17ME662 - INDUSTRIAL SAFETY 1

MODULE-1
INTRODUCTION TO SAFETY
WHAT IS INDUSTRIAL SAFETY?
Industrial safety is primarily a management activity which is concerned with:

 Reducing
 Controlling
 Eliminating the hazards in industries or industrial units

Objectives of Industrial Safety:

 To prevent accidents in the plant by reducing the hazards to the minimum
 To eliminate accident causing work stoppage and lost production
 To achieve lower workmen compensation, reduced insurance tariff and all other direct and indirect
cost of accidents
 To prevent loss of life, permanent disability and loss of income of workers by eliminating all causes
of accidents
 To enhance morale of employees by promoting safe work place and better working environment
 To educate all members of the organisation in continuous state of safety minded and to make
supervision and intensely safety minded.

DEFINITIONS/ TERMINOLOGIES RELATING TO SAFETY:

ACCIDENT: An unintended, unpleasant, unexpected, unforeseen occurrence arising out of and in the
course of employment of a person resulting in injury, loss, damage etc.,
DANGER: A thing or a situation which may cause injury, loss, damage, accident etc. Such a thing or
situation is dangerous or risky.
DEATH: Fatality resulting from an accident.
HAZARD: To expose to danger, risk, chance of accident.
HAZARDOUS: Dangerous, risky, accident prone.
SAFETY: A Quality or condition of being safe from danger, injury, damage, loss, accident.
SAFETY DEVICES: Devices which ensures safety against injury or loss. E.g: Safety belts, safety glasses,
safety earthing, safety enclosure, safety fence.
PERSONAL PROTECTIVE EQUIPMENT (PPE): Protective devices when used properly, designed to
reduce or eliminate injuries to a worker.
SAFE GUARD: Any person or thing or devices that prevents injury, loss, and to ensure safety and security.
DISABLING INJURY (LOST TIME INJURY): An injury causing disablement extending beyond the day
of shift on which the accident occurred.
NON DISABLING INJURY: An injury which requires medical treatment only, without causing any
disablement whether of temporary or permanent nature.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 2

ACCIDENT:
Definition: Dictionary meaning of “Accident‟ is an unexpected event or mishap. It is defined as an event
that is not expected, intended or imagined. It refers the event not the result of the effect.
An accident is unintended, unplanned event or its sequence caused by unsafe condition(s) or/and unsafe
act(s) and may result in immediate or delayed undesirable effects.

CAUSES OF ACCIDENTS:
1. Unsafe Physical/Mechanical/Environmental conditions (10%)
These consists of factors present due to defects in operating conditions, errors in design, faulty planning or
omission of essential safety requirements, Improper maintenance, poor house keeping, wrong operating
procedure etc. for maintaining a relatively hazard free environment.

 Inadequate illumination
 Poor ventilation
 Inadequate PPE
 Intense noise
 Lack of adequate guards or safety devices
 Lack of warning system
 Poor communication of hazard
 Defective tools and equipment
 Presence of dust, fumes, chemicals or toxic materials
 Unsafe floor surfaces
 Unsafe piling, stacking and storing of materials
 Improper disposal of waste
 Lack of first aid

2. Unsafe Acts or Practices (88%)

This is any illegal action taken by employees in an industry that can cause accident. This type of behaviour
are usually contrary to the company’s rules and regulation and acceptable standard safety practice.

 Unauthorized operation or use of equipment

 Use of defective tools and equipment
 Improper use of tools and equipment.
 Operating tools or equipment at unsafe speed
 Poor house keeping (untidy work environment).
 Removing or by passing safety devices.
 Riding hazardous moving equipment
 Failure to warn or signal as required.
 Standing in an unsafe place or taking an unsafe posture
 Indulging in horseplay
 Failure to wear PPE
 Improper dressing
 Performing unauthorized procedures

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 3

3. Unsafe Personal Factor (2%)

 Unsafe improper attitudes

 Lack of knowledge or skill
 Bodily defects (Faulty vision, poor hearing, BP, convulsions etc)
 Mental State (Worry and stress, Nervousness, Fatigue, Dullness, Slow reaction etc.)
 Lack of concentration
 Taking chances

Five 'E's of Accident Prevention

1. Education & Training (To prevent unsafe acts)
2. Engineering controls (to prevent unsafe conditions)
3. Enforcement (of safety rules)
4. Enthusiasm (to maintain interest)
5. Example setting (to lead for safety)

HAZARD:
Definition: A hazard is any source of potential damage, harm or adverse health effects on something or
someone under certain conditions at work.
"Condition, event, or circumstance that could lead to or contribute to an unplanned or undesirable event."

TYPES OF HAZARD:
PHYSICAL CHEMICAL BIOLOGICAL ERGONOMICS
 Noise  Explosives  Biological wastes  Physical:
 Vibration  Flammable liquids (blood, fluids, etc.) o Prolonged sitting
 Radiation  Corrosives  Drugs (antibiotics & o Poor layout
 Temperature  Oxidizing materials others) o Poor posture
 Pressure, Velocity  Toxic, carcinogenic  Viruses, bacteria o Improper lifting,
 Height substances  Parasites, insects handling
 Electricity  Gases and air  Poisonous or  Environmental:
 Physical particulate diseased plants, o Poor lighting
characteristics animals o Poor ventilation
o Poor temperature
control
o Poor humidity
control
 Psycho-Social:
o Work rest cycles
o Violence
o Discrimination
o Extraneous stress
o Un even work load
o Poor inter staff
relationships

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 4

Examples of Hazard and their effects:

Workplace Hazard Example of Hazard Example of Harm Caused

Thing Knife Cut
Substance Benzene Leukaemia
Source of Energy Electricity Shock, electrocution
Condition Wet floor Slips, falls
Process Welding Metal fume fever
Practice Hard rock mining Silicosis

SLIP, TRIP & FALL:

SLIP:
Definition: Too little friction or traction between feet (footwear) & walking/working surface, resulting in
loss of balance.
Some common causes of slips are:

 Spills
 Hazards created from weather (e.g., puddles, ice)
 Surfaces that are wet or oily
 Loose rugs or mats
 Flooring or other walking surfaces that do not have same degree of traction in all areas

TRIP:
Definition: Trips happen when your foot collides (strikes, hits) an object causing you to lose the balance
and, eventually fall. Stepping down to lower surface & losing balance.
Common causes of tripping are:

 Clutter on the floor (e.g., power cords, boxes)

 Poor lighting
 Uneven walking surfaces (e.g., carpeting, steps, thresholds)
 Sudden change in slip resistance properties of walking surfaces

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 5

 Electrical cords or cables

FALL:
Definition: A fall can be the result of a slip or a trip where your centre of gravity is shifted causing you to
lose your balance. Preventive measures should be taken to avoid slips and trips.
Two types of Fall are:

 Fall at same level - Fall to same walking or working surface, or fall into or against objects above
same surface
 Fall to lower level - Fall to level below walking or working surface

How to avoid Slip, Trip & Fall?

 Identifying all fall hazards at the work site
 Reduce Wet or Slippery Surfaces
 Create and Maintain Proper Lighting
 Regular cleaning and clearing off loose materials, grease, oil, dirt, sand particles, water accumulation
and other contaminants.
 Create a house keeping policy and ensure its implementation
 Create committees for identification of hazards, analysis, recommendations for improvements and
execution of the recommendations
 Training of employees regularly with respect to hazards of Slip, trip and fall and behavioural safety
 Enforcing use of proper PPE like slip resistant foot wears, safety belts
 Usage of Pictograms (hazard warning pictogram)

LADDERS & SCAFFOLDING:

LADDERS:
Definition: A ladder is a vertical or inclined set of rungs or steps.

The main risks associated with work at height:

 The worker falling from height: this accounts for largest percentage of annual fatalities in the workplace.
This can result in,
 Fatalities
 Neck or spinal injury leading to permanent disability or paralysis
 Multiple fractures
 An object falling from height onto someone below : can cause severe injuries that may result in,
 Death
 Brain damage

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 6

 Paralysis
 Multiple fractures
 The distance (vertical distance) of a fall is not always the deciding factor in the cause of injuries.

Ladder Safety Rules:

 Select the correct ladder for the task.
 Use proper lifting and carrying techniques while transporting ladders.
 Watch for overhead obstructions and power lines (keep a minimum of 10’ from power lines).
 Inspect for physical defects before use. Make sure labels are present and legible.
 Ladders are not to be painted except for numbering purposes.
 Do not move or shift a ladder while a person or equipment is on the ladder.
 Do not use ladders for skids, braces, workbenches, or any purpose other than climbing.
 When you are ascending or descending a ladder, do not carry objects that will prevent you from
grasping the ladder with both hands.
 Always face the ladder when ascending and descending.
 If you must place a ladder in front of a doorway, barricade the door to prevent its use and post a
warning sign.
 Only one person is allowed on a ladder at a time.
 Do not jump from a ladder when descending.
 All joints between steps, rungs, and side rails must be tight.
 Rungs must be free of grease and/or oil.
 Do not place the top of a ladder against a window or an uneven surface.
 Have someone steady near the ladder if it cannot be secured otherwise
 Use fiberglass (nonconductive) ladder if you must work near electrical sources.
 Never over reach when working from a ladder. Keep your body between the rails at all times

Safety Climbing Guidelines While Using Ladders:

 All ladders must be securely placed, held, tied, or otherwise made secure to prevent slipping or
falling.
 Avoid placing the ladder at an angle which is too extreme. The distance between the bottom of the
ladder and the supporting point must be approximately one fourth of the ladder length.
 A ladder shall be used when performing overhead work that cannot be safely performed from floor
level. Do not stand on boxes, chairs, desks, bookcases, radiators, or makeshift supports.
 Ladders should not be placed in front of doors or directly around any corner without proper warning
signs in each approaching walkway.
 Only one person can be on the ladder at one time. If two employees are required, a second ladder
must be used. Never splice two ladders together to form a longer one. Never use ladders as scaffold
platforms.
 The maximum height a person should climb on the ladder is the third step from the top. Make sure
stepladder legs are fully spread while in use. When working on a step ladder over ten feet high (With
the exception of a platform ladder), the ladder must be held by another person.
 When ascending or descending ladders, use both hands (free of other objects) and face the ladder.
When dismounting from a ladder at an elevated position (as at a roof), make sure that the ladder side
rails extend at least three feet above the dismount position, or that grab bars are present.
 Do not place hand tools on a ladder at any time. Carry all hand tools in an appropriate holster.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 7

SCAFFOLDS:
Definition: It is a temporary structure on the outside of a building, made of wooden planks and metal poles,
used by workmen while building, repairing, or cleaning the building.

Main Hazards of Scaffolds:

 Falls from elevation: This is the most common scaffolding hazard. Preventing falls from heights, the
Occupational Safety and Health Act (OSHA) requires that proper fall protection be placed on all
scaffolds suspended over 10 feet above ground.
 Bad planking: When planks are uncleated or not secured enough, they might slip off and cause the
worker to fall.
 Getting struck by falling tools or debris: Scaffolding-related injuries involve being struck with
falling debris. Guardrails are an important component of scaffold construction, not only to protect the
worker from falling but also to prevent any material from falling off a scaffold and hitting people
below.
 Electrocution: Safety standards require scaffolds and workers to maintain a secure clearance from
power lines. Ideal clearance is 10 feet if the voltage is less than 50 kV (kilovolts) and more than 10 feet
and 4 inches for every 1 kV over 50 kV.

Important considerations while erecting and using scaffoldings are:

OSHA has established a set of guidelines to which companies should strictly adhere while using scaffolds

 Scaffold must be sound, rigid and sufficient to carry its own weight plus four times the maximum
intended load without settling or displacement. It must be erected on solid footing.
 Unstable objects, such as barrels, boxes, loose bricks or concrete blocks must not be used to support
scaffolds or planks.
 Scaffold must not be erected, moved, dismantled or altered except under the supervision of a
competent person.
 Scaffold must be equipped with guardrails, midrails and toeboards.
 Scaffold accessories such as braces, brackets, trusses, screw legs or ladders that are damaged or
weakened from any cause must be immediately repaired or replaced.
 Scaffold platforms must be tightly planked with scaffold plank grade material or equivalent.
 A "competent person" must inspect the scaffolding and, at designated intervals, re-inspect.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 8

 Rigging on suspension scaffolds must be inspected by a competent person before each shift and after
any occurrence that could affect structural integrity to ensure that all connections are tight and that
no damage to the rigging has occurred since its last use.
 Synthetic and natural rope used in suspension scaffolding must be protected from heat-producing
sources.
 Employees must be instructed about the hazards of using diagonal braces as fall protection.
 Scaffold can be accessed by using ladders and stairwells.
 Scaffolds must be at least 10 feet from electric power lines at all times.

LOCKOUT AND TAG OUT (LOTO):

 De-energization is a process that is used to disconnect and isolate a system from a source of energy
in order to prevent the release of the energy. By de-energizing the system, you are eliminating the
chance that the system could inadvertently, accidentally or unintentionally cause harm to a person
through movement, or the release of heat, light, or sound.
 A lockout device is "a mechanical means of locking that uses an individually keyed lock to secure an
energy-isolating device in a position that prevents energization of a machine, equipment, or a
process."
 Tag out is a labelling process that is always used when lockout is required. The process of tagging
out a system involves attaching or using an information tag or indicator (usually a standardized label)
 A common feature of these devices is their bright colour, usually red to increase visibility and allow
workers to readily see if a device is isolated.
 A person's lock and tag must only be removed by the individual who installed the lock and tag unless
removal is accomplished under the direction of the employer. Giving approval for the removal of a
tag over the phone is prohibited.

LOCKOUT AND TAG OUT (LOTO) PROCEDURES:

Step 1: Detailed procedures for equipment
 Identify the equipment correctly and accurately, including its specific location.
 Determine the correct procedure for shutting down and restarting the equipment.
 Detail that procedure, step by step, in writing.
 Consider all of the energy sources that may be connected to the equipment.
 Be very specific, because ambiguous language could lead to an incorrect or even dangerous action.

Step 2: Notify affected employees

 When maintenance is going to be performed, all of the employees that may be affected should be
notified.
 Let them know the timing of the work, and how long the equipment may be unavailable.
 If the unavailability of the equipment requires a change in work processes, be sure they are familiar
with the steps to be taken.

Step 3: Shut down equipment properly

 Explain the shutdown process in detail. It’s not enough to say something like “disconnect the
machine.”

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 9

 To ensure everyone’s safety and reduce the potential for damage, the shutdown instructions should
be detailed.
 Spell out the exact actions to be taken and the correct sequence for performing those actions.

Step 4: Disconnect all primary energy sources

 Although this may seem fairly self-explanatory, once again, it’s important to be very detailed.
 The primary energy sources include electricity, steam, water, gas, compressed air, or others should
be disconnected.
 Do not assume that the person performing maintenance will know the correct procedure to follow.
Again, explain exactly what needs to be done.

Step 5: Address all secondary sources

 While disconnecting the primary energy sources may remove much of the potential danger, it is
possible that there may be sources of residual energy, such as trapped heat in a thermal system,
fumes that may need to be vented, or even tension in a spring assembly.
 Identify the process that will relieve any remaining pressure or other energy.
 Also consider other hazards, such as moving equipment that must be secured before work begins.

Step 6: Verify the lockout

 Once you’ve disconnected all primary and secondary sources of energy, attempt to start the
equipment to verify that the lockout has been successful.
 Before you try to start it, verify that nobody is in a position where they could be hurt.
 Assuming that the procedures have been successful, return all switches and other equipment back to
their “off” positions so the machine won’t start unexpectedly when the energy sources are
reconnected.
 Once you’ve verified the lockout, attach a lockout or tagout device to the equipment to ensure that it
cannot be started without removing the device.

Step 7: Keep it in force during shift changes

 The equipment must remain in lockout/tagout condition across shift changes, so that workers arriving
at the site are aware that the equipment is out of service.
 During switching over of shifts, both shift operators must be present during handing over of shift
incharge.

Step 8: Bring the equipment back on line

 When the work is done and all tools and other materials have been removed, the machine can be
brought back into operation.
 The procedure should spell out the exact steps that are involved, along with the correct sequence. For
example, you may need to open a particular machine’s discharge valves before you open the inlet, so
any unexpected water or steam remaining in the lines has a place to go.

MATERIAL SAFETY DATA SHEET (MSDS):

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 10

A material safety data sheet is a technical document which provides detailed and comprehensive information
on a controlled product related to:

 Health effects of exposure to the product

 Hazard evaluation related to the product’s handling, storage or use
 Measure to protect workers at risk of exposure
 Emergency procedures

The data sheet may be written, printed or otherwise expressed, and must meet the availability, design and
content requirements of Workplace Hazardous Material Information System (WHMIS) legislation. The
legislation provides for flexibility of design and wording but requires that a minimum number of categories
of information be completed and that all hazardous ingredients meeting certain criteria be listed.

Material Safety Data Sheet Content:

I. Hazardous Ingredients
This section will include:

 The chemical names and concentrations concerning the hazardous ingredients

 The LD 50 and LC50 indicate the short term toxic potential
 CAS number which is useful in locating more information especially if the product is known by
numerous names.

II. Preparation Information

 The name address and telephone number of who prepared the MSDS
 The date the MSDS was prepared
 If more than three years old, it must be updated

III. Product Information

 Identifies the product by the name on the supplier label
 Provides the chemical name, family and formula (including molecular weight
 Lists the product identifiers, manufacturer and supplier names, addresses and emergency telephone
numbers

IV. Physical Data

 Information indicating how it looks and how it will behave when it is used, stored, spilled and how it
will react with other products indicated through: The state it is in e.g. liquid
 The odour and appearance of the product
 The specific gravity, vapour density, evaporation rate, boiling point and the freezing point
 The vapour pressure, the higher the concentration the higher the possible air concentration
 The odour threshold, which is the lowest airborne concentration of a chemical that can be perceived
by smell
 The pH reflecting the corrosive or irritant nature of the product

V. Fire and Explosion Hazard

 The temperature and conditions that can cause the chemical to catch fire or explode

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 11

 UEL (upper explosion limit) or UFL (upper flammable limit) will indicate the highest concentration
of a substance in the air that will produce a fire or explosion when a source of ignition (heat, spark or
flame) is present.
 LEL (lower explosion limit) or LFL (lower flammable limit) will indicate the lowest concentration of
a substance in the air that will produce a fire or explosion when a source or ignition is present.
 Means of extinction including the type of fire extinguisher required.
 Personal Protective Equipment required for fire fighting.
 Some of the storage requirements.

VI. Reactivity Data

 The chemical stability of the product and its reactions to light, heat, moisture, shock and
incompatible materials.
 Storage requirements based on the reactivity or instability of the product
 Incompatible products that must not be mixed or stored near each other
 The need for disposal before they become extremely reactive

VII. Toxicology Properties

 The harmful effects of exposure
 How the product is likely to enter the body and what effects it has on the organs in the body
 The short-term (acute) and long-term (chronic) health effects from exposure to the product
 The exposure limits

VIII. Preventative Measures

 Instruction for the safe use, handling and storage of the product
 The personal protective equipment or safety devices required
 The steps for cleaning up spills
 Information on the waste disposal requirements

IX. First Aid Measures:

 Specific first aid measures related to acute effects of exposure to the product
 First aid steps in the correct sequence
 Information to assist in planning for emergencies

Occupational Safety and Health Administration (OSHA):

The Occupational Safety and Health Act of 1970 (OSHAct) was passed to prevent workers from
being killed or seriously harmed at work. The law requires that employers provide their employees with
working conditions that are free of known dangers. The Act created the Occupational Safety and Health
Administration (OSHA), which sets and enforces protective workplace safety and health standards. OSHA
also provides information, training and assistance to workers and employers.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 12

FUNCTIONS OF OSHA:
 Sets Standards
 Listens and Responds to Worker Appeals
 Publishes Research and Data on Workplace Safety
 Issues Hazard Alerts That Help Employers Keep Workers Safe
 Provides Training and Education

WORKPLACE INSPECTIONS:
OSHA conducts workplace inspections using a priority hierarchy:

 Imminent danger - Situations where accidents or injuries can be expected to happen in the near
future are given top priority. OSHA will take immediate action to prevent harm from coming to
workers.
 Fatalities and hospitalization of multiple workers - After situations where OSHA may be able to
intervene before people are injured, the next highest inspection priority is situations where a worker
has been killed on the job or if something has occurred that has caused three or more workers to be
hospitalized.
 Employee complaints - The third highest priority for OSHA is employee complaints. All workers
have a right to report perceived violations of the OSH Act to the agency and it is illegal for
employers to retaliate against them for doing so.
 Agency Referrals -- The next priority is placed on companies that are referred to OSHA by other
government agencies. For example, if a state agency charged with environmental management visits
a work site and notices conditions that are not compliance with OSH regulations, a representative
may notify OSHA of the violation and an inspection will be triggered.
 Targeted Inspections - The final priority is given to industries and companies that are targeted
based on criteria determined by OSHA. For example, particular businesses with an unusually high
rate of on-the-job injuries or occupational illnesses may be targeted. Additionally, companies doing
business in industries that pose a particularly high risk of significant injury, including those that
involve working around hazardous chemicals or with dangerous substances, may be targeted.
 Follow Up - OSHA's final priority emphasis is follow-up inspections with sites that require one or
more subsequent visits following an initial visit. A follow up would be required for organizations
that are found to be in violation of OSH regulations during an inspection. Significant problems may
lead to high priority imminent danger inspections, or low priority problems may be classified as
follow-ups.

Rights and Responsibilities under OSHA Law:

Employers MUST:

 Employers have the responsibility to provide a safe workplace.

 Employers MUST provide their workers with a workplace that does not have serious hazards and
must follow all OSHA safety and health standards.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 13

 Employers must find and correct safety and health problems.

 Prominently display the official OSHA Job Safety and Health – It’s the Law poster that describes
rights and responsibilities under the OSHAct. This poster is free and can be downloaded from
www.osha.gov.
 Inform workers about chemical hazards through training, labels, alarms, color-coded systems,
chemical information sheets and other methods.
 Provide safety training to workers in a language and vocabulary they can understand.
 Keep accurate records of work-related injuries and illnesses.
 Perform tests in the workplace, such as air sampling, required by some OSHA standards.
 Provide required personal protective equipment at no cost to workers.
 Provide hearing exams or other medical tests required by OSHA standards.
 Post OSHA citations and injury and illness data where workers can see them.

Workers have the right to:

 File a confidential complaint with OSHA to have their workplace inspected.

 Receive information and training about hazards, methods to prevent harm, and the OSHA standards
that apply to their workplace. The training must be done in a language and vocabulary workers can
understand.
 Receive copies of records of work-related injuries and illnesses that occur in their workplace.
 Receive copies of the results from tests and monitoring done to find and measure hazards in their
workplace.
 Receive copies of their workplace medical records.
 Participate in an OSHA inspection and speak in private with the inspector.

The National Institute for Occupational Safety and Health (NIOSH)

ABOUT NIOSH:
 The Occupational Safety and Health Act of 1970 established NIOSH.
 NIOSH is part of the U.S. Centers for Disease Control and Prevention, in the U.S. Department of
Health and Human Services.
 It has the mandate to assure “every man and woman in the Nation safe and healthful working
conditions and to preserve our human resources.” NIOSH has more than 1,300 employees from a
diverse set of fields including epidemiology, medicine, nursing, industrial hygiene, safety,
psychology, chemistry, statistics, economics, and many branches of engineering.
 NIOSH works closely with the Occupational Safety and Health Administration (OSHA) and the
Mine Safety and Health Administration (MSHA) in the U.S. Department of Labor to protect
American workers and miners.

OBJECTIVES OF NIOHS:
NIOSH works closely with diverse partners to identify the most critical issues in workplace safety and
health.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 14

 Agriculture, Forestry, and Fishing: NIOSH role and impact has its accomplishments such as
reducing child death rates from agricultural worksite risks, reducing fatalities from tractor rollovers,
and adopting life-saving personal flotation devices in commercial fishing.
 Construction: NIOSH Projects have addressed the causes of falls and electrical hazards,
musculoskeletal disorders associated with construction work, and health hazards such as noise,
asphalt fumes, silica, and welding fumes.
 Healthcare and Social Assistance: NIOSH provides detailed recommendations for workers who
serve the sick and those in need of assistance.
 Manufacturing: NIOSH has developed and distributed education materials on major hazards in this
sector and promoted reduction of injuries and fatalities due to contact with equipment, falls, hearing
loss, and other exposures.
 Mining: NIOSH has created engineering controls for reducing noise levels in the mines, proximity
detection systems for mining equipment, and LED cap lamps. NIOSH has developed practical
solutions to critical problem areas in mining, which include providing emergency oxygen through
self-contained self-rescuers and improving underground communications and personnel tracking.
 Public Safety: NIOSH networks with fire service and law enforcement professionals and promotes
best practices among public safety workers responding to emergency calls.
 Transportation, Warehousing, and Utilities: NIOSH established a Centre for Motor Vehicle
Safety to find solutions for fatalities and severe injuries in transportation.

World Health Organisation (WHO):

GOAL: To improve equity in health, reduce health risks, promote healthy lifestyles and settings, and
respond to the underlying determinants of health.
WHO's main functions can be summed up as follows: to act as a directing and coordinating authority on
international health work, to ensure valid and productive technical cooperation, and to promote research.

OBJECTIVES OF WHO:
The objective of WHO is the attainment by all peoples of the highest possible level of health. Health, as
defined in the WHO Constitution, is a state of complete physical, mental, and social well-being and not
merely the absence of disease or infirmity. In support of its main objective, the organization has a wide
range of functions, including the following:

 To act as the directing and coordinating authority on international health work;

 To promote technical cooperation;
 To assist Governments, upon request, in strengthening health services;
 To furnish appropriate technical assistance and, in emergencies, necessary aid, upon the request or
acceptance of Governments;
 To stimulate and advance work on the prevention and control of epidemic, endemic, and other
diseases;
 To promote, in cooperation with other specialized agencies where necessary, the improvement of
nutrition, housing, sanitation, recreation, economic or working conditions, and other aspects of
environmental hygiene;
 To promote and coordinate biomedical and health services research;
 To promote improved standards of teaching and training in the health, medical and related
professions;

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 15

 To establish and stimulate the establishment of international standards for biological,

pharmaceutical, and similar products, and to standardize diagnostic procedures;
 To foster activities in the field of mental health, especially those activities affecting the harmony of
human relations.

SAFETY IN THE LABORATORY:

Purpose: Is to increase the awareness of the possible risks or hazards involved with laboratory work and to
make laboratory a safe place to work if safety guidelines are properly followed.

STANDARD OPERATING PROCEDURES TO BE FOLLOWED IN LABORATORY:

1. General personal safety
2. Eye safety
3. Handling of biologically hazardous material
4. Handling of needles and sharps

1. General Personal Safety

 Eating, drinking, smoking, applying cosmetics, handling contact lenses are prohibited in areas where
specimens are handled.
 Long hair, ties, scarves and earrings should be secured.
 Appropriate Personal Protective Equipment (PPE) should be used where indicated:
o Lab coats or disposable aprons should be worn in the lab to protect you and your clothing
from contamination. Lab coats should not be worn outside the laboratory.
o Lab footwear should consist of normal closed shoes to protect all areas of the foot from
possible puncture from sharp objects and/or broken glass and from contamination from
corrosive reagents and/or infectious materials.
o Gloves should be worn for handling blood and body fluid specimens, touching the mucous
membranes or non-intact skin of patients,
o Protective eyewear and/or masks may need to be worn when contact with hazardous aerosols;
caustic chemicals and/or reagents are anticipated.
 NEVER MOUTH PIPETTE!! Mechanical pipetting devices must be used for pipetting all liquids.
 Frequent hand washing is an important safety precaution after and before leaving the laboratory.

2. Eye Safety

 KNOW WHERE THE NEAREST EYE WASH STATION IS LOCATED AND HOW TO
OPERATE IT.
 Eye goggles should be worn:
o When working with certain caustic reagents and/or solvents, or concentrated acids and bases.
o When performing procedures that are likely to generate droplets/aerosols of blood or other
body fluid.
o When working with reagents under pressure. When working in close proximity to ultra-violet
radiation (light).
 Wearing contact lenses in the laboratory is discouraged and requires extra precaution if worn.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 16

3. Safe Handling of Biologically Hazardous Material

 YOU SHOULD HANDLE ALL PATIENT SAMPLES AS POTENTIALLY BIOHAZARDOUS

MATERIAL. This means UNIVERSAL PRECAUTIONS should be followed at all times!!
 All biohazardous material should be discarded in a biohazard bag to be autoclaved.
 All counter and table tops should be disinfected with a proper disinfecting solution:
o At the beginning of the day.
o If you should spill a patient sample.
o At the end of the day.

4. Proper handling of SHARPS:

 Contaminated needles and other sharps are never broken, bent, recapped or re-sheathed by hand.
 Used needles are not removed from disposable syringes.
 Needles and sharps are disposed of in impervious containers located near the point of use.

ROAD SAFETY:
Pedestrian and bicyclist safety:
 Reserving adequate space for non-motorized modes on all roads where they are present.
 Free left turns must be banned at all signalized junctions. This will give a safe time for pedestrians
and bicyclists to cross the road.
 Speed control in urban areas: maximum speed limits of 40-50 km/h on arterial roads need to be
enforced by road design and police monitoring.
 Maximum speeds of 30 km/h in residential areas need to be enforced by judicious use of speed-
breakers and mini roundabouts.
 Increasing the conspicuousness of bicycles by fixing reflectors on all sides and wheels and painting
them yellow, white or orange.

Motorcyclist and motor vehicle safety:

 Notification of mandatory use of helmet and daytime headlights by two-wheeler riders.
 All cars to conform to latest international crashworthiness regulations.
 Pedestrian safety regulations for cars to be notified
 Enforcement of seatbelt use laws countrywide.
 Restricting front-seat travel in cars by children and the use of child seats has potential for reducing
injuries to child occupants.
 Introduction of active safety technologies like automatic braking, pedestrian detection, electronic
stability control, and alcohol locks.

Enforcement:
 The most important enforcement issue in India is speed control. Without this it will be difficult to
lower crash rates as a majority of the victims are vulnerable road users.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 17

 The second most important measure to be taken seriously is driving under the influence of alcohol.
30%–40% of fatal crashes in India may have alcohol involvement.
 Enforcement of seatbelt and helmet use.

SAFETY SAMPLING TECHNIQUES:

Safety sampling is a technique performed in a workplace or hazardous area that is used to measure potential
for accidents. This is done using a list of standards or regulations from a federal agency including The
Occupational Safety and Health Administration (OSHA), or The American National Standards Institute
(ANSI), and any unacceptable deviations from those standards or regulations.

 Safety sampling is performed by routine checks or inspections

 It is a repeatable process designed to ensure compliance to federal standards over a long term basis
and to keep safety levels high consistently.
 Employers should work with a qualified safety coordinator who has experience in creating,
reviewing and maintaining standard operating procedures and their documentation, as well as
perform safety inspections and help staff to comply with federal standards through staff training
procedures.
The protocol serves as a guide in performing the survey. The amount of detail necessary will depend on the
purpose of the survey and to whom the results will be submitted. At a minimum, the protocol should include
the following:

 Purpose of the survey: Why the survey being conducted and what is the desired outcome?
Background information such as previous surveys, operational or equipment changes should be
referenced.
 Where to sample: This identifies expected exposure sites. It is based on where chemicals are stored,
transported, and used at the site, and what ventilation and airflow patterns exist.
 What to sample: This is based on available information. What are the potential chemical hazards?
 Who to sample: This is based on knowledge of the potential exposure sites and the various job
requirements at the site. What job classifications or specific individuals should be considered for
monitoring? Workers with the greatest potential for exposure must be included.
 How many samples should be collected: Consider the number of exposure sites, job classifications,
and potential chemical hazards. How many samples are necessary to assess the various exposure
hazards?
 How will the samples be collected and analyzed: After determining the potential hazards, what
published methods are available, and which ones will provide the most meaningful data. Is there a
potential for other chemical hazards in the area and should methods be considered which may
provide screening information?

SAMPLING METHODS:

 Direct Reading: Direct reading instruments provide an excellent mechanism to monitor potential
exposures. They allow significant amounts of data to be collected and the workers exposure profile
during operations to be determined. They, also, provide qualitative data relative to worker exposures.
However, they may not provide the necessary specificity, detection limit, or precision for compliance
monitoring or exposure assessment.

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 18

 Bulk samples: Bulk samples may be collected and shipped to the laboratory as an aid in assessing
sources of contamination. In order to prevent contamination of personal samples, they should be kept
separate from the personal samples when transporting and packaged in separate containers when
shipping.
 Surface Contamination: Provides safety and health information related to surface contamination in
the workplace.

SAFE MATERIAL HANDLING AND STORAGE:

More than 50% of the total accidents resulting in injury or property damage are caused during material
handling in Engineering industries i.e, every third accident in industries is caused while handling of
materials.

 Attempts to be made to reduce/eliminate material handling since they add to the cost but do not add
to the value
 Material handling adds 36% of the production costs
 Nearly 50-100 tons of material are handled and re-handled for every one ton of finished product
 About 2/5th of manufacturing cycle time is spent on handling
 About 20-80% of total labour cost go to labour used in handling of material
 Between 30-40% of industrial accidents are caused while handling materials. In other words, every
third accident in industries is caused while handling materials.

FACTORS INFLUENCING SELECTION OF HANDLING OF MATERIAL:

 Weight
 Physical characteristics
 Size
 Shape
 Rate of handling
 Distance to be moved
 Purpose of moving
 Obstacles in the pathway

UNSAFE WORK HABITS:

 Lifting improperly
 Carrying too heavy loads
 Unsafe gripping
 Failure to wear PPEs

MANUAL MATERIAL HANDLING:

Simple safety precautions to be followed in case of manual handling

 Correct positioning of feet

 Bent knees

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 19

 Straight back
 Arms close to the body
 Correct grip
 Raise head slightly before lifting
 Use of body weight

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 20

MECHANISED MATERIAL HANDLING:

Most of the handling is done with the help of mechanical power inside the factory. It is essential that the
equipment /devices/ accessories are maintained in good working conditions and persons engaged in
operation are trained and aware of potential hazards of mal-operation and precautions to overcome them.
Some of the important equipments using mechanical power

 EOT Crane / Jib Cranes / Goliath cranes

 Chain pulley blocks
 Hoists
 Fork lifts
 Wire rope slings and Chains slings

MECHANICAL AIDS/EQUIPMENTS:
 Hand tools (Crow bar, Hook, Mallets)
 Skids, rollers, or other devices used for dragging/sliding
 Wheelbarrows, hand trucks, any special carrying devices
 Lift trucks
 Power trucks and tractors
 Hoisting apparatus
 Over head cranes (EOT)
 Conveyors/Elevators/escalators

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 21

 Chutes (gravity or under pressure)

 Ducts for gases
 Pumps and pipelines for liquids

*_*_*_*_*_*_*

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.

 17ME662 - INDUSTRIAL SAFETY 22

VITTAL BHAT M-ASST PROFESSOR-DEPARTMENT OF EEE-P A COLLEGE OF ENGINEERING-MANGALURU.