Industrial Accident and Safety

INDUSTRIAL ACCIDENT AND SAFETY

PRESENTED BY:- CHANDAN SINGH

BASIC PRINCIPLES OF ACCIDENT PREVENTION

Industrial Safety means freedom from accidents happening in an industry.

Accident means an unplanned, unexpected event, which may or may not result into an injury.

BASIC PRINCIPLES

PRINCIPLE - ONE

An unsafe act, an unsafe condition, an accident; all these are symptoms of something wrong in

management system.

BASIC PRINCIPLES

PRINCIPLE - TWO

Certain sets of circumstances can be predicted to produce severe injuries. These

circumstances can be identified and controlled.

BASIC PRINCIPLES

PRINCIPLE - THREE

Safety should be managed like any other company function. Management should direct the safety effort by setting achievable goals, by planning, organizing, and controlling to

achieve them.

BASIC PRINCIPLES

PRINCIPLE - FOUR

The key to effective line safety performance is management procedures that fix

accountability.

PRINCIPLE - FIVE

The function of safety is to locate and define the operational errors that allow accident to

occur

BASIC PRINCIPLES

BASIC PRINCIPLES

Review the entire system in detail to define likely modes of failure, including human error and their

effects on the safety of the system.

Identification and

appraisal of The accident

problems

Development of accidentPrevention and loss –Control

procedures

Communicatingon of

accident information

Measurement of

Effectivenessof control

Feedback to be used for modification

FUNDAMENTAL TRUTHS IN ACCIDENT PREVENTION

There are two fundamental truths in accident prevention.

TRUTH – ONEThe accident –causes and injury –causes are different.

TRUTH - TWOThere are more than one cause for any accident

HOW TO DECIDE WHETHER A PARTICULAR INCIDENT IS AN ACCIDENT OR NOT?

A) Injury to any Person

B) Damage to Property

C) Damage to Equipment

D) Damage to Material

TYPES OF ACCIDENT

1.No accident even though accident potential is there

2.Near miss accident –called as incident

3.Accident –No damage or injury

4.Accident –Damage or injury

5.Accident-injury to person and damage to equipment, material or property

CHAIN OF ECVENTS

Injury

Accident

Unsafe acts Unsafe condition

HUMAN FAILURE

Relation of Major Accidents, Minor Accidents and Near-Miss Accidents

1

29

300

Serious Accidents

Minor Accidents

No Damage / Injury cases

CAUSES OF AN ACCIDENT

Unsafe conditionsThe major unsafe conditions are as below Improper guarding ,un-guarded Defective tools Slippery floors, work places Improper house keeping

THE MAJOR UNSAFE ACT ARE

Operating without authority Failure to secure or warn Operating or working at unsafe speed Making safety devices inoperative Using unsafe equipment ,hands instead of

equipment or equipments unsafely Taking unsafe position or posture Failure to use personal protective equipment

Cost of an accident

Every accident happening on shop floor, at home or in –between, costs something to

The injured person The family members of the injured The factory where he works The society in which he is living The nation

The accident costs are of mainly two types

• Direct Cost (costs which can be seen and measured

• Indirect Cost ( Hidden cost)

Direct cost Compensation Medical expenses Direct expenses made by injured

Indirect cost Loss of production by the injured Loss of production by other workers who comes for help Cost of training a new worker Low production by the worker Low production by the victim for some time

The accident costs are of mainly two types

The three basic steps in accident prevention

Discovering causes

Eliminating unsafe acts

Eliminating unsafe conditions

Discovering Causes

There are five techniques to deal with discovering potential causes of accident

a. Job safety analysis

b. Plant /site inspection

c. Accident investigation

d. Recording and tabulation of data

e. Analysis of data.

Unsafe act can be eliminated by

a. Personnel adjustment

b. Education and training

c. Supervision

d. Discipline

Unsafe condition can be eliminated by keeping a watch of it and remove it as early as possible

Safety in P&M Operations

Most accidents ,whether they occur in project sites, on the farm, at home or on the highway are caused by the carelessness of some

individual or failure of plant and machinery.

Some basic and common safety rules and regulations are: 1.Know your machine in details 2.No operator should be assigned to a job until he completes the

following minimum requirement:-

a. He has been properly trained to operate the machine assigned to him. b. He has read and understood the operator’s manual for the machine.

Safety in P&M Operations

c .He has essential personal protective equipment and know how to use it.d. He has the knowledge about the job requirements, any dangerous

condition which may arise and other emergency procedures

3.Maintain safe job condition and working procedure4.Examine the work site for restricted traffic patterns, obstructive views,

congestion etc5.Never attempt to clear oil or adjust a machine while it is in motion.6.Attend to all fuel and oil leakage immediately and use only approved

grades of lubricating and fuel oils

7.Keep the battery terminals covered with petroleum jelly.

Concrete Mixer

1. All gears ,chains and rollers of concrete Mixer should be adequately guarded to prevent damage /danger

2. Concrete Mixer hopper shall be protected by side railing to prevent workers from passing under them and operator shall make sure before lowering the skip that all workers are safe.

3. Hopper hoisting wire rope has to be checked for its condition periodically.

Concrete Mixer

4. Hopper hoist and anchoring brake should be checked and adjust while slipping occurs.

5. Nothing should be kept inside the motor enclosure.

6. Keep hoist clutch to be checked and adjusted while slipping occurs7.Be sure that motor fan guard is secured timely

8.Be sure that wiring is properly connected and insulated

9.Ensure double earthling is done to electric mixers

Welding Generators

1.Install the machine in a well ventilated environment with a proper Earthing.

2.Operator/welder should be well aware of sequence of operations3.Direction of rotation is to be ensured thoroughly.4.Adoption of correct size of supply &welding cables with lugs (sockets)5.Insulation of machine should not fall below 2MΏ6.Fuse rating should not exceed 50 Amps7.Only genuine parts should be used 8.Avoid grinding work, near generator.

Dumpers & Trucks

1.Only experienced operators with valid license should be permitted to work

2.Allm parts and accessories should be kept in safe condition3. All lights ,reflectors and brakes should function otherwise truck

should be removed from services until repairs are made4.All vehicle plying on the road should abide by the provision of the

motor vehicle Act

Dumpers & Trucks

5.No person should be permitted to remain on the truck while being loaded by excavating equipment or crane.

6.Materila loaded should be within safe weight limit.

7. While reversing the truck /dumper ,Reverse Horn should be used. If reverse horn is not available signalman should be provided.

8. Never keep the PTO lever engaged while the tipper is running on the road .PTO level should be engaged only during the tipping operation

Water Pump-Safety Precaution

1.Ensure proper foundation is provided for placing water pumps to prevent possible toppling and avoid vibration

2.Ensure mounting bolts of both pump and motor /engine is secured well

3.The coupling used should be of correct size with proper keyway and keys and the alignment should be perfect.

4.Ensure the power supply is switched off before attending any type of repairs on the water pump.

5.Ensure all the bolts are tightened properly and keys are placed well before starting the pump

6. Before starting the pump ensure that there is no unwanted tools left near the pump

Water Pump-Safety Precaution

7.No cloth or cotton waste or paper shall be allowed to come in contact with the shaft when the pump is in running condition.

8.Proper cover should be provided for the motor to prevent it from rain or any unexpected water spillage

9.No loose connection is to be allowed in the water line, especially near the pump. The water may spill on the motor and pump causing damage

10.Proper earthling is a must for electrically operated pumps

Safety in Electricity

Hazards associated with electricity

1.Electric shock

2.Electric fire &explosion

3.Electric flash &burns

-Joules burns

-Flash burns

These are the other types of hazards ,which are not directly related

to electricity, but may occur .These may be termed as Secondary Hazards. These are

1.Person falling from height

2.Dropping of tools &objects

Safety in Electricity

3.Health hazards due to release of toxic gas and production of UV rays

4. Psychological effect Emotionally anxious DistractedAnd hence more prone to accidents.

Electric shock It is a sudden & accidental stimulation of body’s nervous

system by the passage of electric current .Shock is felt when person becomes part of electric circuit

Severity of shock depends on

1.Amount of current passing through body 2. Duration of flow 3.Path of flow of current 4.Type of energy

Body resistance: A person’s main resistance to current flow is skin’s surface.

Callous or dry skin has a fairly high resistance .A sharp decrease in resistance takes place ,however ,when the skin is moist .Once the skin’s resistance is broken down ,the current flows readily through the blood and the body’s tissues.

Effect of electric shock on human

The effects are as follows Human voluntary and involuntary nervous system which

control and co-ordinates thought signals ,biological functions & muscles has data transmission through neuro-humoral (chemical) transmission. This gets disturbed due to flow of external electric current through human body cells, muscles ,nerves, tissues etc. The interface between biological tissues and electrical current manifest in the form of electric shock

How shock occurs

1. By simultaneously touching the phase and neutral conductor thus completing the circuit through his body.

2. By touching the phase conductor and standing on the ground

3. By touching the metallic part that has become live by itself being in contact with energized wire and standing on the ground

Shock Protection Method

Isolation:

All electrical equipment should be isolated from accidental contact & approach by unauthorized men, providing barrier .Panel boards, generators, large motors, batteries should be enclosed. Low & medium voltage OH lines should be kept 19”above the ground.

Isolation Switches:

The switches should be connected in phase only. The switches should be easy and free to operate .Body of the metallic switches should be earthed. Every DB should be provided with a switch. It is advisable to keep switch as near as possible to the work-place. If switch is connected in neutral, person who repairs the equipment, could get shock though the supply is cut using the switch

Shock Protection Method

Isolation transformer:

Power can be tapped from isolation transformer for the power tools and for testing electric equipment (in working condition). Avoids shock between earth and phase.

Double Insulation:

In addition to the normal insulation required for functioning of the equipment, a second layer of insulation known as protective insulation is interposed between functional insulation and any accessible metal parts of appliances

Earthing

Earthing is of two types Neutral Earthing (System Grounding): Intentional connection of

neutral point to earth is called neutral or system earthing.If neutral point is earthed ,the phase to ground voltages under earth fault conditions do no arise to high value. Earth fault protection becomes easy. Hence it is universal practice to have a neutral earthling at each voltage level.

Equipment Earthing: If is quite different from neutral earthing.Connecting to earth the non-current carrying metal parts of equipment is equipment earthing.The potential of earthed body does not reach to dangerously high value since it is connected to earth.

The equipment Earthing is the essential safety measure

Fuses:

Fuses are proven Safety devices for overloads conditions. Current Limitation

Safety is assured by purposely limiting the shock intensity from a device (ELCB) to a value known to be reasonable safe.

Cable routing: All electrical cables should run either overhead (7 feet) or underground .Cable routing layout map to be prepared so that it does not cause tripping hazards. Welding and power cables not to be overlapped. Protect cables against mechanical damages, heat.


Cable joints: Staggered joints: Joints are not to be overlapped. One primary insulation and an overall secondary insulation are to be done. Proper insulation tapes are to be used. For high voltage cables use jointing kits.

Manpower: Employ qualified electrician, preferably ‘B’ licence

holders. Identification of the electrician –red helmets. Hand Lamps: Only 24 V hand lamps are to be used. Totally enclosed

and protected Hand lamps are to be used. Hand lamps used for confined space work should be of all insulated type with no joints.


Electric burns:

1. Burns from electric Flash

2. Burns from electric heat

Working near overhead lines:

Minimum height of overhead cable: 400 KV 7.3 M(24 ft)

275 KV 7.0 M(23 ft)

132 KV 6.7 M(22 ft)

33-66 KV 6.0 M(19 ft 9 in)

11-33 KV 5.2 M(17 ft)

Fire Prevention

Fire:

Fire is a chemical reaction ,in which substance (fuel) combines with oxygen. The reaction is exothermic and usually associated with emission of light and heat.

Elements of fire: Fuel Heat Oxygen Explosion

Chain reaction

Fire Triangle Fire tetrahedron (Pyramid)

Oxygen Heat

Fuel

Chain Reaction

Heat

FuelOxygen

Fire Tetrahedron (Pyramid)

Oxygen

Heat

FuelChain Reaction

Classification of fire (based on material burning)

Class “A” fireOrdinary combustible fire Solid combustible material normally organic in nature

(compounds of carbon) cooling effect of water is essential for extinguishing the fire E.g. wood ,Cloth ,Paper etc which leave carbon after combustion.

Class “B” fireFlammable liquid fire Flammable liquids or liquifiable solids where blanketing

effect is essential for extinguishing the fire e.g. Petroleum products , solvent, paints etc


Class “C” fire

Flammable gas fire: These are the fires involving gases or liquefied gases under pressure where it is necessary to isolate the burning gas at a fast rate with an inert gas ,powder or vaporizing liquid for extinguishment e.g. fuel gas, hydrogen, liquefied petroleum gas etc.

Class “D” fire

Metal fires: Metals generally called Alkali Metals such as Magnesium, Sodium, Titanium etc. Specialized techniques ,extinguishing agents &equipments are required to control such fire.


Electrical fires

According to latest concepts ,the electrical fires do not constitute a particular class. Any fire involving an electrical equipment is in fact be a fire of class A,B or C. The normal procedure in such fires is to cut off the electricity and use an extinguishing method appropriate to the burning material. Special extinguishing agents which are non-conductor of electricity and non –damaging to the electrical equipment such as dry chemical powders and carbon di-oxide should be used.

Principle of extinguishing fire

Starvation -Elimination of fuel Smothering - Limiting oxygen supply Cooling - Limiting rise of temperature Chain inhibition

Principle of extinguishing fire

CLASS OF FIRE

Type of Fire Extinguisher

Water Foam CO2 DCP

A Suitable

B

D

Unsuitable

Unsuitable

Electrical Unsuitable Unsuitable

Suitable Suitable

Unsuitable

Suitable for non-polar flammable liquids only

Unsuitable

C Unsuitable Unsuitable Suitable Suitable

Suitable for some cases if special type dry chemical used

Suitable Suitable

Not suitable ,but will control small fires

Not suitable,but will control small fires

Not suitable,but will control surface fires in textile fibers

Fire Extinguisher-Do’s

Keep it at its designated place Always use suitable extinguisher In case of abnormality, inform fire control room For electrical fires, use DCP & CO2 extinguishers only Avoid physical damage

Fire Extinguisher-Don’ts

Do not misuse fire extinguisher Do not use water type extinguisher on electrical fires Do not attempt to open fire extinguisher Do not relocate extinguisher on your own Do not remove operating instruction sticker Do not obstruct the visibility & access.

Safety in welding

Body of the welding machine should be earthed. Terminal of the welding cables should be provided with lugs and

kept tight. Joint in the cables should be made with terminals, kept tight and

well insulated with heat resistance tape. Cable should be free from joints at least for a length of three

meters from electrode holder to avoid shock hazard. Other electrical cables should not be kept laid with welding

cables , to avoid insulation damage. For the return lead only proper cable should be used. Using

rods ,angles ,channels etc should be avoided Never change electrode with bare hands or wet gloves ,when

standing on wet floor

Safety while working at height

THE ARE THREE MAIN HAZARD ASSOCIATED WITH WORK AT HEIGHT.

Falls Falling objects Falls from collapsing structure

Risk Assessment

First, as a part of the planning of the work, carry out a risk assessment.

Plan to do as much of the work as possible at low level. Do not work at height unless it is absolutely unavoidable If this is not possible, consider the following The activity Equipment to be used Location, e.g. near or over water, roads, under power lines ,etc Environment, e.g. weather, temperature, lighting Duration of the work. Condition and stability of the work surface

Precautionary Measures

1.Falls

There are four ways of preventing falls of people. They are

i) Edge protection, e.g. Guard rails ,toe boards.

ii) Maintaining a safe distance from an edge.

iii) Safety nets.

iv) Safety harnesses

Cont…

2.Falling objects To prevent objects falling onto people you need a proper

management system which: Provides barriers, e.g. a toe boards or mesh guards to prevent

items from slipping or being knocked off the edge of a structure Secures object to the structure, e.g. lashing of scaffold boards Ensures that there are no loose objects and that any loose tools

are properly secured Creates an exclusion zone ,where necessary ,beneath areas

where work is taking place. In addition, when people are working at a heights above other

work areas ,it is mandatory to provide safety helmets to protect the workers below against falling objects.

Cont…

3.Falls from collapsing structures A competent person should inspect and attach a notice to a

structure after completion and before it is put into use.

LADDERS Ladders are frequent cause of accidents. They should not be

used as a working platform-ONLY FOR ACCESS. Ladders use is only permitted when the ladder is used for short duration and the ladder is:

Fixed to prevent slipping Placed on firm level surface with the top part of the ladder

resting against a solid surface

Cont…

The ladder is correctly angled ( at 75 degree to the horizontal/one out for every four up)

Positioned such that working on it does not require stretching out

Positioned so that a good handhold is available if used for access or must protrude sufficiently above a working platform that is to be accessed

All ladders including steps must be thoroughly inspected on a regular basis, by a person who is qualified to judge the suitability/safe condition of the equipment. A record of such inspections must be recorded

Cont…

When extension ladder are used the overlap of any adjacent sections should be as follows:

Closed length Less than 5 metres-11/2 rungs overlap 5-6 metre – 21/2 rungs overlap Over 6 metres- 31/2 rungs

Working platform Be securely footed on stable ground Support the weight of the personnel and equipment to be used Provide a stable access and will not overturn Be secured to an existing structure ,where necessary and

wherever possible Take account of the gradient of the ground, especially where

mobile platforms are used. Provide guard rails to the platform Provide barriers on open edges ,holes and openings in the

platform floor, the edges of roofs and working areas. Ensure that only standard /approved Personal Protection

Equipment is used for working at height

Working on roof

Precautions for all roof work Is the work necessary? Risk assessment and method statements Getting on and off the roof Edge protection Work platforms Falls arrest equipment Falling material Prevent unauthorized access Avoid working on/ near fragile materials Training Weather conditions Short duration work

Safety nets

Safety nets are the least problematic and hence the preferred option. Make sure that either safety net is used to protect against falls through the gaps created as the leading edge moves forward .If safety nets are used make sure that they:

Are installed as close as possible beneath the roof surface. Are securely attached and will withstand a person falling

onto them. Are installed and maintained by competent personnel.

Thank

You

Documents

Industrial Accident and Safety