Learning Outcomes for BBS

• CO1. To demonstrate the role and Responsibility of safety officers,

hazards in industry
• CO2. To apply the statutory rules and regulations applicable in Petroleum
industry mainly
• CO3. Conduct Accident Investigation process and find the root cause of
Accident
• CO4. Calculate the compensation money for injured person and
reporting to higher authorities
• CO5. Form a Safety policy, rules, Regulations, Standard operating
Procedure for any organization and demonstrate its need
• CO6. To explain the various elements of Process safety Management
• C07. To form Emergency Management plan and execute for any
Organization
• C08. To explain and control major risk in Material Handling, Petroleum,
Mining and Manufacturing industry.
 Definition- Safety, Health and Environment
Safety is the state of being "safe" (from French sauf),
 
Health- As defined by World Health Organization (WHO), it
is a "State of complete physical, mental, and social well
being, and not merely the absence of disease.

Safety can be defined to be the control of recognized hazards

to achieve an acceptable level of risk.

Environment- the surroundings or conditions in which a

person, animal, or plant lives.
 Hazard and Risk

What is a Hazard? What is Risk?

Hazard: Source, Risk: Combination of the
Situation or act with a likelihood of an
potential for harm in occurrence of a
terms of human injury hazardous event and the
or ill health or a severity of injury
combination of these.

Examples:
a)Unguarded rotating
parts,
b) Inadequate use of
Personal Protective
Equipment like
Respiratory mask and
Hand gloves
c) Flying Chips, Dusts
Accident refer to an sudden unplanned, unwanted event which leads to injury,
property damage or loss. 

Near Miss: An incident, which did not result in bodily harm or property damage,
but had a high potential to become an accident under slightly different
circumstances.

An incident is an occurrence of an unusual event, apparently of minor

significance

Fatal Accident: An accident, which results in the death of an individual

.

Incident can be accident or near miss. 

Incident - A brick fall from the building  

Situation 1 - After that brick hit over the worker head  and got
injured (Accident)

Situation 2- if that brick fell down on floor 1 feet away from

the worker  ( Near Miss- Critical and Non critical)
Accident statistics - Wikipedia
 ACCIDENT DATA

UNSAFE CONDITION-10%

UNSAFE ACT -88%

OTHERS(Unavoidable) -2%

- Accidents involving electricity are very serious.

- About 1 in 30 of all electrical accidents are fatal
-Compared with about 1 in 600 of other types of accidents
 UNSAFE CONDITION
• the unsafe condition is one in
which the tools, work
environment and machine is in
full of hazards leading to
accidents .
Example
1. Oily floor
2. unguarded floor opening
3. staircase, work platform without
hand rail
4. Unguarded machinery
 UNSAFE ACT
• Unsafe act is the violation
commonly accepted safe work
practices i.e breaking of safety
rules.
1. Smoking in flammable area,
2. overspeed rash driving
3. Tampering with safety device
4. Not using PPE
5. Unauthorised working
• In the manufacturing industry, the major causes of
accidents resulting in personal injury can be grouped as
follows:
1. Handling goods and materials - 27 %
2. Machinery - 17 %
3. Persons falling from a height - 15 %
4. Persons stepping on or striking
against objects -10 %
5. Falling objects -08 %
6. Transport -08 %
7. Hand tools -08 %
8. Miscellaneous - 07 %

Understanding
 DISTRIBUTION OF FATAL
ACCIDENTS IN CONSTRUCTION SITE
• Fall of person 74%
• Lifting equipment 7.4%
• Fall of material 5.4%
• Electrical 3.3
• Transport 3.1%
• Machinery 1.5%
• Excavation 1.3%
Understanding
• Fire and explosion 0.8%
• Poisoning and gassing 0.8%
• Others 2.4%
 INDUSTRIAL ACCIDENT

WITH INJURY WITHOUT INJURY

FIRST AID INJURY LOST TIME INJURY

REPORTABLE ACCIDENT NON-REPORTABLE ACCIDENT

NON-REPORTABLE
Less than 48 Hrs ACCIDENT
Disablement
More than 48Hrs
REPORTABLE Disablement
ACCIDENT

MINOR ACCIDENT MAJOR ACCIDENT FATAL ACCIDENT

Less than 21 Days More than 21Days 6000 Man days Lost
Disablement Disablement
Lost Time Injury - An injury causing
disablement extending beyond the day
of shift on which the accident
occurred. As per IS 3786.
 Identify the Incident type
1. Deep cut on right foot while using saw cutting
machine. The worker returned after 20 days.
2. Fall of material form height but luckily no one
was there below.
3. Minor injury in hand while grinding. Within 4
hours the victim returned to work.
4. Fall of load on head resulting death
5. Due to wind, Dust got accumulated in eye. The
worker was taken to site doctor. Eye drops were
given to him. After that he returned to work.
6. Fracture of leg due to slip in the ground
 Partial Disablement

This is of two types:

1. disablement of a temporary nature which reduces the earning

capacity of an employed person in any employment in which he was
engaged at the time of the accident resulting in the disablement;
Example – Fracture

2. disablement of a permanent nature,

which reduces his earning capacity in every employment which he was
capable of undertaking at the time.
Example- Loss of thumb finger, Loss of a hand
Total Disablement –

Disablement, whether of a temporary or permanent nature, which

incapacitates a workman for all work which he was capable of performing
at the time of the accident resulting in such disablement, provided that
permanent total disablement shall be deemed to result from every type of
injury specified in Part A of Appendix A or from any combination of
injuries specified in Part B of Appendix A where the aggregate percentage
of the loss of earning capacity, as specified in that part against those
injuries, amounts to one hundred percent.
2.9 Man-Hours Worked - The total number of employee-hours worked by
all employees working in the industrial premises. It includes managerial,
supervisory, professional, technical, clerical and other workers including
contractors’ labour.
In a Visaka Industries 2000 in morning shift and 1000 workers in night
shift Contractor workers are working and 300 Visaka employees are
working. Number of working days are 200 per year. Average working
hours for any employee are 8 hours per day. The following are the injury
statistics of the company

Year No of Non No of No of No of
reportable reportabl First Accide
Lost time e lost aid nts
injuries time cases
injuries
2013 18 15 300 4
2014 9 13 40 3
2015 12 12 26 3

Calculate the frequency rate of the 1. reportable lost time injury for
2013,2014 1nd 2015
In a Visaka Industries 3000 in morning shift and 1000 workers in night
shift , Contractor workers are working and 300 Visaka employees are
working. Number of working days are 300 per year. Average working
hours for any employee are 8 hours per day. The following are the injury
statistics of the company

Year No of Non No of No No of
reportable reportabl of reportable
Lost time e lost First Accidents
injuries time aid
injuries case
s
2013 18 13 300 14
2014 9 14 40 3
2015 12 20 26 3

Calculate the frequency rate of the 1. reportable Accident for 2013,

2014,
In a Visaka Industries 2000 workers are working during morning shift
and 1000 during night shift. Number of working days are 300. Average
working hours for any employee are 8 hours per day. The following are
the injury statistics of the company
Year No of Non No of reportable No of First aid cases
reportable lost time
Lost time injuries
injuries

2013 18 50 300
2014 9 32 40
2015 12 21 26

Calculate the Incident rate of the 1. reportable lost time injury 2.Total
lost time injury.
Man days lost Calculation
• In the case of disablement of a temporary nature, the number of
days on which the injured person was partially disabled
• In the case of death or disablement of a permanent nature whether it
be partial or total disablement as defined in 2.7 and 2.8 man-days
lost means the charges in days of earning capacity lost due to such
permanent disability or death as specified in Appendix B.

In other cases the day on which the injury occured or the day the
injured person returned to work are not to be included as
man-days lost; but all intervening calendar days ( including Sundays
or, days off, or days of plant shut down ) are to be included. It
after resumption of work, the person injured is again disabled for any
period arising out of the injury which caused his earlier disablement,
the period of such subsequent disablement is also to be incluced in the
man-days lost.
In a Visaka Industries 2000 workers are working during morning shift
and 1000 during night shift. Number of working days are 300. Average
working hours for any employee are 8 hours per day. The following are
the injury statistics of the company of year 2014

1. Number of fatalities - 3
2. Number of first Aid injuries- 5
3. One got injured in leg and taken to hospital, given treatment and
returned back in next shift of his work
4. One lost both of the his hand permanently
5. Two lost index finger only
6. 5 fractured their leg and returned to work after 21 days
7. Three lost one of their eye and the other eye being normal
8. One went to COMA state
9. One got injured in leg and taken to hospital, given treatment and
returned back to work before the end of shift.
10. Loss of one eye (other being normal), Loss of four finger in one hand
11. Loss of one eye (other being normal), Loss of four finger in one hand
And loss of all toes both foot

Calculate the 1.severity rate of the reportable lost time injury?

In Bharat Industries 5000 workers are working during morning shift,
2000 during evening and 1000 during night shift. Number of working
days per year are 300. Average working hours for any employee are 8
hours per day. The following are the injury statistics of the company of
year 2014,
a) Total number of accidents happened in the year 2014 - 10
Reportable Accidents
b) Number of fatalities - 3
c) Number of first Aid injuries- 15
d) One got injured in leg and taken to hospital, given treatment and
returned back in same shift of his work
e) One lost both of the his hand permanently
f) Two lost index finger only
g) One got facial disfigurement
h) Amputation through hip and loss of four fingers in hand - two
person
i) Three fractured their leg on 30th November 2014 and returned to
work on 15 December 2014

Calculate the reportable Severity rate

3. CALCULATION OF MAN-HOURS WORKED
3.1 Man-hours worked shall be calculated from the pay roll or time
clock recorded including overtime.
When this is not feasible, the same shall be estimated by multiplying
the total man-days worked for the period covered by the number of
hours worked per day.

The total number of man-days for a period is the sum of the number of
men at work on each day of the period. If the daily hours vary from
department to department separate estimates shall be made for each
department and the result added together.

2.3 Disabling Injury ( Lost Time Injury ) - An injury causing

disablement extending beyond the day of shift on which the accident
occurred.
 ACCIDENT REPORTING
SN TYPE OF FORM PERI SEND TO
O ACCIDENT USED OD
1 FATAL FORM 18 12 PD –IF-CIF,
HRS DM,

2 REPORTABLE FORM 18 48+24 IF

ACCIDENT HRS

3 DANGEROUSO FORM 18-A 12 PD-IF-CIF

CCURANCE HRS
Dangerous occurances are incidents
with a high potential to cause death
or serious injury, but which happen
relatively infrequently

example- Fall of load from tower

crane, Leakage of poisonous gas
 H.W. Heinrich Triangle-
During 1931
H.W. Heinrich estimates that in a unit group of 330 accidents of the same
kind and involving the same person, 300 result in no injuries, 29 in minor
injuries and I in a major lost-time injury.
Frank E. Bird – During 1969
Frank E Bird, in 1969, analyzed 1753498 accidents reported
by 297 companies of America.
Inference of this 1-10-30-600 ratio is that 630 no injury
accidents, with 10 minor and I major (serious) injury
accidents, provide a much larger basis for many opportunities
to prevent any injury accident
 COST OF AN ACCIDENT
To the victim
 pain
 worry
 no recreation
 loss of wages
 loss of life
 medical expenses
 inability to perform normal work
 TO THE MANAGEMENT
Direct cost

 medical expenses
 compensation to the worker
 time lost by employees
 reduction in productivity
 TO THE MANAGEMENT
Indirect cost

 production delay
 loss of morale
 cost of training another employee
 repair cost
 loss of prestige
Effect of Accident
The Iceberg
Effect

39
 Reasons to investigate a workplace accident
include

• to find out the root cause of accidents and to prevent similar

accidents in the future
• to fulfill any legal requirements (Factories Act ( 1948
Amended in 1987) SECTION 90
• to determine the cost of an accident
• to determine compliance with applicable safety regulations
• to process workers' compensation claims

Incidents that involve no injury or property damage

should still be investigated to determine the hazards that
should be corrected.
Benefits of Having an Accident
Investigation Program
Accident prevention
Identification of training needs
Improved operations and systems
Increase in employee morale
Increase in employee involvement
 Accident Investigation in
India
Factories Act ( 1948 Amended in 1987) SECTION 90
 State Government may initiate an accident
investigation for any accident occurring in a factory
 State Government may also investigate illnesses that
might have been contracted in a factory
 State Government may also appoint a competent
person to investigate the incident or illness
> Has powers to interview witnesses
> Has powers to enquire documents and material
objects
 India Reporting Requirements

Factories Act (1948 Amended in 1987) section 88

and 88A

To whom should reports be made?

• Deaths and serious injuries likely to
cause death or dangerous
occurrences must be reported to the
following:

District Magistrate or Sub divisional Office

Officer in charge or nearest police station
Relatives of injured or deceased persons
Written report to the above authorities
within 12 hours
Causes of an Accident
 Who should do Accident
investigation ?
• employees with experience in investigations
• First –line supervisor
• Safety team
• Safety coordinator
• Fire Chief / investigator
• employees with knowledge of the work
• safety officer
• health and safety committee
• union representative, if applicable
• "outside" expert
• representative from local government
Should the supervisor should be in the team ?
The advantage is that this person is likely to know most
about the work and persons involved and the current
conditions. Furthermore, the supervisor can usually take
immediate remedial action
Functions of Investigator
• To locate and identify evidence which
may relate to a loss incident
• To examine the evidence
• To ascertain its relationship to the loss
incident
• To reconstruct the events leading up to
the loss incident
• To develop conclusions about
measures needed to prevent a
reoccurrence
The accident investigation process involves
the following steps:
 
 Report the accident occurrence to a designated person
within the organization
 Provide first aid and medical care to injured person(s)
and prevent further injuries or damage
 Investigate the accident, Find the Evidences
 Identify the causes
 Report the findings
 Develop a plan for corrective action
 Implement the plan
 Evaluate the effectiveness of the corrective action
 Make changes for continuous improvement
 Four Types of Evidence
• Position
• People
DECREASING
• Parts
FRAGILITY
• Paper
POSITION EVIDENCE

1. Accident Site Map

2. Taking Photographs
 POSITION EVIDENCE
Accident Site Map

MR POSITION
A

B
AA
C

BB

FF
CC

EE DD
Position Data Identification
Date

Key Item Reference Point Distance Direction

AA Grinder Wheel on Rt. end 13 ft. 110

Tool Shop Doorway
A 11 oz piece grinder wheel AA, Rt. end 13 ft. 70
BB 8 ft. 340
B 3 ft. 316
B Scar on Wall AA, Rt. end 16½ ft. 86
BB 6 ½ ft. 360
C Chisel AA, Rt. end 4 ft. 130

E Protective Goggles AA, Rt. end 7 ft. 340

CC Sand blast machine AA, Left end 6 ft. 180

DD Shop Supervisor
Desk
EE Shop Supervisor AA, Left end 14 ft. 140
FF Witness_______________ AA, Left end 12 ft. 120
 Uses of Photography

• General orientation to the scene

• Detailed record of injury and damage
• Relative positions of people and parts
• Witness view of the scene
• Details of marks, spills, signs,
instructional aids, etc.
• Disassembly of parts detail for analysis
 Taking Photographs
• Photograph important evidence twice
• Take medium distance photographs
(midrange) that show the evidence and
its position relative to other evidence
• Take close-up photographs that include a
scale and fill the frame.
• Prior to entering the scene, acquire prior
photographs, blueprints or maps to the
scene.
 People Evidence
Incident recall technique (IRT)
IRT is to gain the cooperation of the employee so that he
can and will freely relate all incidents from the past that
he can recall.
Procedure
• Put the employee at ease.

• Explain the purpose of the interview and of the

IRT .
IRT PROCEDURE cont…
• Give assurance that the IRT is totally confidential.

• Point out the benefits of the IRT to every one to

employee, his family, his department, his company.

• Show and explain the report form to him.

• Conduct the interview. Simply ask him to recall each

near miss accident that he has seen or heard about on
the job.

• Note down all pertinent information.

 Parts Evidence
• Parts can be solid, liquids or gases
• Parts that should be considered for
further examination:
– Any components which are fractured,
distorted, scarred, chafed or ruptured
– Parts requiring lubrication
– Controls and displays
– Substituted or modified parts
– Parts showing signs of leak or age along
with stains or spills
 Parts Evidence (Continued)
– Foreign objects that seem different in size,
shape, color, smell, or location

– Parts suspected of internal failure, or

abnormal stress

– Parts suspected of improper assembly or

mating

– Parts improperly mounted or supported

– Power sources and vital electrical

components
Tags for Identification of Parts Removed from an
Accident Site for Analysis
Types of Paper Evidence
Certification/licenses
Trade union records
Employee training
Skill certification test records
Operating manuals
SOPs
Training course manuals
Employee appraisal and counseling
ACCIDENT PREVENTION METHODS- 5 ES

1. Engineering Controls
Some engineering controls are- substitution of less hazardous material,
machine, method, process, vessel etc., risk reduction, process
modification, isolation, segregation, guarding, fencing, barricading,
enclosure, dilution, safe design; failsafe device and safety devices
including alarms, trips, safety valve,

2.EDUCATION &TRAINING
 1.BASIC TRAINING
 2.SPECIAL TRAINING

 3.REFRESHER TRAINING
3.Enthusiasm
Like a catalyst it adds to safety awareness and motivation. It should come from the top
management to the lowest worker. It will keep the workers safety conscious. It can be
developed and maintained by proper safety attitude, competition, prizes, awards, publicity,
incentives etc.
This includes motivation and participation in safety programmes

4.Enforcement
All statutory safety provisions should be followed for our own safety and safely of others.
Self initiation for full compliance is necessary, otherwise government authorities may take
action. In addition, other safety rules for our plant should also be framed and followed.
Wilful neglect or disobey of safety rules or orders should be dealt with strictly.
Enforcement measures include - new law, amendment in old law, company safety rules,
implementation and legal action
5. Example setting
The top executives, managers and supervisors
should set an example to others by the self-enforcement of
safety rules. Then others will follow them. This is a chain
reaction to increase and maintain safety.
HISTORY OF SAFETY MOVEMENT/
EVOLUTION OF SAFETY MANAGEMENT

Before 1870
 Invention and application of new tools for mass
production brought danger

 Injuries/ Fatalities due to industrial accidents were

more than due to world war

 Employers ignored the problem as a disabled worker

could be easily replaced and wages were low
 Workers and managers believed that accidents were
inevitable.
 Accident was considered as an "act of god”(it was a time
when people believed that sickness was the result of evil
spirits or a curse of god).
1870:
 Accelerated the upward trend of serious and fatal
injuries .The news papers became interested and published
more details about serious cases which made public
interest grew
Labour fought for two things:
-Guarding of machinery
-Compensation for the accident dependent

1877
The first law requiring the guarding of
hazardous machinery was established
1911
Factories act amended with rules for cleanliness
over crowded, ventilation and lighting etc.
1923
Compensation act was enacted
1933
Factories inspectors were appointed to
see the proper implementation of these
acts
1948
The full factories act was passed and
came into force from 1st April,1949.
 Further amendments made in forthcoming
years

 In recent times lot of efforts are being made in

terms of safety health and environment
HSE POLICY
 Every organization must have a written policy on
health, safety and environment signed by the
Head of the organization with date.
 HSE policy spells out the values, beliefs and
commitment of the organization towards health,
safety of its employees, community and at the
macro level of the nation.
 The copies of this policy should be displayed at
prominent places in the organization so that
everybody is familiar with its contents/intentions.
Some organizations ensure that every employee
receives a copy of its HSE policy
SAFETY AND HEALTH POLICY
 Became mandatory as per sec-7A sub Sec-3 of
factories act 1948
 It is the starting point for all the activities in safety
management program
 Policy should do three things

1. -it should affirm long range purpose

2. -it should commit management at all levels to
affirm and reinforce this purpose in daily
decisions
3. -it should indicate the scope left for discretion
and discussion by lower level management
For effective safety policy, it must be

 Prepared by safety professional

 Signed by management and
 Published in all departments
including office in local language and
common language
AREAS TO BE COVERED IN
POLICY IN GENERAL

 Management intention
 Scope of the activities covered
 Responsibility
 Accountability
 Staff safety assistance
 Safety committee
• Health and safety of personnel and protection of environment overrides all production
targets in our organization
• Production and HSE are complementary to each other
• Safety and environment protection is everybody's business in the organization
• All statutory requirements must be complied with at all times
• All personnel must use approved safe working procedures without making
any risky short cuts
• All personnel-own or contractors-must be given relevant training before assigning
them work
• All plants, facilities and work procedures/ systems must be audited periodically by
in-house teams as well as external agencies
• Plant and ambient environment as well as various effluents must be monitored
continuously to maintain a clean and safe environment in and around the plants
•
A very high standard of house keeping must be maintained at all places of
work-plants, offices and facilities
• Every employee must be subjected to a pre-employment, periodic and
any specific medical check-up for early identification and treatment of
any occupational health hazard
• All employees must keep abreast with the latest codes, standards and
practices on health, safety and environment
• All accidents, however small, must be investigated and followed up. The
lessons learnt from these accidents should be disseminated to all levels of
workforce
• No modifications in plant, facilities or procedures will be done without
proper scrutiny and approval by an authorized person(s)No contractor will
be engaged without ascertaining his safety performance/record
• Non-compliance of this policy will attract severe disciplinary action
Who is responsible for Safety at work?
1. Employee
2. Employer
3. Both

 HSE Chief should be a qualified engineer with long

experience in various functions. He should have a team
of qualified professionals to advise on safety,
occupational health, fire protection and environment
 In order for the HSE management of an organization to
be efficient and effective, it is important that the Chief of
HSE should report to the Head of the organization.
HSE should be an advisory function reporting to the top
management
SAFETY ORGANIZATIONS
Types
Type A organization
- Line organization
Type B organization
- Staff Organization (Safety director)
Type C organization
- Safety committees
 TYPE A ORGANIZATION -LINE ORGANIZATION

Line function : decision making area in an organization

which is in daily operations
Safety: line function
Advantage:
safety function is part of the day by day activities of
every personnel in an organization.
Disadvantage:
 The supervisor personnel occupied with production
problem find difficult to action
 Chief executive should be safety minded.
LINE ORGANISATION
TYPE B ORGANIZATION - SAFETY DIRECTOR
Safety : staff function
Advantages : safety provisions can be successively
implement
-Type C organization- safety committees
 For better cooperation and involvement of employees in
safety activity
 Employees like to participate in decision making
concerning their safety and health.
 contributes to the safety promotional activities through
group efforts
 Recognition to employees who contribute in safety
activities
 Encourages closer relation between management and
employees
 Statutory requirements(section 41G and factory rules)
 These committees will advise the safety engineering
department for achieving a better performance in
safeguarding the men, machines and materials
 The employees representatives must also be included as
members in these committees so that they can present
the view of workers and come with their ideas and
suggestions.
TYPES OF COMMITTEES
 Central safety committee
 Departmental safety
committee
 Safety sub committee
 Area safety committee
CENTRAL SAFETY COMMITTEE
 Functions :
 plant level safety education, accident investigation, selection
and development of PPE’S and other safety promotional
activities
 Advisory body on safety policy.
 Frequency-meet once in 3 months
 Governing body:

Chairman : unit head

Members : respective head of department,
representatives from various unions
General secretary: safety head
Safety sub committee
Function :
The four elected worker’s representatives
nominated from the works committee
visit the plant for safety survey and
finding safety problems
Frequency : once in a week, along with
safety officials
Departmental Safety Committee
Function : Implement the various safety measures
Frequency : once in a three months

Area safety committee

Function :
To identify potential hazards with in the area/section and
implement the remedial steps with a time bound
programmes and continuously monitoring and safety
measures
Frequency : Once in a month
SAFETY PERFORMANCE
Safety performance of a company can be
measured by
1. Lagging indicators
2. Leading indicators
 MEASUREMENT OF SAFETY
PERFORMANCE- LAGGING NDICATORS
1. First aid cases (First Aid Cases/1000
employee/month)
2. Lost Time Injury Frequency rate (No. of LTI cases*
1000000 / man-hours worked)
3. Fatality
4. Number of medical illness cases
5. Complaints from the workforce regarding safety
MEASUREMENT OF SAFETY
PERFORMANCE- LEADING INDICATORS
1. HSE Training Factor (Training Hours/
employee/ annum)
2. HSE Audit Rating
3. Number of inspections, safety survey,
safety sampling and safety tour
4. Man hours worked without accident
5. Safety Observations (No of
observation/employees/year)
Safety Audit:. “A safety audit subjects every area of
organization’s activity to a systematic Critical
examination to reveal the strengths and weaknesses and
the areas of vulnerability”.  One of the first systematic
methods of hazard identification used in the chemical
industry was the safety audit
Safety Survey: It is a detailed examination a narrow field
such as specific procedures or a particular plant.
Safety inspection: Which is a scheduled inspection of a
unit carried out by the units own personnel. Eg. Crane
inspection
Safety Tour: It is unscheduled tour carried out by an
outsider such as works manager or a safety
representative.
WHAT IS SAFETY CULTURE

 Safety culture … forms the environment

within which individual safety attitudes
develop and persist and safety behaviours
are promoted.

 It is important to have a consistent way of

talking about culture – the Bradley Curve (a
Dupont concept) so that there is a common
way of describing culture
SAFETY MATURITY AND
CULTURE – BRADLEYY CURVE
 Reactive- There is no real order, structure or
framework. Employees use their wits to stay safe.

 Dependent- This is when there are published H&S

standards, SWPs, and permits which the managers
value and enforce the workers to use.

 Independent- This is when the workers value the

standards and safe working procedures, and
whether managers are there or not they follow the
rules

 Interdependent- This is when employees actively

look out for each other – brothers keepers – and
ensure that they all follow the correct standard
 HSE RULES FOR VISITORS
 Visitor shall be responsible for his own safety
 Photography inside is prohibited

 Never go to the site in case of any fire or other emergency

 Visitor is not allowed to touch any equipment/ interfere with the plant
activities
 All persons must wear safety helmets and safe shoes in process areas.
Requirement of any other personal protective equipment will be advised by
plant personnel
 Use following telephone nos. in case required: Fire l00, Security 101,
Medical 102. Visitors should report to security gate for entry pass
 Every person must display a valid identification badge issued by the security

 Visitor should visit the designated area only for which he has obtained the
entry pass
 He should be accompanied by a company employee.It is forbidden to take
children inside the premises
TRAFFIC RULES
 Vehicles should have valid access pass to enter the premises
 All vehicles entering hazardous areas should have spark arrestor
and a unit entry permit
 Maximum speed limit inside the premises is 30 km/hr

 Park the vehicle at designated places

 Overtaking is prohibited

 In case of an emergency alarm, stop the vehicle and take to the

side of the road and wait for clearance
REGULATIONS ON NAKED LIGHTS
SPARKS AND ALCHOHOL RESTRICTION
 Matchboxes, lighters, flashlights and cameras are not
allowed inside the premises
 Only intrinsically safe mobile phones are allow inside

 Use of 100% nylon or synthetic clothes inside the

premises is prohibited.
 The entire.-refinery is a tobacco free zone

 Tobacco in any form-cigarettes, biddies, gutka, etc., is

prohibited
 Use of alcohol and drugs is prohibited
HSE PLANS AND PROCEDURES

Plans and procedures is the heart of a good HSE

management system. They are the basis of setting up an
effective and efficient management system.
A large number of industrial accidents and mishaps have
occurred all over the world due to human errors and the
main cause of these errors has been the lack of written
procedures and/or non-compliance of the same. In some
cases, courts have penalized the organizations because
victims of the accident did not have written procedures to
be followed by them.
 The various HSE related procedures should be developed broadly
based on Process Safety Management System, PSM, which is a
well-known framework of HSE management all over the world.
 All these procedures should be compiled in the form of an HSE
manual-many times called the HSE bible.
 The procedures should be revised and updated periodically to
reflect changes that might have taken place over time
 SAFETY RELATED PROCEDURES
 Basic safety rules for employees, contractors and visitors
 Safe work permit system

 Mechanical isolation

 Pre-start up safety review

 Entering and working in confined spaces

 Working at height

 Safe scaffolding and ladders

 Safe evacuation

 Safe handling of hazardous substances

 Safe handling of hydrogen sulfide, chlorine, ammonia etc.

 Safe uses of hoses

 Contactor safety

 Ionization radiation safety

 Traffic safety inside and outside the installation

 Safe use of cranes, hoists and other mechanical devices

 Safety in manual handling of material

 Accident/ incident reporting and investigation

 Selection and safe use of personnel protective equipment

 Safe transportation of hazardous materials by road, water and rail

 Management of plant changes and procedures

 Safety audits

 Personnel movement and transportation by road, cranes, basket, boats and helicopters

 Grinding, welding and cutting

 Safety signage’s labeling and posters

 Onsite emergency and disaster management.

ENVIRONMENT RELATED PROCEDURES

 Air Pollution Control and Monitoring

 Effluent Monitoring

 Industrial Wastes Management

 Biodegradable and Office Wastes Management

 Fugitive Emission Monitoring

 Ground Water Monitoring

 Environment Inspection and Audit

OCCUPATIONAL HEALTH RELATED
PROCEDURES
 Health Care System
 Medical Management of Obnoxious Substances

 Hygiene and Sanitation

 First-aid

 Health Risk Assessment

 Pre-employment and Regular Medical Checks

 Wellness and Fitness Program me for Employees and

Families
 Emergency Medical Care
5S: GOOD HOUSEKEEPING TECHNIQUES FOR
ENHANCING PRODUCTIVITY, QUALITY AND SAFETY
AT THE WORKPLACE
5S: GOOD HOUSEKEEPING TECHNIQUES FOR
ENHANCING PRODUCTIVITY, QUALITY AND SAFETY
AT THE WORKPLACE
 ADVANTAGES OF 5S OF HOUSEKEEPING
 „ Workplace becomes cleaner, safer, well organized and more
pleasant
 Time saving

 Errors are minimized

 „ Quick retrieval

 „ Accidents & mistakes minimized

 „ Increases space

 „ Creates workplace ownership

 HSE in Petroleum Industry
In order to manage HSE effectively in a petroleum installation or
complex which is usually a large entity it is important and desirable
to demarcate each area of the installation/complex and assign the
ownership/custodianship to a senior member of the concerned area.
These areas are commonly called safety districts. A big petroleum
complex may have 10-15 safety districts. These districts should be
shown on the layout drawing of the complex with all the boundaries
clearly identified and marked. The objective of safety districts is to
decentralize the HSE responsibility to the functional owner/ custodian
of the area who is fully responsible and accountable for all management
functions in his district with specific reference to control/management of
health, safety and environment. HSE department acts as a catalyst
 EMERGENCY
 An emergency is a situation that poses an immediate risk to
health, life, property or environment.
 The word "disaster" refers to those emergency situations where
the number of casualties is very large like in natural calamities.
 The Emergency plan should also follow the provisions of Section
41-B of the Factories Act, 1948 and the guidelines from the Chief
Inspector of Factories of the state. OISD also gives guidelines for
developing an emergency plan.
 Most emergencies require urgent intervention to prevent a
worsening of the situation,
 EMERGENCY IN PETROLEUM INDUSTRY
 A list of probable emergency scenarios applicable to petroleum
installations is given below:
• Fire
• Explosion
• Toxic Release
• Blow-out (A sudden escape of a confined gas)
• Drowning
• Oil spill on water
• Oil spill on land
• Cyclone/Storm
• Earthquake
• Flood
Some of the man made emergency situation includes
1. Arson (Arson is the crime of setting a fire with intent to
cause damage.)
2. Civil Disorder (riots; sabotage; and other forms of crime)

3. Terrorism refers to the use of violence for the purpose of

achieving a political, religious, or ideological goal
4. Wars

5. Biological diseases
On-site Emergency
If an accident/incident takes place in a factory, its effects are
confined to the factory premises, involving only the persons
working in the factory and the property inside the factory it is
called as On-site Emergency

Off-site Emergency
If the accident is such that its affects inside the factory are
uncontrollable and it may spread outside the factory premises, it is
called as Off-site Emergency .
The civic authorities of the area usually prepare disaster plans for
emergency situations outside the premises. The management of the
installation should give full cooperation to the civic authorities in
preparing what is called as Off-site Emergency Plan
CATEGORISATION OF EMERGENCY
 Level 1
 Level 2

 Level 3

Level 1- The emergency situation arising in any section of

one particular plant/area which is minor in nature and can
be controlled within the affected section itself with the help
of in-house shift staff. Such an emergency does not have
the potential to cause serious injuries or damage to
property, environment and the domino effect to other
sections of the installation.
LEVEL-2
 The emergency situation arising in one or more plants/areas
which has the potential to cause serious injuries, property loss
and/or environmental damage in the installation. Such an
emergency situation always warrants to mobilize all the resources
available in-house and /or outside to mitigate the emergency. The
impact of this level of emergency is however, within the
installation.

LEVEL-3
 If level-2 emergency by virtue of its consequences can spread and
affect the nearby community outside the premises, it is termed as
level-3 emergency.
OBJECTIVE OF EMERGENCY
PREPAREDNESS AND RESPONSE PLAN
Emergency Preparedness & Response Plan (EPRP)
envisages serving the following purposes;
• Prevention of loss of human life and injury
• Prevention of damage to the immediate environment
which includes flora and
fauna
• Provide a mechanism to evolve EPRP, execute it, review
and update it continually
• Maintain Business Continuity through cycle of
prevention, preparedness, response, recovery and
mitigation
 Each factory or industrial unit should prepare an emergency plan
incorporating details of action to be taken in case of any major
accident/disaster occurring inside the factory. The plan should
cover all types of major accident/occurrences and identify the
risk involved in the plant.
 Mock drills on the plan should be carried out every six months
periodically.
 The plan will vary according to the type of industry and
emergency.
PRINCIPLES OF MANAGING EMERGENCY
 Emergency management revolves around five pillars;
1. Prevention

2. Preparedness,

3. Response,

4. Recovery &

5. Mitigation in a cyclic order.

 Conspicuously, it is a dynamic process aimed at continual
improvement
PREVENTION
 Prevention may not be always practical in case of natural
disasters. But certain planning consideration can help minimize
the impacts during above emergency situation.
 Contrary, towards man-made emergency, prevention can be
quite effective.
 Example- incidents and occupational diseases can be prevented
by applying various controls; elimination, substitution,
engineering, administrative & PPE
 PREPARDNESS
 It involves developing mechanism towards emergency
preparedness
 a. Defining EPR team structure at project level

 b. Demarcation of roles, responsibility & authority

 c. Determining line of command and control

 d. Allocation of resources including training

 e. Developing & maintaining inventory of emergency

management equipment’s
 Preparedness also involves periodical testing through planned
Mock Drill & Table Top exercises.
 Tabletop exercises are discussion-based sessions where team
members meet in an informal, classroom setting to discuss their
roles during an emergency and their responses to a particular
emergency situation
RESPONSE
Response is execution of preparedness plans and typically
involves,
 a. Put preparedness plan in execution

 b. Evaluate its effectiveness i.e. determine the gap

between the plan and the execution
 c. Revisit plan and improve it in view of gap analysis (as
part of Mitigation)
 d. Incorporate the learning’s for continual improvement
RECOVERY
 Response is followed by recovery wherein projects need
to take steps to bring back normalcy as soon as possible.
The focus should be to maintain continuity of business
by minimizing / eliminating disruptions and delays.
 Clear up from the incident or help the people involved
overcome their mental trauma
 Repair/ renovate offices, Labour camps, stores, work
fronts, machinery/equipment
 Reorganizing workforce and re-inducting them
MITIGATION
 Mitigation involves taking steps to ensure no re-
occurrence is possible, or putting additional plans in
place to ensure less damage is done next time.
Main Controller
The MC has an overall responsibility for directing operations and
calling outside help. The Main Controller will function with all
powers within his command within the premise.

Incident Controller
 On hearing of an emergency, he will rush to the site of the
occurrence & take overall charge & report to Main Controller.
On arrival to the site of incident he will assess the scale of
emergency & decide if major emergency exists & inform the
Main Controller accordingly.
Incident Controller (IC)
 His main function is to direct all operations at the scene of emergency,

 Search for trapped persons or casualties, if any. Prepare for rescue promptly.

 Initiate rescue operations until the rescue team arrives.

 Evacuate the non-essential persons to the allocated Assembly Point.

 To divert rescue and firefighting control fire brigade activities.

 To search for casualties to arrange evacuation of non-essential persons

 To set –up communication with emergency control centre

 To assume the responsibilities of site main controller until he arrives

Communication Officer
 Will be stationed at the Emergency Control Centre i.e., Project office during
the emergency.
 Will undertake the instructions from the Main Controller.

 Under the direction of the Main controller, handle police, press & other
enquiries. Liaison with senior officials of Police, Fire Brigade, Medical &
Directorate of Industrial Safety & Health & other government officials
 EMERGENCY COMMUNICATION
 A reliable system of informing the various people in the
installation should be in place. This can be a siren or an alarm
system, which is audible in the whole installation. VHS radio
can be used to communicate the emergency situation to civic
authorities and other outside agencies, which need to be informed
of the emergency.
 Alternate locations for housing the evacuees should be identified.
A safe assembly point should be identified for each plant/area in
the installation where people not required during the emergency
will assemble from where they can be easily taken out to alternate
locations
EMERGENCY CONTROL CENTRE
An emergency control centre in a safe place in the installation
should be identified. This centre should be equipped with necessary
communication equipment-telephones, walkie-talkies, VHS radio
sets, mobile phones, etc. and essential documents of the
installation. The chief emergency commander and most of the
emergency team members will operate from this centre.
MOCK DRILLS.
 The emergency plan should be rehearsed regularly by conducting
mock drills to keep the emergency team members refreshed with
their roles during an emergency. Based on the weaknesses or
shortcomings observed during the mock drills, the emergency plan
should be updated. As required by the statutory authorities, mock
drill of a major on-site emergency plan should be conducted at
least once in six months. Organization may opt for more frequent
drills.
MUTUAL AID SCHEMES
Some times the internal resources of an organization
may not be adequate to handle a major emergency situation. In
such situations, external help can be sought from the
neighboring units and government agencies. A written
agreement should be made with the neighboring organizations in
the area to help each other with additional resources in case of
any emergency situation arising in their installations.
Some industrial areas like Vadodra; Mumbai, Ankleshwar etc.
have very effective mutual aid schemes. Member industries in
each of these areas have pooled their resources to set up a round
the clock emergency/disaster management control room in the
area
EMERGENCY RESOURCES
 The plan should include lists of important consultants/ agencies
from whom additional help could be obtained in case required
during emergency situations. Lists of important suppliers and
vendors of medicines, safety equipment, fire fighting equipment
and materials, pollution control equipment and consumables, etc.
should also be included.
 EMERGENCY INVENTORIES

It is necessary for every petroleum installation to maintain a

minimum inventory of various emergency consumables and
equipment for fire fighting, medical, pollution control and safety. A
list of these inventories should be a part of the emergency plan.
Regular physical check of stock levels of these inventories should be
done against this list and immediate action should be taken to
replenish them if required.
 ELEMENTS OF A MAJOR EMERGENCY MANAGEMENT
PLAN
A good and effective emergency or disaster plan should have the
following elements:
 • Emergency Organization with responsibilities of key members
 • Key Members and their contact numbers
 • Emergency Control centre

b. ALARM AND COMMUNICATION MECHANISM:

 Communication is a crucial factor any employee should be able to
raise the emergency alarms so that action can be taken immediately.
C. APPOINTMENT OF PERSONNEL
KEY MEMBERS AND THEIR CONTACT NUMBERS
 A key member for coordinating each of the following functions of
an emergency should be identified:
 Operations

 Security

 Medical

 Rescue/Evacuation

 Human Resources

 Emergency Maintenance and Repairs vii. Emergency Materials

 Technical and Engineering Services

 Transportation

 Public Relations

 A list showing the contact telephone numbers of all the key

members should be made which should be regularly updated to
incorporate any changes. This list should be available to each
member to be kept handy in his wallet.