MODULE 1

U C TI O N TO S AFE T Y
IN TR OD
1.0 Introduction
 Technological development is taking place at a very fast rate in all
the fields namely mechanical, metallurgical, chemical, electrical
and civil.
 These days every man is surrounded by automobiles, trains,
explosives, noise etc.…., which may cause accidents.
 The danger of life of human being is increasing with the
advancement of scientific developments in different fields.
 Safety is a very important aspect of any particular activity.
 Suppose, we are playing a game, we have to play it in a very safe
mode otherwise, we will get injured.
Definition
 Industrial safety is a branch of management which is concerned
with reducing, controlling and eliminating hazards from
industries or industrial units.
 Industrial Safety refers to protection of worker from danger of
industrial accidents.
 Industrial safety is of prime importance in any organization,
because if safety measures are not taken chances of industrial
accidents are definitely going to be increased.
1.1 Objectives of safety and security measures:
a. To achieve 100% safety and 100% security installations,
equipment, human life and animal life
b. To bring awareness about safety rules
c. To educate personnel
d. To prevent accidents by reducing the hazards to minimum
e. Study of unsafe acts and unsafe conditions leading to accidents.
To take corrective measures to eliminate them
f. To ensure first aid and emergency help in case of accident
g. To understand the cause and effect relationship in accidents
associated with any system
h. To establish safety management system, safety audit system
1.2 Terms Used:
1. ACCIDENT: An unpleasant, unexpected, unforeseen or unintended
happening sometimes resulting from negligence, that results in injury, loss,
damage, etc., and is caused by mistake or machine failure or natural disaster
Accidents may cause ‘Mishap, ruin, destruction, injury, death. Accidents must
be prevented by precautions and safety measures and safety management. For
instance, in an organization a person while working receiving an electric
current, a labor cut his finger from machine, blast in chemical industry, a fire in
textile industry etc.
2. SAFETY: A quality or condition of being safe from ‘danger, injury, damage,
loss, accident’. Safety means freedom from the occurrence of injury or loss.
3.HAZARD: To expose to, ‘danger, risk, chance of accident’.
Hazard is a term associated with a substance that will cause an
injury in a given environment or situation. Industrial hazard is
defined as any condition produced by industries that may cause
injury or death to personnel or loss of product or property
4. SAFE: Free from injury, damage, accident, loss’.
5.SAFETY DEVICES: Devices which ensure safety against injury
or loss. Example- Safety belt, Safety glasses, Safety earthing,
Safety enclosure, Safety fence etc.,
6.SAFETY GUARD: Any person or thing or devices that prevents
injury, loss and ensure safety and security.
7.SECURITY: State of sense or safety protection or defence
against attack, interference etc

8.PRECAUTION: Care or measure taken beforehand against

possible danger.
9.CAUTION: a) A word or sign by which warning is given b) Act or
practice of being cautious.
10.APPLIANCE: Device which performs specific task Example:
Stove, Heater etc.
 1.3 SLIP, TRIP and FALL:
 Falls and slips from elevations or on the same level occur in all
industries, in all occupations and in all work settings.
 One of the more serious and potentially deadly hazards are falls
from elevations.
 Falls and slips on the same level are equally injurious though not
equally severe to result in fatality.
 When fall hazards are recognized, provisions to reduce the
hazards can be developed, implemented and reinforced on a
timely basis to prevent deaths and injuries.
The management of a company develops, implement and enforce a
comprehensive, written fall protection programme. The programme
should include the following
1. Addressing all aspects of safety and hazards in the planning
phase of projects.
2. Identifying all fall hazards at the work site.
3. Training employees in the recognition and avoidance of unsafe
conditions and the regulations to control or eliminate the hazards
applicable to their work environment.
Fall protection training is recommended to include classroom
instruction supplemented by hands-on training with equipment.
Training should commence at the time of appointment of new
employees who will be exposed to fall hazards and continue
periodically.
Workers can be involved in identifying tasks that create fall
hazards and methods used to eliminate these hazards.
4. A job hazard analysis for each task to be performed
5. Providing appropriate fall protection equipment, training
workers on its proper use.
6. Conducting scheduled and unscheduled inspection
7. Establishment of medical and rescue programmes
8. Encouraging the workers to actively participate in the
workplace safety
1.4 Fall Protection Programme:
1. Ladders: Safety features provided in ladders are slip-resistant
steps, positioning feet and top and bottom stabilizers.
Some factors to be considered before using or climbing a ladder are,
a) Placement
b) Climbing style
c) Descending style
d) Angle of inclination
Factors that contribute to falls from ladders are
e) Ladder slips (from top or bottom)
f) Slipping on steps
g) Defective equipment
h) Improper ladder selection for a given task
The workers should be knowledgeable of the following
when using ladders:
a. Visually inspect for structural damage such as, split/bent
side rails, broken or missing steps
b. Damaged safety devices such as rung locks
c. Safety shoes/feet
d. Grease, dirt or other contaminants that could cause slip
e. Paint or stickers that could hide possible defects
Ladder Climbing Guidelines:
a. Wear slip-resistant footwear
b. Keep the area around the top and bottom of the ladder clear
c. Wear approved fall protection equipment where applicable
d. Never carry large objects while ascending or descending a ladder
e. Keep both hands free for climbing or coming down
f. Face the ladder and maintain three point contact i.e., two hands
and one foot or one hand two feet on the ladder
g. Do not overload the ladder
Types of Ladders a. Portable Ladders:
1. Self supporting ladders
2. Straight or extension ladders
b. Fixed ladders:
1. Each step should be capable of
withstand 114 kg applied in the
middle of the step
2. Steps of fixed metal ladders
should be corrugated, knurled or
coated with skid resistant
material
3. Cages, wells, ladder safety
devices or self retracting life lines
should be provided to fixed
ladders, where length of climb
exceeds 24 feet
2. Scaffolds: Every worker should be knowledgeable of the
following when using scaffolds:
a. The footing for scaffolds should be rigid
b. Loose bricks or concrete blocks should not be used to support
scaffolds or planks
c. Guard rails and toe- boards should be installed on all open sides
and ends of platform more than 10 feet above the ground level
d. Damaged parts should be repaired or replaced
e. A competent person should inspect the scaffolding
f. Employees should be trained for climbing scaffolds
1.4.1 Falls from buildings or other structures:
Safety measures include:
a. Permanent structural members should be provided across
the length
b. A competent person should evaluate the critical points and
check the safety equipment's (safety belts if required)
c. A competent person should routinely inspect all protective
devices( e.g., guard rails., etc.)
d. Plant/ operators should identify areas that are hazardous
and restrict the use of these areas
1.4.2 Falls and Slips on the same level:
Slipping are the common hazards for falls on the same level, in order
to prevent slips and falls one should ensure the following:
a. Identify the factors that contribute to slips and falls in the work
area
b. Good housekeeping is essential in preventing falls and slips
c. Regular cleaning and clearing of grease, oil, dirt or chemical
accumulation is a must
d. Work floors should be maintained with non-skid material
e. Use slip resistant footwears
f. Floor cracks, floor joints or ditches should be repaired
g. Manual handling of material should be observed and the
individual should not be overloaded because this may
imbalance him and cause a fall
h. Inspection of work area should be conducted by the
competent personnel Periodically
1.5 ACCIDENT:
• An unpleasant, unexpected, unforeseen or unintended happening sometimes
resulting from negligence, that results in injury, loss, damage, etc., and is
caused by mistake or machine failure or natural disaster.
• Accidents may cause ‘Mishap, ruin, destruction, injury, death’.
• Accidents must be prevented by precautions and safety measures and safety
management.
• For instance, in an organization a person while working receiving an
electric current, a labor cut his finger from machine, blast in chemical
industry, a fire in textile industry etc.
Causes of Accident:
1. Unsafe physical/mechanical/environmental condition:
a. Inadequate mechanical guarding
b. Defective equipment such as ladders, floors, piping etc.,
c. Unsafe design
d. Hazardous process, operation or arrangement
Example: storage, overloading, violation of desired norms of good
housekeeping
e. Inadequate illumination
f. Inadequate ventilation
g. Unsafe dress and personal protective equipment
Example: loose clothing, defective gloves, aprons, shoes etc.
2. Unsafe personal acts :
a. Working unsafely Examples: Improper lifting, performing maintenance or
repairs on moving machinery, working under suspended loads, incorrect
mixing of materials etc
b. Performing operations without supervisors permission or without training
c. Removing safety devices
d. Operating at unsafe speeds
e. Use of unsafe tools or equipment
Example: Using a chisel with a mushroomed head, Removing chips by hand
and not by brush
f. Teasing and abusing
g. Working under the influence of drugs or alcohol
h. Failure to use safe cloths or personal protective equipment
3. Unsafe personal factors:
a. Unsafe improper attitudes
b. Lack of knowledge or skills
c. Faulty vision
d. Poor hearing
e. Fatigue, slow reaction
1.5.1 Reasons for accidents:
Accidents occur due to following factors:
a) Lack of knowledge on the activity being undertaken
b) Lack of safety aspects in design 7
c) Lack of commitment to safety
d) Lack of control
e) Lack of education, training
f) Lack of team work
g) Lack of discipline
h. Lack of social responsibility and personal responsibility
i. Failure to learn from past experiences of similar incidents
j. Failure to employee competent and well trained people
k. Failure to identify critical components
l. Lack of safety policy
m. Absence of safety officer at the workplace
Stages to an accident:
1.6 Hazardous energy control (or Lockout/Tagout)
a) What is hazardous energy?
Hazardous energy is defined by the Canadian Standards Association (CSA) as:
"any electrical, mechanical, pneumatic, chemical, nuclear, thermal, or other
energy that can harm people"
b) What is lockout/tagout procedures?
"Lockout/tagout" refers to specific practices and procedures to safeguard
employees from the unexpected energization or startup of machinery and
equipment, or the release of hazardous energy during service or maintenance
activities.
 A lockout uses a lock to hold an energy isolation device in a
safe position and prevents the energization of the machine or
equipment.
 Tagout is when a tag is placed on a piece of equipment to
indicate that the equipment being controlled may not be
operated until the tagout device is removed.
1.6.1 Lockout/tagout Procedure
1. Notify all affected employees that a lockout is required and the reason
therefore.
2. If the equipment is operating, shut it down by the normal stopping
procedure (such as: depress stop button, open toggle switch).
3. Operate the switch, valve, or other energy isolating devices so that the
energy source(s) (electrical, mechanical, hydraulic, other) is disconnected
or isolated from the equipment.
4. Lockout energy isolating devices with an assigned individual lock.
5. Stored energy, such as that in capacitors, springs, elevated machine
members, rotating fly wheels, hydraulic systems, and air, gas, steam or water
pressure, must also be dissipated or restained by methods such as grounding,
repositioning, blocking, bleeding down.
6. After ensuring that no personnel are exposed and as a check on having
disconnected the energy sources, operate the push button or other normal
operating controls to make certain the equipment will not operate.
CAUTION: Return operating controls to neutral position after the test.
7. The equipment is now locked out.
1.7 What is a Material Safety Data Sheet (MSDS)?

A material safety data sheet is a technical document which provides detailed

and comprehensive information on a controlled product related to:
a. Health effects of exposure to the product
b. Hazard evaluation related to the product’s handling, storage or use
c. Measure to protect workers at risk of exposure
d. Emergency procedures.
MSDS are to be provided by Supplier’s with all deliveries, must be Accessible
to EVERYONE in the workplace.
Material Safety Data Sheet Content:
A supplier must provide at least nine categories or sections of content and
approximately sixty items of information distributed among those categories.
An MSDS must be reviewed at least every three years.
The categories must have the following similar headings:
1.Hazardous Ingredients
2. Preparation Information
3. Product Information
4. Physical Data
5. Fire and Explosion Hazard
6. Reactivity Data:
7. Toxicology Properties:
8. Preventative Measures:
9. First Aid Measures:
1.Hazardous Ingredients
This section will include:
1) The chemical names and concentrations concerning the hazardous
ingredients
2) Chemical Abstracts Service (CAS) number which is useful in locating
more information especially if the product is known by numerous
names
2. Preparation Information
This section includes:
1) The name, address and telephone number of who prepared the MSDS.
2) The date the MSDS was prepared, If more than three years old, it must be
updated.
3. Product Information
This section:
3) Identifies the product by the name on the supplier label
4) Provides the chemical name, family and formula (including molecular
weight)
5) Lists the product identifiers, manufacturer and supplier names, addresses
and emergency telephone numbers
4. Physical Data
This section includes 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:
1) The state it is in e.g. liquid
2) The odour and appearance of the product
3) The specific gravity, vapour density, evaporation rate, boiling point and
the freezing point
4) The vapour pressure, the higher the concentration the higher the possible
air concentration
5) The odour threshold, which is the lowest airborne concentration of a
chemical that can be perceived by smell
6) The pH reflecting the corrosive or irritant nature of the product
5. Fire and Explosion Hazard
This section describes:
1) The temperature and conditions that can cause the chemical to catch fire
or explode
2) Type of fire extinguisher required
3) Personal Protective Equipment required for fire fighting
6. Reactivity Data:
This section describes:
4) The chemical stability of the product and its reactions to light, heat,
moisture, shock and incompatible materials
5) Storage requirements based on the reactivity or instability of the product
1) Incompatible products that must not be mixed or stored near each other
2) The need for disposal before they become extremely reactive
7. Toxicology Properties:
This section describes:
3) The harmful effects of exposure
4) How the product is likely to enter the body and what effects it has on the
organs in the body
5) The short-term (acute) and long-term (chronic) health effects from exposure
to the product
6) The exposure limits, which indicates the maximum concentration in air of a
hazardous substance (gas, vapour, dust, mist, fume) to which nearly all
workers (without personal protective equipment) can be repeatedly exposed
without adverse health effects
8. Preventative Measures:
This section provides:
1) Instruction for the safe use, handling and storage of the product
2) The personal protective equipment or safety devices required
3) The steps for cleaning up spills
4) Information on the waste disposal requirements
9. First Aid Measures:
This section describes:
1) Specific first aid measures related to acute effects of exposure to the
product
2) First aid steps in the correct sequence
3) Information to assist in planning for emergencies The MSDS may contain
additional sections providing further information related to the specific
product.
Location of the MSDS:
1) Hard copy readily available
2) Computer terminals
3) Employees and others must know where the MSDS is and how to use
them
1.8 Occupational Safety and Health Administration (OSHA):
 The Occupational Safety and Health Administration, more commonly
known by its acronym OSHA, is responsible for protecting worker health
and safety in the United States.
 It is to ensure safe and healthy working conditions for workers by
enforcing workplace laws and standards and also by providing training,
education and assistance.
 OSHA rules cover numerous industry workplaces from construction to
agriculture. To help employers adhere to its standards and requirements,
OSHA offers training and tools to educate employers and employees.
 OSHA is required to explain the procedures, equipment and training that
employers and workers must use to reduce hazards and ensure safety
measures specific to the employers’ workplace and workers’ jobs.
 To comply with OSHA requirements, employers must take a number of
specific actions; those include inspecting the workplace for potential
hazards, eliminating or minimizing hazards, keeping records of workplace
injuries and illness, training employees to recognize safety and health
hazards, and educating employees on precautions to prevent accidents.
 OSHA also requires employees to follow rules, such as complying with all
applicable OSHA standards, 11 following OSHA safety regulations,
wearing required protective equipment, reporting hazardous conditions, and
reporting job-related injuries and illnesses.
1.9 Safe material handling and storage:
More than 30% of the total number of accidents resulting in injury or property
damage is caused during material handling in industries. Attempts should be
made to eliminate or reduce material handling to the minimum as it does not
add value to the cost.
a. The basic facts with respect to material handling:
1. Material handling does not add any value
2. Material handling accounts for 36% of production costs
3. Nearly 50 to 100 tons of material are handled and re-handled for every one
ton of finished product
4. About 2/5th of manufacturing cycle time is spent on handling
5. About 20-80% of the total labour cost go to labour used in handling
6. Between 30-40% of industrial accidents are caused while handling materials
b. Factors influencing selection of handling materials:
1. Weight
2. Size
3. Shape
4. Rate of handling
5. Distance to be moved
6. Purpose of moving
7. Obstacles if any in the pathway
c. Mechanical aids/equipment:
1. Hand tools, Example: hook
2. Rollers for dragging or sliding
3. Trucks and tractors
4. Hoisting apparatus
5. Overhead travelling cranes
6. Conveyors
7. Shovels
8. Elevators and escalators
9. Pipelines/pumps for liquids
d. Unsafe work habits:
Common unsafe work habits in material handling are:
1. Lifting improperly
2. Carrying too heavy a load
3. Unsafe gripping
4. Failure to wear personal protective equipment

1.10 Assignment:
Students should identify the unsafe acts near their surroundings like
housekeeping lab layouts, road safety, campus layout, safety sign