. Re-educate all employees on the PPE
Requirements (i.e. face mask, chemical coveralls, full sleeves rubber hand gloves &
Safety shoes) as mentioned in MSDS (if available).
CASE STUDY 5: ARC FLASH ACCIDENT

On the 18th of October 2016, a electrical flash occurred whilst technician was working on an
electrical panel at a sewage pumping station within Emirates Hills, the subcontractor employee
was completing electrical testing following a breakdown of the panel. While replacing the
ECLB, the ELCB’s wires came into contact with each other causing an arc flash. The IP
sustained burn injuries to both hands and to his face.

What Went Wrong?

1. WMS and RA were not properly briefed to the team prior to start of the task.
2. PTW was issued without proper assessment and checks.
3. Team failed to isolate the power from the main panel prior to starting the task and the
LOTO process was not followed.
4. Lack of planning and ineffective front line supervision.
5. Inadequate illumination of the task.
6. Appropriate PPE was mentioned on the Risk Assessment but not worn by the IP.

Action required:

ACTION REQUIRED

1. This Learning Bulletin to briefed business wide.

2. Site team to ensure that tasks are planned and the WMS/ RA briefed to all concerned
parties.
3. Site operations team to ensure that the adequate task lighting is in place.
 4. Site team must ensure that the power supply is isolated and proven dead before work
starts.
5. LOTO procedure shall follow when working with energised systems.
6. Site team to ensure that the appropriate PPEs are used by the employees.

A Electrical Arc Flash incident was reported on the 21st November 2016 at The site contract
when a technician (IP) was completing a scheduled Preventive maintenance on a low voltage
Sub-main distribution Board. The distribution Board flashed when the metal part of a paint brush
technician was using for cleaning came into contact with the live Distribution Board wiring.
Technician sustained 2nd degree burn injuries.

What Went Wrong

1. The Electrical PTW was issued after the incident and LOTO procedure was not followed
2. The power was not isolated prior to start of the task despite the supervisors instructions to
do so
3. IP was not wearing appropriate PPE (electrical gloves)
4. Their was a lack of Supervision when the Task was being carried out
5. The incorrect tool was used for the task, a paint brush used instead of a air blower
6. IP ignored his supervisors instructions.

Actions required: REQUIRED

1. This Learning Bulletin to briefed business wide

2. Site team to ensure that tasks are planned and the WMS/ RA briefed to all concerned
parties
3. Site operations team to ensure that the adequate task lighting is in place
4. Site team must ensure that the power supply is isolated and proven dead before work
starts
5. LOTO procedure shall followed when working with energised systems
6. Site team to ensure that the appropriate PPEs are used by the employees.
 7. CASE STUDY 6: EMPLOYEE WAS RUN-OVER BY A VEHICLE

On the 10th of November 2016, a employee was run over while he slept During his lunch break
in the shade of an company mini-bus.

1. The driver was sleeping in the drivers seat of the minibus, when he woke up he realised
he had over slept and was late for his duties, he quickly started up the vehicle and moved
it forward, in the process running over his colleague.
2. The injured person very luckily survived the accident however he sustained serious
injuries to his chest, knee and collarbone. He is very fortunate to be alive!

What Went Wrong

1. The injured person was resting in an unauthorised location. No person may rest under or
near to any vehicle or plant, this includes trailers.
2. The driver failed to check his vehicle and the surrounding area, as required by company,
prior to starting and moving the vehicle.

ACTION REQUIRED

1. Remind everyone of the dangers of resting in unauthorised places

2. Remind everyone that a 360o check of any company vehicle, or privately owned vehicle
driven while at work, must be completed prior to starting it.
Abbreviations used above

IP- Injured Person

PPE- Personal Protection Equipment

IMS- Infrastructure management system

MSDS- Material Safety Data Sheet

LOTO- Log Out Tag Out

ECLB- Electrical Contractor Licencesing Board

ELCB- Earth Leakage Circuit Breaker

WMS- Workflow Management System

RA-Risk Assessment

PTW- Permit To Work