INDUSTRIAL HAZARDS AND SAFETY GUIDE

INDUSTRIAL HAZARDS AND SAFETY
Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D
Department of Pharmaceutics
KLE University College of Pharmacy
BELGAUM-590010, Karnataka, India
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com
24 August 2012 KLE College of Pharmacy, Nipani 1
CONTENTS
Introduction
Types of hazards
Recommendations and Suggestions
Industrial effluent testing and treatment
Discussion on industrial accident case
studies
Questions
References
INTRODUCTION
Industrial hazards:
It can be defined as any condition produced by

industries that may cause injury or death to
personal or loss of product or property.

Heat and Cold
Burns Foot sore
Heat stroke Immersion

foot
Heat
cramps Frost bite
Preventive Measures
A reasonable temp. of 20-250C must be

maintained
Noise have two type of effects
Auditory
Non auditory effects
Preventive measures
a. At source:
Source of noise can be enclosed with an insulation
material or concrete wall.
Proper maintenance of machinery
b. By distance
c. Personal protection against noise.

Equipment noise sources ,level & potential control solutions
Equipment Sound level in Possible noise control

dBA at 3 feet treatments
Air coolers 87-94 Aerodynamic fun blades,
revolutions/min pitch,
pressure drop
Compressors 90-120 Install mufflers on intake,&
exhaust, enclosure the
machine with casing,
vibration isolation & lagging
of piping system
Electric motors 90-110 Acoustically lined fun
covers, enclosure 7 motor
mutes
Equipment noise sources ,level & potential control solutions
Heater & 95-110 Acoustic plenums, intake mufflers,

furnaces lined & damped ducts
Valves <80-108 Avoid sonic velocities, limit

pressure drop & mass flow,
replace with special low noise
valves
Piping 9-105 Inline silencers, vibration isolation

Radiation
Radiation are divided into two groups
Natural Man made

Cosmic rays Medical /dental x-rays isotopes
Environmental (radioactive Occupational exposure

elements e.g. uranium)
Internal (potassium,) Nuclear radioactive fallout
Approx 0.1 rad/yr Miscellaneous
Use of radio active substances
by different industries

Effect of hazards
Somatic
Genetic
i. Preventive measures
ii. Radiation source should be housed in a building
that shields any surrounding area.
iii. Radiation badges should be worn.
iv. Periodical medical examination.
v. Proper use of lead shields & lead rubber aprons.

Fire & explosion hazards
Causes
Smoking in the factory
Defective heating equipment, electrical equipment &
wiring.
Explosive gas leakage.
Inadequate protection of electric motors
Sparking of electric wires & equipment
Protection & prevention
Types of fire

Preventive measures
Prohibition of smoking in manufacturing areas.
Oxygen present in the inflammable atmosphere may
be by dilution with gases such as nitrogen, co2,steam
or combination of these.
Hazardous operation should be isolated
Eliminating the ignition sources
Using fire resistant material in construction
Suitable emergency exits
Adequate venting
Automatic sprinklers
Equipment should design to meet the specifications &
code of recognized authorities, such as ISA, API
&ASME
The design & construction of pressure vessels &
storage tanks should follow API & ASME codes.
Inspection

Local Inhalatio
n
Dermatitis Gas Poisoning
Eczema
Ulcers
Cancer Chemical
Hazards
Ingestio
n
Living tissue may be destroyed by chemical reactions such as
Dehydration
Digestion
Oxidation

Source, effect & precautions of chemical hazards
Type/ source of Effect/ organ Precautions to be taken

chemical contaminant affected
Acridines, Dermatitis Cleanliness, removal of people

phenothiazines from the areas as soon as first
sign of skin reaction is observed.
Solvents like Handle with care

chloroform, benzene
Vegetable drugs like Dust evolves, Goggles are to be worn
capsicum & affects eye
podophyllum
Long term use of filter Dust explosion Regular cleaning
without cleaning

Source, effect & precautions of chemical hazards
Improper use of contamination Follow established

cleaning agents cleaning procedures
Working with radio Hazards due to Wearing lead coat,

pharmaceuticals emitted radiation maintaining pressure
of working area
slightly less than
atmospheric pressure
Underground tanks Difficulty in Minimal use of

monitoring underground tanks
interior & exterior

PREVENTIVE MEASURES
Tolerance levels for toxic chemicals set by federal

regulations have to be followed.
Strict observation of operations of all safety

regulations

Biological hazards
Disease due to biological hazards
Brucellosis (dairy industry)
Byssinosis (textile industry)
Bagassosis (sugar-cane)
Loco motor disorder
Preventive measures
Periodic health check up
Personal protection
The manufacturer should also provide
First aid facilities
Initial examination
Facility for vaccination
Routine sanitation programme
Mechanical hazards
Accidents usually take place by the combination of unsafe
condition & carelessness.
Most of industrial accidents are due to
Faulty inspection
Inability of employee
Poor discipline
Lack of concentration
Unsafe practice
Mental & physical unfitness for job
Faulty equipment or improper working condition
Improper training regarding the safety aspects

Mechanical hazards
In order to prevent mechanical accidents factories act
lay down certain requirements
For cranes
End buffers
Indicating lamps
Signals
Proof loading
upto20 tons 25% in excess
20 to 50 tons 5 tons in excess
above 50 tons 10% in excess
Mechanical hazards

Building planning
Floors must be of unskid/non-slippery type.
Enough space for employees to work.
Passages between working places.
Proper arrangements of temperature control; like fans,

A.C., heaters.

Building planning

Safe material handling
Careless handling of heavy materials and components
should be avoided.
Full use of mechanical material handling equipment.
All material handling equipments should be repaired

and maintained properly.
Containers employed to transport liquids should not

be defective or leaking.
Personal protective devices
Protection of head by using hard hats/helmets.
Protection of ears by using earmufffs and plugs.
Protection of face by using face marks, face

shields.

Electrical hazards
Shocks
Sparking
Fire
Wiring faults
Preventive measures
Proper maintenance of wiring & equipment
High voltage equipment should be properly enclosed
Good house keeping
Water should not be used for dousing electric fire
Worker should avoid working in electric circuits or
equipment in wet clothing or shoes.
Pollution hazards
Types
a. Air pollution
b. Water pollution
c. Thermal pollution
d. Sound pollution
Air pollution
Sources
Automobiles
Industries
Domestic
Preventive measures
i. Those suitable for removing particulate matter
a. Ventilation
Exhaust ventilation
Plenum ventilation
b. Air purifying equipment
ii. Those associated with removing gaseous pollutants
Water pollution
1. Types of water pollutants
Physical
Chemical
Physiological
Biological
Preventive measures
2. Problems of water pollution
3. Preventive measure
a. Control of water pollution
i. Physical treatment
Storage
Filtration
ii. Chemical treatment
iii. Biological treatment
b. Treatment of industrial waste
Primary treatment
Secondary treatment
Tertiary treatment
Preventive measures
c. Thermal pollution
Effects
Damage to aquatic environment
Reduction in assimilative capacity of organic waste
Various off stream cooling systems

i. Wet cooling towers
ii. Dry cooling towers
iii. Cooling ponds
iv. Spray ponds
Recommendations & suggestions
Proper treatment & disposal methods for effluents

should be adopted
An awareness program
Measures for increase efficiency of the water use

Classification of signs according to use
(1) Danger signs.
The DANGER header is used when there is a hazardous

situation which has a high probability of death or severe
injury. It should not be considered for property damage
unless personal injury risk is present.

2) Caution signs. (i)
The CAUTION header is used to indicate a hazardous

situation which may result in minor or moderate
injury. However, Caution should not be used when
there is a possibility of death or serious injury.

(3) Safety instruction signs
General Safety Signs (SAFETY FIRST, BE

CAREFUL, THINK) should indicate general
instructions relative to safe work practices,
reminders of proper safety procedures, and the
location of safety equipment.

(4) Biological hazard signs.
The biological hazard warning shall be used to

signify the actual or potential presence of a
biohazard and to identify equipment, containers,
rooms, materials, experimental animals, or
combinations thereof, which contain, or are
contaminated with, viable hazardous agents.

Pictograph
Pictograph means a pictorial representation used to

identify a hazardous condition or to convey a safety
instruction

Signal Word
Signal word means that portion of a tag's inscription

that contains the word or words that are intended to
capture the employee's immediate attention.

Tag
Tag means a device usually made of card, paper, pasteboard,
plastic or other material used to identify a hazardous
condition.

Danger Tags
Danger tags shall be used in major hazard situations
where an immediate hazard presents a threat of death
or serious injury to employees. Danger tags shall be
used only in these situations.

Caution Tags
Caution tags shall be used in minor hazard situations
where a non-immediate or potential hazard or unsafe
practice presents a lesser threat of employee injury.
Caution tags shall be used only in these situations.

Warning Tags
Warning tags may be used to represent a hazard level
between "Caution" and "Danger," instead of the
required "Caution" tag, provided that they have a
signal word of "Warning," an appropriate major
message

Biological Hazard Tags
The symbol design for biological hazard tags shall
conform to the design shown below:

Color Coding-Danger Tag
"DANGER" -- Red, or predominantly red, with

lettering or symbols in a contrasting color.

Color Coding-Caution Tag
"CAUTION" -- Yellow, or predominantly yellow, with

Color Coding-Warning Tag
"WARNING" -- Orange, or predominantly orange, with


Biological Hazard Tag
BIOLOGICAL HAZARD -- Fluorescent orange or
orange-red, or predominantly so, with lettering or
symbols in a contrasting color.

Industrial effluent testing and treatment
Effluent is an outflowing of water from a natural body
of water, or from a man-made structure.
Water pollution or waste water discharge from the
industrial facilities.
REASON OF TESTING
To find out
-Pollution load
-Presence of toxic ingredients
-Color, turbidity, odour and quality of water
-pH and acidity / alkalinity
-Suspended solids and dissolved solids
-Phenolic compounds and oily materials
GUIDELINES FOR TESTING EFFLUENTS
Samples may be collected at specific intervals and

finally can be mixed before analysis.
Containers made up of glass, polythene or any suitable
plastic material may be used.
Samples may also be refrigerated to avoid loss of
volatile matter
Samples could be preserved after adjusting the pH
O2, CO2, CO may be estimated

THE RESULTS OF TESTING ARE REPORTED
AS FOLLOWS:
Effluents may be expressed as mg/ltr, ppm, %/ltr, and

mcg/ltr
Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes
content should be reported
TESTING OF WASTE WATER
TEST (EFFLUENT)
TREATMENT METHOD
pH
Acidic Lime or NAOH
Basic H2SO4
AS FOLLOWS:
Suspended Solids Sedimentation
Oil and grease -grease taps

-skimming
Cyanide
Chlorinated & complex with pyridine -alkaline chlorination
pyroxolene -oxidation with ozone
-Colourimetrically -oxidation with H2O2
Phosphates
-Convert to ammonium molybdatephosphates -ppt with chalk or lime
-extracted with benzene/ isobutyl alcohol -coagulation with alum
mixture
-organic phase treated with tin chloride (blue)
Colourimetrically
AS FOLLOWS:
Mercury
-treated with nitric acid and potassium -Coagulation
dichromate soln- treared with tin chloride
-chelation with
Vapour determined by spectrophotometry trimercaptotriazine
Phenolic compounds Removal by polymeric

adsorbents
Steam distillation-acidify (pH<4)- add CuSO4
soln-
Add aminoantipyrine soln- extracted with
chloroform
calorimetrically

BIOLOGICAL OXYGEN DEMAND
It is the amounts of oxygen required by micro organisms to

bio chemically oxidize carbonaceous organic matter at 20
0C in 5 days.
10 mg/litre or less
Excess makes water toxic
MEASUREMENT
Special designed bottle with flared cap

Incubated at 20 0C for 5 day measuring DO
Microorganism added if required

Dissol oxy in ppm (mg/ltr) = N(V) (8) (1000)
V1
V = Volume of sodium thio sulphate required.
N = Normality
V 1= Volume of sample taken.
CHEMICAL OXYGEN DEMAND

Oxygen equivalent of organic matter present in waste water
that is susceptible to oxidation
Waste water sample is refluxed with a known excess of pot.
dichromate in a 50% sulphuric acid solution in presence of
silver sulphate and mercuric sulphate

CHEMICAL OXYGEN DEMAND
The organic matter of the sample is oxidised to water, carbon

dioxide and ammonia
The excess of dichromate remaining untreated in the solution
is titrated against standard ferrous ammonium sulphate
(V1-V2) x N x 8 x100
COD(mg/l) =
Where, X
V1 = Volume of ferrous ammonium sulphate solution
consumed in blank
V2 = Volume of ferrous ammonium sulphate solution
consumed for test solution
X= Volume of sample taken
N= Normality ofKLE
24 August 2012 ferrous
College ofammonium
Pharmacy, Nipani sulphate solution 58
Limit for Discharge into Systems
Sr. No. Parameters Tolerance limits

1 pH 5.5 9.0
2 Oil and grease 10
3 Total suspended solid, mg/l 100
4 BOD, mg/l 30
5 COD, mg/l 50
6 Mercury 0.01
7 Arsenic, mg/l 0.20
8 Cyanide, mg/l 0.10
9 Sulphides, mg/l 2.00
10 Phosphates, mg/l 5.00
Waste Water Treatment
Waste Water Pretreatment
Attempted to render the effluent suitable for further
treatment
Equalization
Concentrated waste is diluted if necessary
-by mechanical mixing
-by aeration mixing
Neutralization
Removal of Grease and Oils

Primary Treatment of Waste Water
Removal of large floating or suspended particle by
physical and chemical treatment
Screening
Large particles are removed
Coarse screen of metal bars or heavy wires spaced 25-50
mm apart
Finer materials are separated by screening through 0.8-6
mm meshes
Grit Chambers
Removal of particles by centrifugal action and friction
against tank walls
Diffused air used for mixing pattern
It is used
To prevent any damage to equipment
To avoid settling in pipe bends
Chemical Reaction
Involves agglomeration of tiny particles into large
particles
Flocculation
-by mechanical stirring and by chemical flocculants
Precipitation
-Large amount of suspended solid formed
Coagulation
-Formation of large and quick settling flocs by
a) Reduction of charges and repulsive force
b) Adsorption on long chain molecular structure
Secondary Treatment of Waste Water
It is a biological process
C, H, and O sources are available
Nitrogen should be 5% of the BOD
Phosphorus should be 20% of mass of nitrogen
Environmental conditions are provided
Advantages
Continuous waste treatment is favored
Low cost system
Disadvantages
Prior prediction of biological degradability is not possible
Solubility limits biodegradability
Activated Sludge Process
Microbial Floc is suspended in tank
Air is continuously supplied
Biological degradation of waste into CO2 and H2O
Bacterial flora grows and remains suspended in the form
of floc called as activated sludge
20% of sludge is recycled
6 to 24 hours aeration is required

Advantages
-Removal of soluble organic substance, colloidal
matter, particulate matter, inorganic substance
-Produce high quality effluent
Disadvantage
-Maintenance cost is high
-Growth of anaerobic bacteria fungi etc

Activated Sludge Process

Trickling filtration process
Microorganisms are attached to fixed bed
It acts as a filter
Bed is maintained at height of 2.5 meter
Gelatinous film is formed
Effluent is sprayed over the surface
Slots at the bottom for air inlet
Aerobic metabolism occur on the surface
Anaerobic metabolism occur at the bottom

Trickling Filtration Process

Trickling Filtration Process
Advantages
Produce effluent of consistent quality
Aerobic and anaerobic digestion are achieved
More economical
Sludge can be removed quickly
Disadvantage
Cost for ventilation duct for air supply is high
Efficiency decreases in the winter

Oxidation Ponds
Depth should be 1 to 2 meters.
Bottom and sides are lined with polyethylene, cement.
Oxygen released by algae, carbon dioxide generate from
biodegradative
Aerobic oxidation producing carbon dioxide and water.
Advantage:
Operation is simple and economical.
Disadvantages:
Required disinfections
Use for wastes having low BOD.
Tertiary Treatment Of Waste Water
Meant for polishing the effluents.
Bacteria are removed by keeping in maturation
ponds.
Chlorinated, if still contain bacteria.
Methods are more expensive than biological
treatment.
Coagulation :
Reaction take place upon addition of the
coagulants.
-Metal salts
-Organic Polymers
In water, form insoluble product with impurities.
Coprecipitation :
Ions in solution phase precipitate with the carrier
molecule by
-Adsorption Process
-Inclusion Process
Filtration
Most common type in addition to disinfection.
Practiced prior to the chlorination.
Should be done after coagulation.
May be made up of sand, activated charcoal.
Adsorption
Involves treatment with activated carbon.
Useful for removal of pesticides

REFRENCES
Pharmaceutical Production and Management By C. V. S. Subrahmanyam
www.geocities.com
www.britannica.com
http://nptel:iipm.ac.in
www.waste_management_world.com
Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel
The Theory & Practical of Industrial Pharmacy By Leon Lachman, Herbert

A. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House.
www.osha.gov
THANK YOU
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com

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INDUSTRIAL HAZARDS AND SAFETY

Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D

It can be defined as any condition produced by

24 August 2012 KLE College of Pharmacy, Nipani 3

Burns Foot sore

Heat stroke Immersion

A reasonable temp. of 20-250C must be

24 August 2012 KLE College of Pharmacy, Nipani 8

Equipment Sound level in Possible noise control

Heater & 95-110 Acoustic plenums, intake mufflers,

Valves <80-108 Avoid sonic velocities, limit

Piping 9-105 Inline silencers, vibration isolation

24 August 2012 KLE College of Pharmacy, Nipani 10

Natural Man made

Environmental (radioactive Occupational exposure

24 August 2012 KLE College of Pharmacy, Nipani 12

24 August 2012 KLE College of Pharmacy, Nipani 13

24 August 2012 KLE College of Pharmacy, Nipani 15

24 August 2012 KLE College of Pharmacy, Nipani 17

24 August 2012 KLE College of Pharmacy, Nipani 18

Type/ source of Effect/ organ Precautions to be taken

Acridines, Dermatitis Cleanliness, removal of people

Solvents like Handle with care

24 August 2012 KLE College of Pharmacy, Nipani 19

Improper use of contamination Follow established

Working with radio Hazards due to Wearing lead coat,

Underground tanks Difficulty in Minimal use of

24 August 2012 KLE College of Pharmacy, Nipani 20

Tolerance levels for toxic chemicals set by federal

Strict observation of operations of all safety

24 August 2012 KLE College of Pharmacy, Nipani 21

24 August 2012 KLE College of Pharmacy, Nipani 23

24 August 2012 KLE College of Pharmacy, Nipani 25

Enough space for employees to work.

Passages between working places.

Proper arrangements of temperature control; like fans,

24 August 2012 KLE College of Pharmacy, Nipani 26

24 August 2012 KLE College of Pharmacy, Nipani 27

Full use of mechanical material handling equipment.

All material handling equipments should be repaired

Containers employed to transport liquids should not

Protection of head by using hard hats/helmets.

Protection of ears by using earmufffs and plugs.

Protection of face by using face marks, face

24 August 2012 KLE College of Pharmacy, Nipani 29

Various off stream cooling systems

Proper treatment & disposal methods for effluents

Measures for increase efficiency of the water use

24 August 2012 KLE College of Pharmacy, Nipani 35

The DANGER header is used when there is a hazardous

24 August 2012 KLE College of Pharmacy, Nipani 36

The CAUTION header is used to indicate a hazardous

24 August 2012 KLE College of Pharmacy, Nipani 37

General Safety Signs (SAFETY FIRST, BE

24 August 2012 KLE College of Pharmacy, Nipani 38

The biological hazard warning shall be used to

24 August 2012 KLE College of Pharmacy, Nipani 39

Pictograph means a pictorial representation used to

24 August 2012 KLE College of Pharmacy, Nipani 40

Signal word means that portion of a tag's inscription

24 August 2012 KLE College of Pharmacy, Nipani 41

24 August 2012 KLE College of Pharmacy, Nipani 42