Accident Prevention-trng Module

8/2/2019 Accident Prevention-trng Module

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Accident Prevention InIndustry

BYSURESH PATIL

JSW STEEL LIMITED, TARAPUR.


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SAFETY

S - STANDARDS

A - AWARNESS

F - FULLFILLMENT.

E - EFFICIENCY T - TRAINING

Y - YOU.

FOR SAFETY


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SAFETY

INDUSTRIAL SAFETY :-It is an activity carried out to minimize the contact of workers

with the existing danger in factory and thus reducing accidents.


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Accident is an unplanned and Unexpected

event which causes or is likely to cause an

injury or results into property damage orcauses interruption in production activity.

It Damages Three M-

Man

Material

Machine.

WHAT IS AN ACCIDENT


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1. UNSAFE ACT

2. UNSAFE ACTION

CAUSES OF ACCIDENTS


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Operating without authority.

Working at unsafe speed.

Making safety device inoperative. Using unsafe equipment.

Unsafe loading.

Taking unsafe position. Teasing,abusing .

Failure to use of PPE.

UNSAFE ACTS


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If someone committed 360 unsafe acts.

Out of 360 he found, 1

330 are no accident, 29 29 are minor injury or near misses,

1 is lost time injury.

330

ACCIDENT MODULE DUETO UNSAFE ACT


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Inadequate guarding.

Unguarded moving parts.

Defective conditions.

Unsafe design.

Hazardous arrangement:Layout,Storage,Exits .Overload.

Inadequate illuminiuation.

Inadequate ventilation.

Unsafe working dress.

Unsafe Practices and Procedures.

UNSAFE CONDITIONS(MECHANICAL/PHYSICAL)


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LOSSES DUE TO ACCIDNET

Loss of LIFE

Loss of limbs i.e.Temporary/permanent disability.

Loss of great magnitude in the form of painFinancial losses.

Hidden losses are like iceberg


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HUMAN

Suffering to the injured.

Loss of life. Suffering to the family

members,relatives & friend .

Loss of earning

Medical expenses.


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ECONOMIC

Direct cost / Indirect cost.

Loss of production.

Cost of medical treatment.

Damage to property:Equipment, Building, Materials.

Time loss by other employees.

Interruption in production.

Cost of training new employees. Loss of morale.

Loss of efficiency.

Cost of repair / replacement.


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LEGAL

Obligations for both to worker &

management at various act.


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COST OF AN ACCIDENT.SOCIETY.

1)Liveslost.

2)maydayslost

3)cost ofmaintenance of thedisabled &dependent.

INDIRECT COST

1)lost time ofinjuredemployees

2)lost time ofinjured otheremployees.

3)lost time offoreman,supervisor,executives.

4)cost of time

spent by first aidattendant.

5)cost due todamage.

6)costs underemployees

welfare & benefitscheme.

SUPERVISOR

1)worry.

2)loss ofprestige.

3)good manlost.

4)selecting&training

substitute.5)moresupervision

6)loss ofoutput.

7)loss of

morale.

DIRECT COST

1)compensationpayment.

2)medicalexpenses.

INJUREDPERSON

1)Suffering&pain.

2)Worry.

3)Incapacity toperform normaloutput of work

4)medicalexpenses.

5)loss of life.


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MISCONCEPTION

Accident happen-they are inevitable.

When there are huge machinery & fast movingproduction lines accidents are inevitable.

Safety rules are for new comer.

It will not happen with me as I am experiencedperson..


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ADVANTAGE

Human safety

Increase productivity

Ensure quality of product

Time saving


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DO NOT FORGET.

Prevention is better than cure.

Safety is key to success

You are responsible for your safety.

Lean safety teach safety practice safety Act with will to make accidents nil.


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-Unsuitable anatomical& physiologicalcharacteristics

-lack of knowledge

-Improper phy.condition

-faults/Failures of person

-Unsafe act

-Unsafe condition-Mech./Physical.

-Accident

-Injuries.

BASIC THEORY.


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HARZADS

PHYSICAL

CHEMICAL

BIOLOGICAL


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MECHANICAL HAZARDS

Due to rotating machines.

Due to operating machines in wrong manner.

Due to absence of guards to rotating parts


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CHEMICAL HAZARDS

Due to exothermic runaway reactions

Due to overconfidence

Due to lack of knowledge

Due to lack of safety measures

Due to failure of control systems

Due to mis-operations

Due to unattended reaction premises during

reaction


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ELECTRICAL HAZARD

Due to improper earthing continuity Due to poor maintenance of switches.

Due to open live ends

Due to absence of precautionary measures


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RADIATION HAZARDS

Due to emission of radiation of radioactive rays

Due to lack of using required PPE Due to prolonged contact with radiations

Due to lack of safety systems

Due to process itself


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HAZARD ASSESSMENT PROCEDURE

A number of methods are available for the various

steps of Risk assessment procedure.

HAZOP study.

SAFETY Audit.

PLANT Inspection.


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AVAILABLE METHODS OF HAZARD

ASSESSMENT.Method Priciple Quantification

Safety review

(What if Analysis?)

Review of components of the

process by an experinced

multidiciplinary team

No

Check - List Comparison of materials

and equipments with data &

codes established by

experience.

No

Hazard & Operability

studies. (HAZOP)

Detection of cause and

effects of deviations by use ofguide words.

No

Failure Mode and

Effect Analysis.

(FMEA)

Detection of critical faults in

the functioning of individual

component.

Possible


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AVAILABLE METHODS OF HAZARD

ASSESSMENT.Method Principle QuantificationFault Tree Analysis

(FTA)

Deductive description of event

leading from failure of

components to a hazardous

situation.

Possible

Event Tree Analysis.

(ETA)

Inductive determination of

pathway of disturbance having

led to a hazardous situation.

Difficult

Cause & Consequence

Analysis (CCA)

As Above Possible

Job Safety Analysis Detection of potential

hazardous interactions.

No


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The no. of accidents per 1000 workers in all

manufacturing industries in India,UK & USA

are as follows.

YEAR 1976 1979 1980 1981

INDIA 68.62 62.19 66.92 72.54UK 0 0 0 0

USA 0 0 0 0

INCIDENT RATE


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More manual operations.

Lower education standards of our employees.

Management being not sufficiently conscious .

Lack of training.

Lack of installing required safety systems.

REASONS FOR BAD RECORD


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Economic.

Humanitarian.

Legal.

REASONS FOR ACCIDENT

PREVENTION


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SAFETY TARGETS

No fires.

No loss time injury.

No accident.


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RESPONSIBILITY.

Management--to initiate the work ofAccident

Prevention.

Workers--every at every level should share the

responsibility.


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Capabilities.Knowledge.Personnel characteristics.

Age.Job experience.Visual functions

Psychological characteristics.Adequate attentions to be paid to --

proper selection, training.Placement, Education.Supervision.

HUMAN LIMITATIONS


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Engineering :proper system & layout.

Education: relevant job & safety education.

Enforcement:clear cut procedure & their enforcement.

Enthusian:keeping the workforce motivated.Evaluation:continues evaluation of program & procedures &

updating them to meet current needs.

FIVE ES.


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PREVENTION METHOD.

Engineering revision.

Personal adjustment.

Instruction ,Appeal.

Discipline


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Eliminating unsafe conditions.

Personal adjustment.

Safety educations.

Supervision

Discipline.

MANAGEMENT CONTROL.


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Eliminating unsafe act.

Safe guarding.

Rectifying preventing defective conditions.

Suitable,safe design construction.

Safe arrangement process.

Adequate & suitable illumination.

Adequate & suitable ventilations.

Safe dress.

Personal protective equipment.

Good housekeeping.

MSDS.

MANAGEMENT CONTROL.


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Discovering causes.

Job safety analysis.

Hazop study. Safety audits.

Inspection of plant.

Investigation of accident. Recording data.

Analysis of data.

MANAGEMENT CONTROL.


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SELFSAFETY

HOW TO PROTECT YOURSELF!


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SELF SAFETY

Follow the SafeOperating Procedure

to avoid Accident.


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SAFETY MANAGEMENT PRACTICES.

Accident/incident report, analysis & follow up.

Training requirement.

Safety audits.

Plant documentation.

Critical instrument system.

Control over safety device bypassing.

Relief device program.

Control of changes.

Work permits system.


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SAFETY MANAGEMENT

PRACTICES.

Formation of HSE policy.

Various safety audits.

Safety induction program. Disaster plant -Mock drill &updating.

MSDS.

TREM cards.

Employees involvement.Safety meetings. Suggestion scheme.

Off the job safety. Family involvement.

Minimum storage. Learning's from incident.


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WORK PRACTICES

1. Store MATERIAL in their respective places.

2. While charging chemicals respective PPEs are to beused.

3. While pouring solvent from bigger container to smallcontainer which develop static charges from both ofthem must be earthed and bonded in order toprevent fire and explosion.

4. Prevent spillage

5. Label all chemicals.

6. Follow the SOP for unloading tanker.

7. Smoking strictly prohibited.


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WORK PRACTICES

Regular checking of instrumentation calibration

Fire protection system to be checked

Avoid wrong sequential operation

Prepare SOP for power failure

Do not sudden start and restart of agitation.

Delay in starting cooling.Vent should be checked

Audiovisual alarm system to be checked


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GENERAL INSTRUCTIONS

1. Operation mistake can result in disaster in most such aplants and hence it is quite essential to ensure that alloperating staff scrupulously and systematic theoperation instruction given to them by supervisory

staff2. Developing safe procedures and practices is an

intelligent exercise those who have to follow them mustunderstand its necessity and know-how to follow themfor ensuring safety

3. Ensure use of proper tool

4. Avoid unsuitable method

5. Avoid equipment failure as a misoperation


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GENERAL INSTRUCTIONS

Ensure that there should not be lack of alertness,negligence, overjudgement, improper physical ormental condition

While shift changeover extra care to be taken forcritical operation

Avoid poor communications

Avoid poor housekeeping status

Operator should be always prepared

Alertness play big role

Alert person smell danger promptly, knows dangerouscondition exists, appraise seriousness, take requisitecorrect action


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PRODUCT SAFETY

By following safe operating practices one can ensurethe product safety.

There will be no cross contamination.

The quality of product will be improved.

Customer satisfaction.


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DO NOT FORGET.

Learn Safety,

Teach Safety

Practice Safety.


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DO NOT FORGET.


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Documents

Accident Prevention-trng Module