Noorul Islam Centre for Higher Education

Department of Fire Technology and Safety Engineering

FS22P5 - PROJECT WORK
4th Year/8th Semester (2022-2023)

1 HEALTH AND SAFETY MANAGEMENT IN

CHEMICAL INDUSTRY

 BATCH I
PROJECT DONE BY-
GUIDED BY-
 ABHIJIT GEO AJOI (1119225001)
 Dr. V .MAGO STALANY
 ADARSH S (1119225002)
ASSISTANT PROFESSOR
 AKASH PRATHEEP (1119225004)
FTSE
 SUDHIKUTTAN S (1119225024)
 DEEPU KRISHNAN K R (1119225014)
2 AIM

 TO STUDY IN DETAIL ABOUT HEALTH AND SAFETY MANAGEMENT SYSTEMS AT

TRAVANCORE COCHIN CHEMICALS LIMITED(TCC).
 TO STUDY IN DETAIL ABOUT HEALTH HAZARDS IN A CHEMICAL INDUSTRY.
 TO STUDY ABOUT SAFETY SYSTEMS USED IN TCC.
 TO STUDY ABOUT SAFETY MANAGEMENT IN TCC.
3 PRESENTATION OVERVIEW

 INTRODUCTION
 ABOUT THE COMPANY
 SAFETY MANAGEMENT SYSTEMS
 HEALTH AND SAFETY CONCERNS
 HAZARDS DUE TO CORROSION
 HAZARDS IN CONFINED SPACE
 SAFETY EQUIPMENTS
4 INTRODUCTION

 In chemical industry, chemicals are researched, tested and manufactured. Many of these
chemicals are hazardous in nature to which both laboratory personnel and plant workers are
exposed.
 It is possible to safely handle, store and use chemicals, once their hazardous chemical and
physical properties are properly understood and the essential precautions along with
appropriate personal protective equipment and safeguards are observed.
 In the chemical industry, it is critical to implement measures that reduce the risk of accidents
and fatalities for workplace safety. In order to achieve this, it is crucial to know the different
types of injuries that take place in chemical plants.
5 ABOUT THE COMPANY

 Travancore Cochin Chemicals (TCC) is a chemical company owned by the Government of

Kerala.
 It is engaged in the manufacture and marketing of Caustic soda (NaOH), chlorine,
Hydrochloric acid and sodium chlorate.
 It is situated in Udyogamandal industrial district of Kochi, India.
 The TCC exports caustic soda to African countries.
 The TCC was founded in 1949 as a partnership between Mettur Chemical & Industrial
Corporation Limited and FACT. It was later acquired by the Travancore Cochin government.
In 1960, it became under the Kerala government.
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8 SAFETY MANAGEMENT SYSTEM

 There exists a well organized safety management system at TCC with well defined "Safety,
Health & Environment Policy ". Besides TCC has well defined Quality policy (ISO-9001),
Environmental policy (ISO-14001) & Occupational Health and Safety policy (ISO-18001).
TCC has all three systems of above mentioned topics which were certified by external agencies
of international repute.
The brief description of activities of safety management system is as follows:
 Safety Committees : At TCC, there are safety committees who meet regularly to discuss safety
problems. These are -Central Safety Committee There is a central safety committee.
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 Internal Safety Audit : There are Internal Safety Audits by core group members of ISO-
9001, ISO-14001 & OHSAS-18001 covering the plant area, workshops and stores
quarterly. Each core group members visit their allotted other than their working area
Quarterly in a year and give recommendations for improvement or safety standards and
compliances of other sections according to above ISO standards. These
recommendations are circulated to all concerned department for implementation.
 Safety Audit by external agency : There is a Safety Audit by external agency which once
in a year conduct thorough audit of entire complex, in line win guidelines mentioned in
8 14489:1998 and submit recommendations for improvement.
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Safety Management System (SMS) is composed of four functional components:

•Health and Safety Policy

• Safety Risk Management
• Safety Assurance
• Safety Promotion

The essential idea of any SMS is to provide for a systematic approach to achieving acceptable
levels of safety risk. SMS is comprised of four functional components, including an intangible,
but always critical, aspect called safety culture.
11 Health And Safety Policy
• TCC is committed to provide every one of its employees and the related public an accident-free and
healthy environment in its efforts to manufacture high quality products at competitive prices.
• The company will comply with all statutory requirements in this regard. The company will provide a
work environment in which identified hazards are controlled, if elimination is not feasible and will
provide personal protective equipments wherever necessary.
• Accident prevention is the direct responsibility of the Line – Management and will be an important
criterion for performance appraisal. Line – Management will ensure that all safety measures are
incorporated in the operating and maintenance procedures as well as in any process technology
changes in the plant/infrastructure. Consideration of health and safety will be given proper weightage
in selection and deployment of the personnel.
• The company will ensure that health and safety aspects are given due consideration in decision
regarding purchase of plant equipments, machinery and materials.
12 Safety Risk Management (SRM)

 Determines the need for, and adequacy of, new or revised risk controls based on the
assessment of acceptable risk
• A formal process within the SMS composed of:
• Describing the system
• Identifying the hazards
• Assessing the risk
• Analyzing the risk
• Controlling the risk
13 Safety Promotion

Includes training, communication, and other actions to create a

positive safety culture within all levels of the workforce
Safety promotion activities within the SMS framework include:
•Providing SMS training
•Advocating/strengthening a positive safety culture
• System and safety communication and awareness
• Matching competency requirements to system requirements
• Disseminating safety lessons learned
 Health and safety concerns
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 Areas of concern in this industry include:
• Dangerous materials –
Explosives, gases, inflammable liquids, toxic, infectious and oxidizing substances
• Hazards of pressure vehicles – Leakage, failure, design defects, corrosion
• Hazards in unit operations – Surface fouling and leakages, mixing of fluids, dust
releases and explosions
• Corrosion hazards – Weakening and falling of structures, spill and toxic releases,
bursting of vessels due to corrosion
• Confined space – Oxygen deficiency, possibility of electrocutions, lack of ventilation
• Sampling and gauging – Splashes and spillages in sample collection, dip gauging of
flammable and corrosive liquids, exposures due to breaking of sight glasses and glass
level indicators
 HEALTH HAZARDS
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 Identification of potential health hazards.
 Assessment of levels of physical and chemical health hazards.
 Control of hazards by various techniques.
 Adequate awareness among the workers.
 Periodic medical examination of the workers.
 Personal protection for occasional exposures.
 Proper hygiene and decontamination facilities .Etc.
16 HAZARDS DUE TO
CORROSION
 Weakening and falling of structures and sheds.
 Falling of workers from height due to breaking of raised platforms, hand rails, toe
boards, stairs and ladders.
 Spills and toxic releases from pipelines due to corrosion.
 Leakages and bursting of vessels due to corrosion.
 Corrosion monitoring and control.
 Testing and inspection of vessels and structures to ensure safety
17 HAZARDS IN CONFINED SPACE

 Oxygen Deficiency
 Toxic Contamination
 Flammable Environment
 Possibility of Electrocutions through electric equipment's
 Possibility of Toxic gas generation during the work
 Lack of Ventilation
 Difficulty in welfare monitoring
 Failure to escape on emergency
 Combustible Substances
 SAFETY EQUIPMENTS

 Gas masks for use in leakage of Gases like Ammonia, Chlorine, etc. area available in all the Plant.
Apart from this, breathing apparatus supplied by MSA, are available in all the control rooms and at
Ammonia storage tank area.
 Explosive meters are available in all the plants for checking any leak of gases and testing the vessel
and operating areas, before issue of hot work permit or permit for vessel entry etc..
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Personnel Protective appliances like safety helmet, safety goggles hand gloves etc., are issued to all
the employees. Apart from this face shields, PVC suits etc. are installed in all sections of the plant.
 Gas Tight suits, chemical splash suits, Fire proximity suits and other suits are available to handle
emergencies like toxic release, fire etc.
Eye Wash Station : The emergency eye wash station provides a means to remove chemical
contamination from the eyes and/or face.
Safety Showers : The emergency safety shower provides a means to remove gross chemical
contamination from the body or to extinguish a fire on the body.
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Fire proximity suits chemical splash suits

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THANK YOU