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MODULE 3

Syllabus: Plant safety, Elements off Industrial safety- Causes and prevention of accidents – Pollution
and environmental consideration.

Need of Plant Safety

• Accident-Accidents can be defined as any occurrence that interferes with the orderly progress
of activity.
• These accidents are the main reason for the direct and indirect losses of an industry.
• Thus the main objective of Plant Safety is to reduce these accidents.

Causes of Industrial accidents

 The main reasons for industrial accidents are:

 Unsafe physical condition: Inadequate ventilation, broken guards, unsafe clothing.
 Unsafe acts: Working at unsafe speed, not using safety devices, improper tools
 Personal Factors: Lack of knowledge, physical weakness, age, health.

Safety measures while setting new plants

• Plant Location: Selection of plot from the point of view of safety is necessary. Geographical
and natural advantages should be considered
• Process Design: Physiochemical and thermodynamic properties of the process elements are to
be considered from the point of view of safety. Fail safe process routes are very necessary
• Equipment and structure design: MOC of equipment should be properly chosen. Equipments
have to be designed to withstand overload and high level parameters so that they do not cause
accidents.

Fire hazard

Causes of fire hazard:

1. Leakages

2. Hot jobs

3. Short Circuiting

4. Electrical Sparks

5. Static Electricity and Friction

Explosion hazard

This causes greater damage and loss of property as compared to fire hazard.
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Common Causes:

1. External use of energy

2. Internal exothermic reaction

3. Result of sudden release of internal energy

4. Dust explosion

5. Salt bath explosion

Toxic hazard

Hazards caused due to exposure of toxic chemicals is called toxic hazards.

Common Causes:

1. Ingestion

2. Inhalation

3. Contact with skin

4. Contact with eyes

Essential Elements for a Successful Health and Safety

Hazard Recognition, Evaluation, and Control

This element is key to any health and safety program. When asked, most people on the street would say
is this is what a safety program is all about. This involves proactive hazard recognition in terms of
environment (the surroundings of the workers), the people actually doing the work, equipment/materials
used in the work process, and processes/practices themselves. A formal “Job Hazard Analysis” assists
with the process and is integral to many of the other elements listed below. In the lab, as part of the
Chemical Hygiene Plan, standard operating procedures (SOPs) are a product of this element. Once
hazards have been identified and prioritized they must be controlled. The generally accepted hierarchy
of controls is elimination/substitution, engineering controls, personal protective equipment, and
administrative controls.

Workplace Design and Engineering

We often see failure in this aspect when we are called in to solve a problem. Designing safety into a
workplace is as important as designing in efficiency (and these often go hand in hand). Some of this is
already done by building code (e.g., electrical standards, fire suppression, and egress requirements)
but other aspects must be consciously addressed such as ergonomics, ventilation, and noise
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requirements for the anticipated work at hand, equipment and machine safeguarding, materials
handling and storage, use of automated processes, and added reserve capacity.

Safety Performance Management

This can be thought of as the measurable actions of employees in relation to safety in their work.
Performance measurement should reflect how workers (management and workers alike) are actually
doing compared to applicable regulatory requirements and identified corporate goals. This should
include a system of accountability for meeting those standards within their control.

Regulatory Compliance Management

Animal care facilities must meet OSHA, EPA, DOT, and often accreditation agency specific
standards. Non-compliance can have serious ramifications in terms of financial liability (penalties and
fines), institutional reputation, and in some cases the ability to continue operations. It is very
important to have a mechanism for staying informed and complying with existing regulations and
standards. It is also very important to keep abreast of new or evolving regulations that will impact
your operations. A self-assessment or assessment conducted by an outside party is a good tool for
determining level of compliance.

Occupational Health
The nature and scope of an occupational health program can vary widely from company to company.
Often in animal care settings one might expect pre-employment health evaluations, periodic medical
surveillance, injury protocols (including first aid and bite/scratch procedures) and maintenance of
medical records, and coordination with the departments when work related health and safety issues
arise. One might typically find coordination of respiratory protection and hearing conservation
programs within the Occupational Health component of a program.

Information Collection

Information is the lifeblood for proper decision making. Equally important to collection of information
is its subsequent management. We have seen situations where important information had been collected
but never analyzed nor distributed to those with a need. Much of the safety and health information
collected must be managed properly to maintain regulatory compliance.

Employee Involvement
Employee involvement in all aspects of a safety and health program benefits both the employees and
management. The front line employees have experienced and seen issues and problems that might not
otherwise be recognized by management. It also serves as a bridge of understanding for actions taken
by the employer in terms of health and safety.
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Motivation, Behavior, and Attitudes

The goal of this element is to change behavior and attitude to promote a safer and healthier workplace.
It places great value on visible management leadership and support for changing unsafe behaviors,
attitudes, and work processes. One additional key component is the reinforcement of the desired
behaviors through positive recognition.

Training and Orientation

Training can assume a variety of forms from classroom style to hands-on, from general concepts to task
specific. Besides the need for safety training from a regulatory standpoint it is critical that employees
know what to do to perform their jobs correctly and safely.

Organizational Communications

Communication within the organization keeps employees informed of new and existing policies,
procedures, lessons learned, and missions. Likewise it provides avenues from the front line to upper
management for consideration in the development and revision of those polices. The flow of
information in both directions is critical for an effective health and safety program.

Management and Control of External Exposures

This might be considered incident or emergency planning. Plans need to be developed for emergencies
such as severe weather, incidents stemming from contractor or “neighbourhood incidents,” and
manmade issues such as protestors or activists.

Environmental Management

Environmental management is a broad and complex enough issue that it requires a program of its own.
Often there is overlap of duties and as such, environmental management is grouped under the health
and safety program umbrella. Issues from proper permitting to preventing potential environmental
liability are considered in this element.

Workplace Planning and Staffing

in providing an effective safety and health program effective human resource management is critical. It
includes development of accurate job descriptions to take into consideration job duties (such as
respirator use or hearing protection use, manual material handling, exposure to allergens) that may
trigger the need for pre-employment evaluations and medical surveillance. Limiting exposures by
administrative controls or other safety considerations (e.g. tasks requiring two people) and development
of safety rules would both be considered in this element.

Assessments, Audits, and Evaluations

This final set of tools provides a measure for how an organization is doing in terms of health and
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safety. These are used to monitor compliance, behaviors, and provide a yardstick for discerning
progress. A variety of tools are required to address these needs. These can be performed by in-house
staff, committees, as part of a job task, or with outside consultants. The assessment results serve as a
springboard for improvement.

We have just skimmed the surface. With this discussion we hoped to provide you with a starting point
for review of your own program, to identify any holes, and to provide a catalyst to move forward. This
approach fits well with many of the process improvement models that organizations have adopted. This
may not cause you to lose unwanted pounds, or make you rich without effort, but it will help those you
work with return home each night in as good condition as they arrived at work that morning.

SAFETY MANAGEMENT SYSTEM

Safety management systems have six elements:

 a safety plan;

 policies, procedures and processes;

 training and induction;

 monitoring;

 supervision; and

 reporting.

A safety management system combines all the different elements in your workplace that need attention
to ensure you provide a safe working environment for everyone who enters it.

Safety management systems make health and safety an integral part of your business’s core operations.
By designing, developing and implementing an effective safety management system, you will have
methods for managing reporting, responsibilities, planning and resourcing to create a safer

1. Safety plan

A safety plan is a strategic action plan that forms part of the business plan. It analyses the current and
prospective risk for a company and charts how the risks will be eradicated and controlled over a
calendar period (the safety plan must have a budget).

This plan will ensure that there is a governance structure within your company that ensures every worker
clearly understands their safety obligations (and how to comply) and is accountable to carry out those
obligations.
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2. Policies, procedures and processes

Policies, procedures and processes include all safety paper infrastructures within your company. This
paperwork will describe all safety behaviour, expectations, record-keeping, incident reporting, and
incident notification documentation.

3. Training and induction

Depending on the nature of your workplace (whether it is low-risk or high-risk), everyone who enters
your workplace should receive training on:

 the rules of your company;

 the rules of the site; and

 the rules of the location they are visiting.

The training content will depend on the level of risk the person is exposed to.

4. Monitoring

Your obligations to monitor your workplace depend on circumstances and need. Always consider the
level of risk. The higher the risk, the more frequent and detailed the monitoring needs to be.

Other times when monitoring will be necessary include:

 to ensure that all risk has been covered by a new risk assessment that has been carried out due
to a change in process, e.g. the installation of new workstations; and

 when an investigation takes place following an incident.

5. Supervision

The only way to ensure your workers are carrying out their safety obligations is to have adequate
supervision.

The level of supervision required in your workplace will increase if the level of safety control put in
place to reduce a risk is low, i.e. the less effective the control measure used, the higher the level of
supervision necessary.

6. Reporting

The governance structure of your company needs safety reporting at all levels, not just at board level.
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Causes and prevention of accidents

The workplace can be dangerous, even more so in an industrial environment. Numerous factors can
cause accidents, ranging from overexertion to mishandling of hazardous materials. There are also a
multitude of variables that can contribute to or influence a workplace incident. Following are eight of
the most common causes of accidents in the workplace:

Lifting

Many employees are prone to sprain, strain or tear a muscle by virtue of lifting an object that is too
heavy for them to lift on their own. Keep in mind that there is no harm in asking for help with objects
that are difficult to lift.

Fatigue

Failing to take a break is another common cause of accidents. In order to recover from grueling manual
labor, it is essential that employees take adequate breaks. Not doing so can lead to a slew of physical
issues, including atrophy and general exhaustion. The results of either of these can be far more
devastating than taking a 10-minute breather.

Dehydration

Not staying hydrated can also bring about disastrous consequences. On exceptionally hot summer days,
failing to drink adequate amounts of water can cause heat stroke or cardiac conditions. This can be
avoided by simply drinking at least eight glasses of water per day. Management should stress the
importance of proper hydration and rest, as it maximizes the efforts of personnel.

Poor Lighting

Inadequate lighting is responsible for a number of accidents each year. This is often overlooked when
attempting to prevent accidents in the warehouse or workplace.

Hazardous Materials

Improper handling of hazardous materials or not wearing personal protective equipment (PPE) is
another common cause of accidents in the workplace. By reading material safety data sheets
and providing the appropriate protective attire, many workplace incidents can be avoided.

Acts of Workplace Violence

Sadly, violence among co-workers has become all too common. It is usually brought about by office
politics or other sensitive issues. Integrating conflict resolution and peer mediation can help to reduce
the risks of such outbursts.

Trips and Falls

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Slick floors and high-traffic corridors can cause a trip or fall. Improper footwear may also contribute to
these accidents, which not only can result in injuries but also workman’s compensation-related cases.

Stress

Stress is one of the leading causes of death. It affects the human body in every facet imaginable. Stress
can foster negative effects physiologically, emotionally and mentally, as well as debilitate or distract
any worker. Therefore, it is essential to encourage a supportive team environment.

PREVENTION

1. Slips, Trips and Falls

Slip, trips and falls account for 1/3rd of all personal injuries in the workplace and are a top cause of
workers’ compensation claims. The types of injuries incurred from slips, trips and falls include head
and back injuries, broken bones, cuts and lacerations, sprains and pulled muscles.

The most common reasons for falls in the workplace are:

 Slips-- Wet or oily surfaces, occasional spills, weather hazards, loose rugs or mats and flooring
that lacks the appropriate degree of traction.

 Trips-- Obstructed view, poor lighting, clutter, wrinkled carpeting, uncovered cables, uneven
walking surfaces and bottom drawers not being closed.

There are three keys to preventing workplace accidents due to slips, trips and falls: good housekeeping,
quality walking surfaces and proper footwear. Beyond that, employees should be reminded to take their
time and pay attention to where they are going. They should also be encouraged to report areas where
clutter, obstruction, spillage or damage have occurred.

2. Being Caught In Or Struck By Moving Machinery

Machinery that’s not properly guarded is a potentially grisly safety hazard. When body parts get
caught in or struck by exposed moving parts or flying objects from machines without protective
guards, the results are often disastrous. The long and horrifying list of machinery-related injuries
includes crushed hands and arms, severed fingers, blindness and worse.
Most mechanical hazards occur in these three places:

 The Point of Operation-- Where work is performed on the material: cutting, shaping, boring
or forming of stock.

 Power Transmission Apparatus-- Components of the mechanical system transmitting energy

to the part of the machine performing the work: flywheels, pulleys, belts, connecting rods,
couplings, cams, spindles, chains, cranks and gears.
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 Other Moving Parts-- All parts of the machine that move while the machine is working:
reciprocating, rotating and transverse moving parts, feed mechanisms and auxiliary parts of the
machine.

The golden rule in preventing mechanical hazards is to remember that any machine part, function or
process that may cause injury must be safeguarded. Also, existing hazards must be controlled or
eliminated and proper operator training and protective clothing must be provided.

3. Transportation And Vehicle-Related Accidents

Where there is equipment, vehicles and large trucks, there’s the potential for vehicle-related accidents.
These accidents include being struck or run over by a moving vehicle, falling from a vehicle, being
struck by objects falling from a vehicle and getting crushed by or stuck under an overturned vehicle.
Vehicle-related accidents are the most common cause of fatal injuries in the agriculture industry, but
they can be equally catastrophic in industrial or manufacturing environments as well.
There are two distinct kinds of vehicle-related accidents.

 On The Road-- Workers can be injured or killed after being struck by a vehicle while repairing
roads or other work in traffic zones.

 In The Workplace --Operators of vehicles and equipment can be injured or cause injury to
pedestrians.

Avoiding workplace transportation accidents begins with assessing who is at risk, as well as where and
when these accidents most commonly occur. Only then are prevention measures, such as vehicle/worker
orientation and safe systems of work, more easily established. You should focus on workplace design,
ensuring layout routes always segregate pedestrians and vehicles and make any obstructions clearly
visible. Directions, speed limit and priority signs are also helpful.

4. Fire And Explosions

Unexpected explosions and fires in the workplace are frequently caused by risk factors such as faulty
gas lines, poor pipefitting, improperly stored combustible materials or open flames. The resulting
injuries incurred include damage to the respiratory system, varying degrees of burns and potential
disfigurement. Explosions and fires account for 3% of workplace injuries and have the highest casualty
rate of all probable workplace accidents.

There are four types of injuries commonly associated with fires and explosions:

 Primary Blast Injuries-- Occurs due to the effects of pressure on body tissues, affecting ears,
lungs and the GI tract.
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 Secondary Blast Injuries-- Occurs when flying objects strike nearby workers.

 Tertiary Blast Injuries-- High-energy explosions can lift someone off the ground and cause
them to fly into surrounding objects.

 Quaternary Blast Injuries-- Everything else that happens as a result of an explosion: crush
injuries, burns and inhalation of toxic substances.

5. Overexertion And Repetitive Stress Injuries

Although more subtle than a catastrophic explosion, musculoskeletal disorders are the most costly
workplace injuries. Complaints of back pain alone cost employers an estimated $7.4 billion annually
and lead to 100 million lost workdays annually. These kinds of injuries contribute to loss of
productivity, millions in direct costs and millions in annual health benefit payout costs.
RSIs (Repetitive Stress Injuries) are the fasting growing category of workplace injury and comprise
more than 100 different types of job-induced injuries from wear and tear on the body. Both overexertion
and RSIs are severe enough to inhibit simple activities with crippling and debilitating pain, not to
mention severe impairment of movement. They may even eventually permanently impair a worker’s
ability to perform his or her job.

Causes of overexertion and RSIs, include:

 Improper Lifting-- Bending at the waist instead of at the knees when carrying or moving heavy
objects.

 Manually Lifting Heavy Objects --Especially objects weighing over 50 pounds, without the
assistance of a co-worker or lifting device (manual or mechanical).

 No Breaks --With repetitive work, short breaks should be required, or the work may eventually
result in too much wear and tear on the body.

 Speeding Up the Line --Automation has created work conditions that are faster and often
reduced to limited, repetitive tasks.

 Intensive Keying --Constant typing and clicking strains muscles and tendons.
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POLLUTION AND ENVIRONMENTAL CONSIDERATION

With the coming of the Industrial Revolution, humans were able to advance further into the 21st century.
Technology developed rapidly, science became advanced and the manufacturing age came into view.
With all of these came one more effect, industrial pollution. Earlier, industries were small factories that
produced smoke as the main pollutant.

However, since the number of factories were limited and worked only a certain number of hours a day,
the levels of pollution did not grow significantly. But when these factories became full scale industries
and manufacturing units, the issue of industrial pollution started to take on more importance.

Any form of pollution that can trace its immediate source to industrial practices is known as industrial
pollution. Most of the pollution on the planet can be traced back to industries of some kind. In fact, the
issue of industrial pollution has taken on grave importance for agencies trying to fight
against environmental degradation. Countries facing sudden and rapid growth of such industries are
finding it to be a serious problem which has to be brought under control immediately.

Industrial pollution takes on many faces. It contaminates many sources of drinking water, releases
unwanted toxins into the air and reduces the quality of soil all over the world. Major environmental
disasters have been caused due to industrial mishaps, which have yet to be brought under control. Below
are few of the causes of industrial pollution that have resulted in environment degradation.

Pollution is the introduction of contaminants into the natural environment that cause adverse change.
Pollution can take the form of chemical substances or energy, such as noise, heat or light. Pollutants,
the components of pollution, can be either foreign substances/energies or naturally occurring
contaminants. Pollution is often classed as point source or nonpoint source pollution. In 2015, pollution
killed 9 million people in the world.

Major forms of pollution include: Air pollution, light pollution, littering, noise pollution, plastic
pollution, soil contamination, radioactive contamination, thermal pollution, visual pollution, water
pollution.

The major forms of pollution are listed below along with the particular contaminant relevant to each of
them:

 Air pollution: the release of chemicals and particulates into the atmosphere. Common gaseous
pollutants include carbon monoxide, sulfur dioxide, chlorofluorocarbons (CFCs) and nitrogen
oxides produced by industry and motor vehicles. Photochemical ozone and smog are created as
nitrogen oxides and hydrocarbons react to sunlight. Particulate matter, or fine dust is
characterized by their micrometre size PM10to PM2.5.

 Light pollution: includes light trespass, over-illumination and astronomical interference.

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 Littering: the criminal throwing of inappropriate man-made objects, unremoved, onto public
and private properties.

 Noise pollution: which encompasses roadway noise, aircraft noise, industrial noise as well as
high-intensity sonar.

 Plastic pollution: involves the accumulation of plastic products and microplastics in the
environment that adversely affects wildlife, wildlife habitat, or humans.

 Soil contamination occurs when chemicals are released by spill or underground leakage.
Among the most significant soil contaminants are hydrocarbons, heavy
metals, MTBE, herbicides, pesticides and chlorinated hydrocarbons.

 Radioactive contamination, resulting from 20th century activities in atomic physics, such as
nuclear power generation and nuclear weapons research, manufacture and deployment.
(See alpha emitters and actinides in the environment.)

 Thermal pollution, is a temperature change in natural water bodies caused by human influence,
such as use of water as coolant in a power plant.

 Visual pollution, which can refer to the presence of overhead power lines, motorway billboards,
scarred landforms (as from strip mining), open storage of trash, municipal solid waste or space
debris.

 Water pollution, by the discharge of wastewater from commercial and industrial

waste (intentionally or through spills) into surface waters; discharges of untreated
domestic sewage, and chemical contaminants, such as chlorine, from treated sewage; release
of waste and contaminants into surface runoff flowing to surface waters (including urban
runoff and agricultural runoff, which may contain chemical fertilizers and pesticides; also
including human feces from open defecation – still a major problem in many developing
countries); groundwater pollution from waste disposal and leaching into the ground, including
from pit latrines and septic tanks; eutrophication and littering.

Causes of Industrial Pollution

1. Lack of Policies to Control Pollution: Lack of effective policies and poor enforcement drive
allowed many industries to bypass laws made by pollution control board which resulted in mass scale
pollution that affected lives of many people.
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2. Unplanned Industrial Growth: In most industrial townships, unplanned growth took place wherein
those companies flouted rules and norms and polluted the environment with both air and water
pollution.

3. Use of Outdated Technologies: Most industries still rely on old technologies to produce products
that generate large amount of waste. To avoid high cost and expenditure, many companies still make
use of traditional technologies to produce high end products.

4. Presence of Large Number of Small Scale Industries: Many small scale industries and factories
that don’t have enough capital and rely on government grants to run their day-to-day businesses often
escape environment regulations and release large amount of toxic gases in the atmosphere.

5. Inefficient Waste Disposal: Water pollution and soil pollution are often caused directly due to
inefficiency in disposal of waste. Long term exposure to polluted air and water causes chronic health
problems, making the issue of industrial pollution into a severe one. It also lowers the air quality in
surrounding areas which causes many respiratory disorders.

6. Leaching of Resources From Our Natural World: Industries do require large amount of raw
material to make them into finished products. This requires extraction of minerals from beneath the
earth. The extracted minerals can cause soil pollution when spilled on the earth. Leaks from vessels can
cause oil spills that may prove harmful for marine life.

Effects of Industrial Pollution

1. Water Pollution: The effects of industrial pollution are far reaching and liable to affect the eco-
system for many years to come. Most industries require large amounts of water for their work. When
involved in a series of processes, the water comes into contact with heavy metals, harmful chemicals,
radioactive waste and even organic sludge.

These are either dumped into open oceans or rivers. As a result, many of our water sources have high
amount of industrial waste in them which seriously impacts the health of our eco-system. The same
water is then used by farmers for irrigation purpose which affects the quality of food that is produced.

Water pollution has already rendered many ground water resources useless for humans and wildlife. It
can at best be recycled for further usage in industries.

2. Soil Pollution: Soil pollution is creating problems in agriculture and destroying local vegetation. It
also causes chronic health issues to the people that come in contact with such soil on a daily basis.
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3. Air Pollution: Air pollution has led to a steep increase in various illnesses and it continues to affect
us on a daily basis. With so many small, mid and large scale industries coming up, air pollution has
taken toll on the health of the people and the environment.

4. Wildlife Extinction: By and large, the issue of industrial pollution shows us that it causes natural
rhythms and patterns to fail, meaning that the wildlife is getting affected in a severe manner. Habitats
are being lost, species are becoming extinct and it is harder for the environment to recover from each
natural disaster. Major industrial accidents like oil spills, fires, leak of radioactive material and damage
to property are harder to clean-up as they have a higher impact in a shorter span of time.

5. Global Warming: With the rise in industrial pollution, global warming has been increasing at a
steady pace. Smoke and greenhouse gases are being released by industries into the air which causes
increase in global warming. Melting of glaciers, extinction of polar beers, floods, tsunamis, hurricanes
are few of the effects of global warming.

The issue of industrial pollution concerns every nation on the planet. As a result, many steps have
been taken to seek permanent solutions to the problem. Better technology is being developed for
disposal of waste and recycling as much polluted water in the industries as possible. Organic methods
are being used to clean the water and soil, such as using microbes that naturally uses heavy metals and
waste as feed. Policies are being pushed into place to prevent further misuse of land. However, industrial
pollution is still rampant and will take many years to be brought under control.