Unit I Industrial Safety

Concepts of Safety – Hazard classification chemical, physical, mechanical,

ergonomics, biological and noise hazards – Hazards from utilities like air,
water, steam
Concepts of Safety
Safety program
A safety program analyzes a company's immediate needs and provides for ongoing, long-lasting
worker protection. Once it is designed, the program should be applied in the workplace. A safety
program serves to anticipate, identify, and eliminate conditions or practices that could result in
work-related injuries and illnesses.

• Safety is the state of being safe.

• Risk is the product of two factors, that is probability of an event which might occur and
severity of the event if it occurs.

• Hazard is defined as the potential condition which might be converted into an event. It is a
state, physical or chemical having potential to injure the person
Industrial Safety - Any method or technique or process which can minimize
unwanted events in an industrial concern is referred to as industrial safety.
Types of hazards
Different types of hazards are Chemical hazards, Mechanical hazards, Biological hazards,,
Environmental hazards,, Electrical hazards, Noise hazards, Fire hazards and Potential
hazards.
Chemical hazard is a type of occupational hazard caused by exposure to Chemicals in
the workplace. Chemical hazards are the hazards which occur by means of chemical
substances such as CO, NO, SO2, hydrocarbons, ozone, H2SO4, acetic acid, fumaric acid
and tannic acid by causing injury when they are absorbed by skin or when they are
injested or inhaled.

Classification of Chemical hazards.

• Physical hazards, for example flammability
• Health hazards, for example toxicity and carcinogenicity, and
• Environmental hazards, for example hazardous to the aquatic
environment
•
An accident is an occurrence, mishap or unwanted event which is not expected
in the course of employment of an industrial worker.

A threshold limit is an amount, level, or limit on a scale. When

the threshold is reached, something else happens or changes

Acute exposure effects are the effects caused by a toxic chemical which can be
treated and can be cured in a limited period of time.

Chronic exposure effects are the effects caused by a toxic chemical which can be
treated but will take high amount of period may be in months or years together to
cure. Sometimes it cannot be cured and may leads to death also.

Four major routes of industrial chemicals are Inhalation, Ingestion, Injection,

contact with skin or eyes

The Threshold limit value ( TLV ) of a chemical substance is believed to be

a level to which a worker can be exposed day after day for a working lifetime
without adverse effects.
Permissible Exposure Limity (PEL) is the maximum upper exposure legal limit
to a hazardous substance exposure that an employee can be exposed to in an
8-hour period.
Chemical hazards
Hazards occuring due to any forms of chemicals including medications, solutions, gases,
vapors, aerosols, and particulate matter that are potentially toxic or irritating to the body
system.

Chemical hazards are classified into groups that include asphyxiants, corrosives, irritants,
sensitizers ( substances which can cause sensitisation in the lungs (respiratory sensitisers)
and/or skin (skin sensitisers) after exposure to them - diazomethane, chromium, nickel,
formaldehyde etc),
Carcinogens (a substance, organism or agent capable of causing cancer by UV, virus,
automobile gas, cigarette, tobacco etc. ),
Mutagens (Chemical or physical agent capable of inducing changes in DNA – tobacco, Xray,
UV etc),
Teratogens (any agent that causes an abnormality following fetal exposure during pregnancy –
rubella, siphilis, varicella etc.)., reactants, and flammables.

Four major routes of industrial chemicals are Inhalation, Ingestion, Injection, contact with
skin or eyes
• Inhalation: Breathing gases, vapors, particulates, dust, or mist
• Ingestion: Accidentally eating or drinking hazardous substances
• Injection: Permeation or absorbing a substance through the skin; piercing or penetration of
skin with needle or other sharp device/instrument (e.g., scalpel or broken glass)
• Dermal: Contact with corrosive or sensitizing materials
Chemical Agent Hazards examples and their routes of exposure
• Antimicrobial: An agent that destroys microbes, inhibits their growth, or
prevents or counteracts their pathogenic action such as antibiotics (e.g.,
amoxicillin, penicillin, and tetracycline)
– Primary routes of exposure: Mucous membrane, dermal absorption,
ingestion
• Anesthetic gases: Gases for general anesthesia such as sevoflurane and
isoflurane, halothane, nitrous oxide during surgical and dental procedures
– Primary route of exposure: Inhalation
• Antineoplastic drugs: Chemotherapy drugs (e.g., cyclophosphamide,
alkylating agents)
– Primary routes of exposure: Dermal absorption, inhalation
• Surface cleaning and disinfecting agents: Antimicrobial agents designed to
destroy microorganisms (e.g., bleach, quaternary ammonium compounds, low
and intermediate level disinfectants, antiseptics, hand sanitizers, detergents)
– Primary routes of exposure: Inhalation, dermal absorption
• Chemical sterilants: High level disinfection of surgical instruments and
medical supplies that cannot withstand the autoclave process (e.g., ethylene
oxide (EtO), hydrogen peroxide gas plasma)
– Primary route of exposure: Inhalation
• Immersion disinfecting solutions: High level disinfectants (e.g.,
glutaraldehyde, orthophthaldehyde, peracetic acid, hydrogen
peroxide)
– Primary routes of exposure: Inhalation, dermal absorption
• Latex (rubber) products: Worn to protect against bacteria and
viruses (e.g., surgical and exam gloves), and tubing, tourniquets,
patient care devices, which may cause allergic reactions in
exposed workers
– Primary routes of exposure: Dermal contact, inhalation
• Surgical smoke from laser use: Generated by thermal
destruction of tissue when using lasers or electrosurgical devices
during surgical procedures. Surgical smoke creates a variety of
toxic vapors, gases, and particulate matter
– Primary route of exposure: Inhalation
• Other: (e.g., adhesives, solvents used in dentistry, labs,
medical/surgical procedures)
– Primary routes of exposure: Inhalation, dermal absorption,
percutaneous, ingestion
Fire hazard
• Fire hazards are workplace hazards that either involve the
presence of a flame, increase the probability that an uncontrolled
fire will occur, or increase the severity of a fire should one occur.
• Fire hazards include: Flames, Sparks, Hot objects, Flammable
chemicals and Chemicals accelerants, which can increase a fire’s
rate of spread.

Explosion hazard
An explosion is a sudden and rapid increase in volume and release of
energy in an extreme manner. This is usually accompanied by the
generation of high temperatures and release of gases caused by
changes in pressure, temperature and phase. In
mining, explosives are the most obvious form of explosion hazard.
Physical hazards
Workplace agents, factors, or circumstances that can cause damage to
tissues, body parts etc. These hazards occurs by means of
• body stressing.
• confined spaces.
• electricity.
• heat.
• heights.
• noise.
• Vibration
Physical hazards in food
It usually result from accidental contamination and /or poor food
handling practices. Examples include, slivers of glass, human hair,
nails, false nails, nail polish, pieces of jewellery, metal fragments
from worn or chipped utensils and containers, dirt, stones, frilled
toothpicks.
Mechanical hazards
Mechanical hazards include:
• Crushing.
• Shearing (Parts of machines that move past each other or
stationary objects can cause a shear point resulting in a crushing
or cutting action) .
• Cutting.
• Entanglement (results from clothing, hair, jewellery, a necktie or
scarf, or other accessories becoming snagged by a
movable/spinning part of workplace machinery) .
• Drawing-in or trapping (body parts can be caught in moving parts
and drawing into equipment mechanisms).
• Stabbing or puncture (Sharp corners, points and tines can cause
injury).
• Friction or abrasion
Ergonomic hazards
(Ergonomics can be defined as the study of people in their working
environment. It is the science of fitting the job to the worker. An
ergonomist designs or modifies the work to fit the worker, not the
other way around. The goal is to eliminate discomfort and risk of
injury due to work)
These include repetition, awkward posture, forceful motion,
stationary position, direct pressure, vibration, extreme temperature,
noise, and work stress.
Ergonomic injuries affect the muscles, bones, tendons, nerves, and
tissues. These terms do not necessarily refer to different conditions.
These disorders include a number of specific diseases such as carpal
tunnel syndrome (abnormal pressure on the nerve can result in
numbness, tingling, pain, and weakness in the hand) , bursitis (injury
or overuse, but it can also be caused by infection), and
tendinitis(condition causes pain and tenderness just outside a joint).
Biological Hazards
Biological hazards are disease producing agents (pathogens) that can be
transmitted to individuals through various routes of exposure. They are organic
substances that pose a threat to the health of humans and other living organisms.
Exposure to these hazards may result in acute or chronic health conditions. It
includes
• viruses,
• toxins from biological sources.
• spores.
• fungi.
• pathogenic micro-organisms.
• bio-active substances.
Biohazardous waste products include infectious waste, animal waste, used sharps,
discarded vaccines, and pathological waste.
These can be controlled by Washing your hands frequently with warm water and
soap. Wearing personal protective equipment (PPE) when responding to situations
involving biohazards. These can include gloves, facemasks and shields,
respirators, aprons, special protective eyewear, and full body gowns or suits.
Noise hazards
Noise is one of the most common physical hazards present in the occupational
setting. Depending on frequency, amplitude (volume) and duration of exposure,
hearing protection may be required. Inadequate hearing protection or prolonged
exposure to noise can result in either temporary or permanent hearing loss
• Exposure to high levels of noise can cause permanent hearing loss. Neither
surgery nor a hearing aid can help correct this type of hearing loss.
• Short term exposure to loud noise can also cause a temporary change in hearing
(your ears may feel stuffed up) or a ringing in your ears.
• OSHA (Occupational Safety and Health Administration requires employers to
implement a hearing conservation program when noise exposure is at or above
85 decibels averaged over 8 working hours, or an 8-hour time-weighted average
Exposure & Controls
• Choose low-noise tools and machinery.
• Maintain and lubricate machinery and equipment (e.g., oil bearings)
• Place a barrier between the noise source and employee (e.g., sound walls or
curtains)
• Enclose or isolate the noise source
Hazards from Steam
1. SLIPS AND FALLS
• One of the biggest hazards of any steam system is the risk of
injury to employees due to slip and fall hazards. On a national
scale, slips and falls account for an estimated 70 billion dollars in
workers compensation and medical bills , according to the Centers
For Disease Control and Prevention.
• Preventive maintenance of steam systems is one of the best ways
to prevent slips and falls at facility.
• Maintenance staff can take action to repair aging assets before
they become a problem.
• Likewise, slip-resistant footwear can protect employees from
hard-to-spot hazards in low-light environments.
2. STEAM LEAKS
• Steam leaks can lead to abnormally warm pipes and ambient
temperatures, making the facility unsafe for workers. This problem is
especially apparent in low-pressure steam systems where feedwater
must be heated past the boiling point.
• Burns caused by steam can severely injure workers and reduce
efficiency over the long term.
• Assuring steam traps (The duty of a steam trap is to discharge
condensate, air and other incondensable gases from a steam system) are
functional is one of the top ways to reduce the risk of dangerous leaks.

3. RUPTURED PIPES
• A ruptured steam pipe is a serious problem with the potential to cause
bodily harm and serious financial risk.
• Poor maintenance of steam systems can also lead to pipe and valve
corrosion, two more precursors to pipe rupture.
• Traps and valves should be monitored regularly for signs of anomalies
4. FINANCIAL LOSS
• If a steam system has never been inspected and isn’t subject to a
recurring maintenance program, upwards of 50 percent of the
system’s steam traps could be failed or blowing live steam.
• This can severely cut into a facility’s operating costs. Managers
who want to control costs and conserve precious resources need to
implement a preventive maintenance system to protect their assets
and employees.
• A annual inspection of a steam system can reduce trap and valve
failures by half, and more frequent preventive maintenance will
increase efficiency accordingly.
Hazards from air
• Air based hazards are those happening because of the pollutants
that are known or suspected to cause cancer or other serious
health effects, such as reproductive effects or birth defects, or
adverse environmental effects.
• Many studies have established that short-term exposure to higher levels
of outdoor air pollution is associated with reduced lung function, asthma,
cardiac problems, emergency department visits, and hospital admissions.
• Mortality rates related to air pollution are also a concern.
There are many potentially hazardous air pollutants including:
• Dioxins and Poly Chlorinated Biphenyls (PCBs)
• Xylene
• Mercury
• Benzene
• Toluene
• Chromium.
• Polycyclic Aromatic Hydrocarbons (PAH)
• Styrene.
The specific disease outcomes most strongly linked with exposure to
air pollution include stroke, ischaemic heart disease, chronic
obstructive pulmonary disease, lung cancer, pneumonia, and cataract

Sources of air hazard

• Household combustion devices, motor vehicles, industrial
facilities and forest fires are common sources of air pollution.
• Pollutants of major public health concern include particulate
matter, carbon monoxide, ozone, nitrogen dioxide and sulfur
dioxide.
• Chemicals released from consumer products, gas appliances,
building materials, smoking, and furniture can all contribute to this
problem. Exposure to indoor air pollutants can result in a range of
health effects, such as eye and throat irritation, asthma and other
respiratory diseases and cancer.
Hazards from water
• Water hazards encompass a range of dangerous situations or
conditions related to water, both natural and man-made. This
includes floods, tsunamis, storm surges, conditions like rip
currents, polluted water sources, and waterborne diseases.
• Contaminated water and poor sanitation are linked to transmission of
diseases such as cholera, diarrhoea, dysentery, hepatitis A, typhoid and
polio.
• Absent, inadequate, or inappropriately managed water and sanitation
services expose individuals to health risks.
• Currents in rivers, creeks and streams can be fast-moving and
unpredictable. While some strong currents such as rapids are visible,
others can flow under the water's surface. In oceans or lakes, waves and
rip currents can be dangerous.
• Abnormally high rainfall and glacial melting leads to floods and
associated water related hazards. On the other hand, drought
conditions persist, it may cause massive damages to ecosystem,
agriculture and economic system.
• Sources of water hazards - Harmful germs and chemicals can get
in the water from many sources, including: Fertilizers, pesticides,
or other chemicals that have been applied to land near the water.,
Concentrated feeding operations (large industrial animal farms),
Manufacturing operations.
• Most disasters are water-related. Floods, landslides, storms, heat
waves, wildfires, extreme cold, droughts and waterborne disease
outbreaks are all becoming more frequent and more intense,
mainly due to climate change.
• Aquatic hazards include drowning, near-drowning, fall impact
injuries, and injuries resulting from improperly designed and
poorly maintained water circulation systems. The latter can result
in swimmer entrapment and bodily injury.