Topics Covered Dr. SANTHI RAJU PILLI 1-Concept and

Dr. SANTHI RAJU PILLIAssistant Professor

Department of Chemical Engineering Technology

Jazan University

College of Applied Industrial Technology,

Baish

Industrial Safety and Environment-213 MMET

Unit-1

Baish

WhatsApp: +919957953155

Email: [email protected]

Notes Source: Some parts of lecture notes were taken from Dr. Essam Saban’s PPTs


Topics CoveredContact

hours

1-Concept and importance of industrial safety,

fundamental safety tenets, safety in the site selection and

layout, definitions and terminologies of health and safety

in the workplace, safety signs and signals.

2-Introduction in OSH is including, but not limited, safety

and health goals, what is hazard, importance of training, and health goals, what is hazard, importance of training,

safety rules and regulations, what is safety committee,

and safety discipline.

3-Fire safety, classes of fire, types of fire extinguishers and

its handling, equipment used in fire detection and

firefighting, fire triangle, fire prevention, emergency and

action plan, employee responsibilities in relation to fire

safety.


Topics CoveredContact

hours

4-Hazards in different workplaces (mechanical, electrical

and chemical) with their corresponding risks; possibility,

effects, instant action and long term solution, common

plant hazards in industry.

5-Identify the hazards associated with the chemical used in5-Identify the hazards associated with the chemical used in

industry, health hazards, flammability, reactivity, storage,

transportation, disposal, first aid, chemical hazard info.

(CHB’s), Personal Protective Equipment (PPE).

6-Risk assessment in different workplace

7-Environmental Pollution

CLOsAligned

PLOs

1 Knowledge:

1.1 Describe the fundamental concepts, and importance of

industrial safety, fire safety, classes of fire, types of fire

extinguishers and its handling, fire prevention, emergency

and action plan, employee responsibilities in relation to fire

safety.

K1

2 Skills:

2.1 Define the basic terminology of Occupational Safety andS1, S2

Course Learning Outcomes

2.1 Define the basic terminology of Occupational Safety and

Health (HazardS1, S2

2.2 Investigate potential workplace safety and health hazards

and determine how to mitigate the hazards through

engineering controls, administrative controls and personal

protective equipment, as well as emergency planning.

S4, S5

2.3

2.4

3 Competence:

3.1 Estimate the environmental pollution and the factors

influencing it.C1,C3

Assessment Tasks

# Assessment task* Week Due

Percentage of

Total

Assessment

Score

1Quiz-1 and Assignment-1 /Case Study

5th Week 15%

2Oral discussion and participation

All weeks 5%2Oral discussion and participation in classroom

All weeks 5%

3 Midterm7th Week 15%

4Quiz-2 and Assignment-2/Case Study

9th Week 15%

5 Final Term ExamAs

scheduled50%

Text Books

• Soft and hard copies of lecture notes and some of sections from Health and safety in engineering workshops, web-friendly version of HSG129, 2nd

edition, 1999

Essential References Materials

• Occupational Health, Safety and Hygiene, EPHTI, University of Gondar, 2002.University of Gondar, 2002.

Electronic Materials• Saudi Digital Library, https://sdl.edu.sa/SDLPortal/en/Publishers.aspx

• www.cdc.gov/niosh/

• www.cdc.gov/niosh/topics/youth

• www.osha.gov/SLTC/

• http://www.aflcio.org/issues/safety/tools/infofs.cfm

• www.lohp.org

• www.nycosh.org/

CONTENTS:Introduction/History, major industrial accidents

Concept and importance of industrial safety

Industrial hazards/Types

Safety signs and signals.Safety signs and signals.

Definitions and terminologies of health and

safety in the workplace

Safety in the site selection and layout

HISTORY!!

Fire Accident in Jazan General Hospital, DECEMBER 24, 2015 Source: J.Maiti, IIT Kgp

Piper AlphaAberdeen,

Scotland

Piper Alpha - Wikipedia

Date 2 to 3 December 1984

Location Bhopal, Madhya Pradesh

Event

Leakage of water into MIC tank

caused increase in Temp. and

Pressure, releases 40, 000kg MIC

Also

known asBhopal gas tragedy

CauseGas leak from Union Carbide India

Limited storage tank

DeathsAt least 3,787; over 16,000

claimed

Bhopal memorial for those killed and disabled

by the 1984 toxic gas release

Injuries At least 558,125

http://en.wikipedia.org/wiki/Bhopal_disaster jabalpurcity.com

In Ukraine

Source: J.Maiti, IIT Kgp


What is Industrial Safety?

• Industrial safety is primarily a

management activity which is concerned

withwith

• Reducing

• Controlling

• Eliminating hazards from the industries

or industrial units.


Significance of Industrial Safety

Industrial causes a great loss to both the Employer &

Employee, that’s it is having importance

• Cost of compensation

• Cost of medical-aid• Cost of medical-aid

• Cost of training a new worker

• Cost of the lost time

• Cost of investigation

• Cost of supervision & inspections

• Cost to the Govt. in terms of factory inspectors, &

public health services


Significance of Industrial Safety

• Cost of spoilage of materials

• Cost of the damage of machinery• Cost of the damage of machinery

• Cost of cost of wages payable during

injury

• Cost of loss of morale

• Cost of loss to the worker and his family

Concept and importance of industrial safetyObjectives of Industrial Safety

• To prevent accidents in the plant by reducing the hazard to

minimum.

• To eliminate accident caused work stoppage and lost

production.

• To achieve lower workmen’s compensation, insurance rates • To achieve lower workmen’s compensation, insurance rates

and reduce all other direct and indirect costs of accidents.

• To prevent loss of life, permanent disability and the loss of

income of worker by eliminating causes of accidents.

• To evaluate employee’s morale by promoting safe work place

and good working condition

• To educate all members of the organization in continuous

state of safety mindless and to make supervision competent and

intensely safety minded.

Concept and importance of industrial safetyCauses of Industrial Accidents

• Unsafe conditions

• The job itself

• Work schedules

• Psychological conditions• Psychological conditions

• Machinery & Equipment

• Unsafe Acts

• Miscellaneous Causes

Concept and importance of industrial safetyMeasures to ensure Industrial Safety

• Safety Policy

• Safety Committee

• Safety Engineering

• Guarding of machinery

• Material handling equipment• Material handling equipment

• Safety devices

• Ergonomics

• Plan maintenance

• General house keeping

• Safety Education & Training

• Role of Government


Safety instruments

• Fencing of machinery

• Work on or near machinery in motion

• Employment of young persons on dangerous machines.

• Striking gear and devices for cutting off power

• Self-acting machines• Self-acting machines

• Casing of new machinery

• Prohibition of employment of women and children near

cotton-openers

• Hoists and lifts

• Lifting machines, chains, ropes and lifting tackles

• Revolving machinery

• Pressure plant


Safety instruments• Floors, stairs and means of access

• Pits, sumps openings in floors, etc.

• Excessive weights

• Protection of eyes.

• Precautions against dangerous fumes, gases

• Precautions regarding the use of portable electric light.• Precautions regarding the use of portable electric light.

• Explosive or inflammable dust, gas, etc.

• Precautions in case of fire

• Power to require specifications of defective parts or tests of stability

• Safety of buildings and machinery

• Maintenance of buildings

• Safety Officers

• Power to make rules to supplement this Chapter

Industrial hazards:

It can be defined as any condition produced by

industries that may cause injury or death to

personal or loss of product or property.

INTRODUCTION

personal or loss of product or property.

24 August 2012 22

HAZARDS

Physical

ChemicalPollution

Fire and dust

hazards

HAZARDS

Biological

Mechanical

Electrical

24 August 2012 23

Physical Heat Physical Hazards

Heat & Cold

24 August 2012 24

Heat and Cold

Burns

Heat

stroke

Foot sore

Immersion

foot

Physical

stroke

Heat

cramps

foot

Frost bite

Preventive

Measures

A reasonable temp. of 20-250C must be

maintained24 August 2012 25

Physical

Heat and Cold

24 August 2012 26

Physical Hazards

Noise

Auditory

Non auditory effects

Preventive measures

a. At source:

• Source of noise can be enclosed with an insulation

Noise have two type of effects

Noise

• Source of noise can be enclosed with an insulation

material or concrete wall.

• Proper maintenance of machinery

b. By distance

c. Personal protection against noise.

24 August 2012 27

Equipment noise sources, level & potential control solutions

Equipment Sound level in

dBA at 3 feet

Possible noise control

treatments

Air coolers 87-94 Aerodynamic fun blades,↓

revolutions/min ↑ pitch,↓

pressure drop

Compressors 90-120 Install mufflers on intake,& Compressors 90-120 Install mufflers on intake,&

exhaust, enclosure the

machine with casing,

vibration isolation & lagging

of piping system

Electric motors 90-110 Acoustically lined fun

covers, enclosure 7 motor

mutes24 August 2012 28

Heater &

furnaces

95-110 Acoustic plenums, intake mufflers,

lined & damped ducts

Valves <80-108 Avoid sonic velocities, limit

Equipment noise sources ,level & potential control solutions

Valves <80-108 Avoid sonic velocities, limit

pressure drop & mass flow,

replace with special low noise

valves

Piping 9-105 Inline silencers, vibration isolation

24 August 2012 29

Heat & Cold

24 August 2012 30

Physical hazards

NoiseRadiation

Radiation

Radiation are divided into two groups

Natural Man made

Cosmic rays Medical /dental x-rays isotopes

Environmental (radioactive Occupational exposure

Radiation

Environmental (radioactive

elements e.g. uranium)

Occupational exposure

Internal (potassium,) Nuclear radioactive fallout

Approx 0.1 rad/yr Miscellaneous

Use of radio active substances

by different industries

24 August 2012 31KLE College of Pharmacy, Nipani

Somatic (Affecting or characteristic of the body as

opposed to the mind or spirit)

Genetic (Occurring among members of a family usually by

heredity)

Preventive measures

Effect radiation of hazards

Preventive measures

i. Radiation source should be housed in a building

that shields any surrounding area.

ii. Radiation badges should be worn.

iii. Periodical medical examination.

iv. Proper use of lead shields & lead rubber aprons.

24 August 2012 32

Physical Hazards

Heat & Cold

NoiseFire &

Explosion

24 August 2012 33

HazardsNoise

Radiation

Explosion

Causes

Smoking in the factory

Defective heating equipment, electrical equipment &

wiring.

Explosive gas leakage.

Fire & explosion hazardsFire &

Explosion

Explosive gas leakage.

Inadequate protection of electric motors

Sparking of electric wires & equipment

Protection & prevention

Types of fire

24 August 2012 34

Preventive measures

• Prohibition of smoking in manufacturing areas.

• Oxygen present in the inflammable atmosphere maybe ↓by dilution with gases such as nitrogen, co2,steamor combination of these.

Fire & explosion hazards

or combination of these.

• Hazardous operation should be isolated

• Eliminating the ignition sources

• Using fire resistant material in construction

• Suitable emergency exits

• Adequate venting

24 August 2012 35

• Automatic sprinklers

• Equipment should design to meet the specifications &

code of recognized authorities, such as ISA, API

&ASME

• The design & construction of pressure vessels &

Fire & explosion hazards

• The design & construction of pressure vessels &

storage tanks should follow API & ASME codes.

• Inspection

24 August 2012 36

Local

– Dermatitis

– Eczema

– Ulcers

– Cancer

Inhalation

– Gas Poisoning

CHEMICAL

HAZARD

Ingestion

Living tissue may be destroyed by chemical reactions such as

Dehydration

Digestion

Oxidation

24 August 2012 37

Biological hazards

• Disease due to biological hazards Brucellosis (dairy industry)Byssinosis (textile industry)Bagassosis (sugar-cane) (sugarcane dust)Loco motor disorder• Preventive measures

Periodic health check up

Biological

Periodic health check upPersonal protectionThe manufacturer should also provideFirst aid facilitiesInitial examinationFacility for vaccinationRoutine sanitation programme

24 August 2012 38

ELECTRICAL HAZARDS

Electrical injuries consist of four main types:

• Electrocution (fatal),

• Electric shock,

• Burns and

• Falls caused as a result of contact with electrical energy.

Electrical

• Falls caused as a result of contact with electrical energy.

An worker will receive a shock when he/she:

• i. Touches two wires at different voltages at the same time.

• ii. Touches phase and neutral wire at a time

• iii. Touches the phase standing on the ground

• iv. Touches the phase having wet cloth, high humidity and

• perspiration.

Hazards in work Place

• Hazards in work place may be due to the following:

7- Lack of machinery safeguarding

8- Manipulation with hazardous substances, particularly metalworking fluids, degreasing

Mechanical

particularly metalworking fluids, degreasing solvents, and dust or fume from welding, brazing, soldering, coating and painting

9- Noise, and vibration.

10- Occupational diseases such as dermatitis التهاب

الربو asthma ,الصمم deafness ,الجلد and problems in back, hand, arm, shoulder and neck

FIRE AND DUST HAZARDS

Source of dust hazards in pharmaceutical industries

• Grinding or milling of drugs, excipients, or herbal products.

• During weighing dusts may float on air.

• During powder mixing dusts may be generated.

• During coating operation dusts are generated.

Pollution

• During coating operation dusts are generated.

• During capsule filling and tablet punching operation dusts

may be generated.

Methods of controlling dust

• Filtration

• Inertial separator

• Electrostatic separator

SAFETY & TRAINING

• Operators of trucks, cranes, winches, etc are to be trained in-house in accordance with governmental requirements. Operators must attend classroom instruction as well as “behind the wheel training the wheel training

ويجب على المشغلين . ينبغي تدريب مشغلي الشاحنات والروافع داخل الشركة وفقا للمتطلبات الحكومية“هو أكثر من مجرد القيادة”حضور حصص التعليم وكذلك التعليم لما

• All employees who work with, or are exposed to, hazardous chemicals are to be trained in Hazard Communication, in accordance with governmental regulations

جميع الموظفين الذين يعملون أو يتعرضون للمواد الکيميائية الخطرة يجب تدريبهم علی التغلب على المخاطر المتعلقة بالكيماويات وفقا للوائح الحكومية

SAFETY & TRAINING

• All employees who don respirators are to be trained in accordance with governmental regulations. Those individuals who don respirators are required to have annual medical check upيجب تدريب جميع الموظفين الذين يملكون اجهزة تنفس وفقا للوائح الحكومية، ومطلوب منهم فحوصات طبية سنوية

• Machine operators and maintenance technicians are required to be trained in Lockout/Tagout procedures. Individual locks/keys will be assigned to those individuals participating in the LOTO program لوك (يجب تدريب مشغلي الآلات وفنيو الصيانة على اجراءات حماية العمال من التشغيل المفاجئ للآلات أثناء الصيانة

)لوتو(أو ) تاج أوت/لوك أوت(ويتم اعطاء مفاتيح تشغيل الآلات لهؤلاء المشاركين فى برنامج ). تاج أوت/أوت

SAFETY & TRAINING

• All employees who need Personal Protective Equipment (PPE) will be trained in the proper use of such equipment

يجب تدريب جميع الموظفين الذين يملكون معدات الحماية الشخصية على الاستخدام السليم لها

• First-aid training and Bloodborne Pathogen (BBP) training should be conducted

يجب إجراء تدريبات الإسعافات الأولية والأمراض المنقولة بالدم

• Machine/Equipment operators are to be trained in-house. No employee is allowed to operate a machine unless it is properly guarded

ولا يسمح لأي عامل بتشغيل الآلة ما لم يتم حماية الآلة بشکل صحيح. يجب تدريب مشغلي الماكينات داخل المصنع

• Employees who operate company vehicles are required to participate in an in-house Defensive Driving Program يجب تدريبقائدي السيارات داخل المصنع على برنامج السلامة في القيادة

SAFETY & TRAINING

• All production, shipping, and warehouse employees are required to attend safety training session on an annual basis regarding material handling and machine guarding to refresh information and get employees aware about new materials which may be existed.

يجب على جميع عمال الإنتاج والشحن والمخازن حضور دورة تدريبية حول السلامة سنوياً، فيما يتعلق بمناولة المواد وحراسة الآلات، وذلك لتحديث المعلومات وإطلاع الموظفين على المواد الجديدة التي قد تكون موجودةالآلات، وذلك لتحديث المعلومات وإطلاع الموظفين على المواد الجديدة التي قد تكون موجودة

• All employees, on hiring, are to be trained in Emergency Action and proper evacuation in case of an emergency.

.يجب تدريب جميع الموظفين، بمجرد توظيفهم، على إجراءات الطوارئ والإخلاء السليم للمبنى في حالة الطوارئ

• Foremen and Assistant Foremen are to meet with the Safety Director on a quarterly basis to discuss training needs and goals يجب ان يجتمع المفتشون ومساعديهم مع مدير السلامة يشكل ربع سنوي لمناقشة احتياجات واهداف التدريب

Safety Committee لجنة السلامة

• The purpose of the Safety Committee:

1- promote safety awareness

2- reduce the potential for injury/loss

• The Safety Committee consists of:• The Safety Committee consists of:

1- The chair: Safety Director

2- The members: representatives from each

department.

3- Membership is limited for a certain period (1 year)


• Meetings are to be scheduled, each meeting has its own Agenda and Minutes. The following points should be considered during the meeting:

1- Agenda should discuss:

(a) A review of the prior month’s minutes(a) A review of the prior month’s minutes

(b) A review of the prior month’s injury/illness

(c) Investigations of losses/claims

2- A copy of the minutes shall be forwarded to the Vice-President


• General functions of the Safety Committee can

include:

(1) Identifying workplace hazards

(2) Enforcement of Safety Rules (2) Enforcement of Safety Rules

(3) Measuring safety performance

(4) Reducing frequency/severity of injuries

(5) Creating safety policies

(6) Developing and monitoring safety programs


• Specific tasks of the Safety Committee can include:

1. Conducting self-inspections of the workplace

2. Review employee reports of hazards

3. Assist in safety training 3. Assist in safety training

4. Publish/distribute safety newsletter

5. Inspect PPE

6. Post safety posters/slogans on bulletin board

Safety Signs and Signals• Symbol meaning

http://safetycoursestraininginchennai.blogspot.com/2015/08/safety-signs-and-

signals-poshe.html

Safety Signs and

Signals??Mandatory signs:

https://www.riigiteataja.ee/en/eli/518112015005/consolide

Safety Signs and Signals• Warning signs


Safety Signs and Signals• Warning signs


Safety Signs and Signals.• Prohibition signs The intrinsic features of prohibition signs are a round shape


• Evacuation and first-aid signs

Safety Signs and Signals.


• Evacuation and first-aid signs



• Fire-fighting signs



Know Your Fire Extinguisher Colour Code Signs

https://www.amazon.co.uk/Duke-Gifts-extinguisher-colour-

workplace/dp/B00SMR00TO

Know Your Fire Extinguisher Colour Code Signs

https://www.indiamart.com/proddetail/fire-fighting-equipment-11077032830.html

Documents

Topics Covered Dr. SANTHI RAJU PILLI 1-Concept and