Electric and Electronic Department Industrial Safety, C14

XIV. Industrial Safety

14.1 Safety Requirements

14.1.1 Occupational Safety and Health Committees

As a minimum the industry must:

¾ Follow all legislative and/or labor requirements relevant to such
committees or joint-labor management safety initiatives;
¾ Ensure safety issues, performance and corrective actions are addressed at
periodic management meetings (at least once a month);
¾ Communicate safety issues, actions and results to all employees.

14.1.2 Managing Contractors

Require contractors to meet safety and health criteria to qualify for the bidding
process such as:
¾ Injury/illness rates, loss experience, accident history over the past 5 years;
¾ References;
¾ An evaluation of the contractor’s prior work history at the facility;
¾ A copy of the contractor’s safety and health program;
¾ Provisions that assure the Company and location safety and health
requirements are included in the bid documents and contracts.

Prior to starting any job, all contracting staff attend an orientation that includes
the following:
¾ A review of the facility’s safety program;
¾ A review of contractor’s work limitations, and hazards associated with
plant activity in their work area;
¾ A review of the plant emergency procedures and a review of the facility
public relation policy;
¾ A review of contractor shutdown, termination and contractor staff
expulsion provisions;
¾ An orientation sign-off sheet stating the contractor has attended the
orientation.

Control the access of contracting staff at the facility

¾ Use barricades, perimeter marking, warning signs or physical direction to
appropriately restrict contractor access to facility;
¾ Limit general contractor access to unrelated areas;
¾ After orientation, issue a method of easy identification to wear at all
times;

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¾ Ensure any contractor added after the start of the project receives
orientation;
¾ Ensure all contractors enter at controlled access points;
¾ Designate the appropriate location for contractors to park their vehicles.

Issue work permits for:

¾ Hot work (cutting, burning, welding);
¾ Lockout/tagout work (electrical, energized equipment or machinery);
¾ Elevated work (scaffolds, staging or others over six feet);
¾ Work in confined spaces.

In order to control hazards:

¾ Review contractor methods and work area exposures prior to
commencing work;
¾ Identify procedures or conditions that pose hazards specific to the area;
¾ Devise a system for issuing and tracking hazardous work permits;
¾ Include how to obtain permits, who is authorized to issue, training
requirements and specific precautions;
¾ Ensure people issuing permits are competent;
¾ Ensure the permit identifies any specialized equipment needed;
¾ Initiate an inspection schedule to verify the permit stipulations are
followed;
¾ Base the inspection frequency on hazards involve (typically each shift);
¾ Retain records for 3 years.

Foster open communication at all times. Appoint a company liaison to maintain

daily contact with the contractor.

14.1.3 Storage Flammable Liquids Guidelines

14.1.3.1 General Activities

¾ Assign responsibility for ensuring storage control practices are followed

¾ Ensure a spill team is part of the emergency response teams
¾ Provide adequate ventilation in storage areas

14.1.3.2 Inside Storage

¾ Stored materials never obstruct any exits from the building

¾ Arrange staging areas to permit assembly, without placing goods in the
aisles
¾ Store flammable liquids in specially designed areas.

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¾ Limit storage (for flammables) in mixing rooms, or staging in production

areas to one shift’s supply.
¾ Keep all storage away from fire doors for a radius of two times the door
opening span.
¾ Storage does not obstruct access to fire protection control valves, or fire
fighting appliances.

14.1.3.3 Outside Storage

¾ Never place outside storage against a building exit door or passage.

Ensure storage never obstructs or disables any exit.
¾ Outside storage does not obstruct hydrants, sprinkler control valves, or
other fire fighting equipment.

14.1.3.4 Dry Parts Area

¾ No accumulation of dust in dry parts area.

¾ Inspect roof areas or other outside locations where vents discharge and
dust accumulation may occur.

14.1.4 Managing Hazardous Materials

14.1.4.1 Loading and Unloading

¾ Provide appropriate access, guarding devices, and equipment to protect

workers from falling when working on tankers or rail cars.

14.1.4.2 Handling

¾ Conduct job hazard analyses to identify Personal Protective Equipment

(PPE) requirements and ensure associates who handle hazardous
materials have appropriate and legally required PPE.
¾ Train associates who use PPE on how to use the PPE effectively and
maintain it clean and in sanitary condition.
¾ Provide equipment to respond to fire and spill emergencies at or near
storage areas for hazardous materials and where associates work with
them.
¾ Place fresh-water eyewashes and safety showers within 5 m of areas
where associates may be exposed to corrosive materials. Eyewashes to
provide 15 min of continuously supplied clean water at a pressure that
will not damage the eyes.
¾ Eyewashes and safety showers to be regularly maintained.

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14.1.4.3 Asbestos

An Asbestos management program with the following minimum elements:

¾ Establish purchasing controls to ensure ACM is not purchased or used in
new construction, renovations or repairs (vehicle parts such as brake pads
and clutches.
¾ Inform contractors of the purchasing policy and include in contract
specifications.
¾ Survey to identify the suspect ACM and document the survey
¾ If ACM detected a written Asbestos Management Program to be
developed to evaluate the potential exposure hazards and establish
appropriate controls. The program must:
¾ Describe the sampling and its results, interpret the data and
quantify the potential hazards
¾ Establish and document administrative controls, work practices,
procedures or physical controls on identified ACM.
¾ Provide procedures for demolition, renovation, maintenance or
custodial activities that ensure worker’s exposure is eliminated.
Provide disposal instructions.

14.1.4.4 Compressed gas-cylinders

¾ Protect compressed-gas cylinders from damaging environments during

storage and use (Chains, valve caps etc.). Keep them dry and away from
extreme temperatures or corrosive atmosphere.
¾ Segregate incompatible gases such as oxidizers, flammables, from each
other or from other reactive elements.
¾ Protect compressed gas containers from physical damage during storage
and use. Use supports, chains, or cylinder racks to keep containers from
falling or tipping. Secure protective valve caps or plugs during storage
and transport. Protect storage areas from accidental contact with vehicles.
¾ Use a suitable hand truck, forklift truck or similar device for handling
materials to move the containers. Do not roll or drag containers. Do not
lift them by the protective caps or valve stems.
¾ Inspect and maintain gas delivery systems regularly to ensure they are gas
tight, and safety devices are working properly.

14.1.4.5 Pressure Vessels

Routine inspection and regular do preventive maintenance. As a minimum:

¾ Inspect each year to identify leaks, corrosion, wears or other factors that
may cause a failure.

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¾ Make sure a competent expert cleans, inspects, and tunes all boilers
annually. Expert must also test and calibrate safety devices.
¾ Make sure a competent expert physically tests all pressurized tanks at
least every 10 years.
¾ Document all these inspection and keep records until decommission.

14.1.4.6 Toxic Gases (ammonia, chlorine)

¾ Post appropriate signs on containers, storage areas, piping or compressor

rooms.
¾ Emergency response plans for worst case scenarios. Train associates.
Document training and annual review of the plan.
¾ Include gas delivery or ammonia-refrigeration systems in overall
maintenance program according to manufacturer recommendations.
¾ Inspect each month to identify leaks, corrosion, wears or other factors
that may cause a failure.
¾ Make sure a competent expert physically tests the system at least every
10 years or as recommended by manufacturer.
¾ Document all these inspection and keep records until decommission.

14.1.4.7 Radioactive materials

¾ Make sure associates working with or near fill-height detectors know

about the radioactive source;
¾ Establish controls to prevent exposure;
¾ Post appropriate warning signs on the equipment if not already installed;
¾ Check with your legal counsel before repairing, removing and disposing
of radioactive materials to ensure legal compliance.

14.1.4.8 Waste Management Standard

¾ Workers exposed to bio-solids must be offered vaccinations

¾ PPE including masks, goggles, gloves, boots and waterproof gear
required.
¾ Workers must observe good hygienic practices including washing
thoroughly and changing contaminated clothing after handling wastes.

14.1.5 Fleet Safety General and Specific Rules

¾ No animals or pets of any type permitted in equipment at any time.

¾ Determine minimum clothing standards for all drivers such as:
⇒ Non-skid shoes for safety
⇒ Personal protective equipment

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⇒ Long hair should be tied back or up

⇒ No large hoop or dangling earrings, large belt buckles, wallets with
chain or loose jewelry.
⇒ No sheath knives from belt

¾ Develop an effective maintenance program including:

⇒ An operator manual with the guidelines on the care and the
maintenance of the vehicle.
⇒ Regular inspection reports on vehicle condition
⇒ Efficient procedures to expedite needed repairs (brakes,
replacement of tires etc.)

¾ Prohibit the use of radar detectors, TVs and head sets while driving.
¾ Prohibit un-authorized modification to any vehicle.
¾ Drivers obtain license and registration renewals in accordance with laws
of the country/state/territory.
¾ Only company provided parking is used.
¾ Encourage all employees and other passengers wear belts (where local
legal regulations do no ask for it).
¾ Develop and implement Substance Abuse procedures and ensure full
compliance and the consequences are clear to all drivers. (Alcohol, drugs
etc.)
¾ Test all associates for controlled substance usage prior to offering
employment. Consider random testing
¾ All drivers must pass a medical examination conducted by a licensed
health care professional
¾ Phone use in a moving vehicle is prohibited unless hands free type.
¾ Use of tobacco in company-owned vehicles is prohibited (exception for
executive and sales vehicles issued solely to an individual)
¾ All traffic violations are reported within 24 hours.
¾ There is a system for evaluating safety recommendations and concerns
from all employees.

14.2 Hazard Assessments

14.2.1 Generalities

The Organization Shall

¾ Establish and maintain procedures for ongoing identification &

assessment of risks and required control measures
– Routine and non routine activities

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– Activities for all parties employees, contractors and visitors

– Coverage of all workplace facilities (owned or third party)
¾ Ensure results of assessments and control measures are considered when
setting objectives. These must be kept up-to date.
¾ Ensure methodology(s) for hazard identification and risk assessment are
proactive rather than reactive. It means
– Defined (scope nature and timing)
– Provided for all classifications of risk
– Be consistent with operating experience and capabilities
– Provide input to determine
– Identification of training needs
– Development of operational controls
– Provide monitoring or required actions to ensure effectiveness and
implementation
¾ Undertake hazard identification and eliminate or reduce hazards and
risks by physical control methodology or risk control tools
¾ Provide appropriate proactive methodology with retained associated
documentation, data and records
¾ Ensure all activities are covered (present, new or modified developments
and activities)
¾ Apply to normal operations but also cover periodic or occasional
operations and procedures(hygiene, maintenance etc)
¾ Following the hazard identification, risk assessments and risk control
process there should be clear evidence that
• Corrective or preventative actions are monitored
• Results from monitoring programmes provided for management
review, input and change if required
• Competency is determined, documented
• Feedback used to amend processes
• Process, procedures and systems are monitored to predetermined
time or period set out in policy

14.2.2 Key Stages to Risk Assessment

Step 1. Make inventory and keep up to date

Step 2. Identify hazards
Step 3. Rate risks (can also be objective - subjective)
Step 4. Decide if risk is acceptable - tolerable
Step 5. Select workplace precautions
Step 6. Record risk assessments
Step 7. Implement and maintain risk control measures
Step 8. Monitor & review as required

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General risk assessment format is as below.

Likelihood
Fr Frequent/likely 5

Pr Probable 4

Ps Possible 3

R Remote 2

U Unlikely/improbable 1

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Severity

14.3 Some Requirement Safety Warning Signs

The following figures are shown some of the requirement safety warning sings
used in the industrial plants.

Figure 14.1 Figure 14.2

Figure 14.3 Figure 14.4

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Figure 14.5 Figure 14.6

Figure 14.7 Figure 14.8

14.4 Safety Equipments (Items)

The following figures are shown some of the safety equipments (items) using in
the industrial plants.

Figure 14.9 Eye wash Figure 14.10 Eye wash

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Figure 14.11 Eye wash Figure 14.12 Welding curtain

Figure 14.13 Filter material mask Figure 14.14 Ear protection 1310

Figure 14.15 Ear protection 1435 Figure 14.16 Ear plug 1100/1110

Figure 14.17 Ear plug 1260/1270 Figure 14.18 Welding curtain

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