Loss Prevention

SRIVATSAN: Re-print on 15.10.
2013
R DIS – 3
I–V
ANNAMALAI UNIVERSITY
DIRECTORATE OF DISTANCE EDUCATION
Diploma in Industrial Safety
COURSE – III
LOSS PREVENTION TECHNIQUES AND

PROCEDURES
Annamalai University
UNITS: I – V
Copyright Reserved
(For Private Circulation Only)
i
DIPLOMA IN INDUSTRIAL SAFETY

Course – III: Loss Prevention Techniques and Procedures
SYLLABUS
Aims
The course is aimed at making the student to understand the loss prevention
techniques and the procedures to be followed in Chemical Process Industries.
Objectives
On completion of course the students are expected to be familiar with various
“Hazard Identification and Analysis” techniques.
Unit – I
Safety Organizations in loss prevention – role, objectives, types, functions and
advantages. Safety Education and Training-Safety Promotion and Publicity
schemes.
Unit – II
Human factors contributing to Accidents – causes for unsafe acts-Safety and
psychology – Thoeries of Motivation and their application to safety.
Unit – III
Hazard Identification and analysis-Fault tree analysis – Event tree analysis –
Failure modes and effects analysis, HAZOP studies, Job Safety Analysis – examples.
Unit – IV
Plant Safety inspection-objectives and types-check list prcedure-inspection
report. Safety Audit – elements and standards-advantages.
Unit – V
Accident investigation-Classification of accidents-purpose and steps of
investigation-accident reports-remedial measures and rehabilitation of workers.
First Aid-Principles-General rules-Training- electric shocks, respiratory problems,
cardiac massage, fainting, poisoning, wounds, burns, bleedings, insect bites, etc.
Reference Books
1. R K Jain & Sunil S Rao – Industrial Safey, Health and Envrionment
management Systems, Khanna publishers, New Delhi (2006).
Frank P Lees – Loss prevention in Process Industries, Vol. 1 & 2, Butterworth-
Heinemann Ltd., London (1991).
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DIPLOMA IN INDUSTRIAL SAFETY

Course – III: Loss Prevention Techniques and Procedures
CONTENTS
UNIT PAGE NO.
I 1
II 11
III 19
IV 39
V 58
1
UNIT–I
CONTENT
1.1 Introduction
1.2 Safety Organizations in Loss Prevention
1.3 Safety Education and Training
1.4 Safety Promotion and Publicity Schemes
1.5 Summary
1.6 Questions
1.1 INTRODUCTION
The advances of science and technology present many benefits to the
mankind. With the progress in technology, process plants are being operated at
extreme conditions of temperature and pressure and uses highly toxic chemicals
and intense energy sources. This in turn leads to hazardous situations. Human
errors and instrument failures may sometimes lead to great disasters to the
industry and eventually to the society. Now a day, all industries state that their
three prime concerns are safety, quality and production respectively.
Objectives
After studying this unit, you will be able to:
 Appreciate the role of safety organizations and their different types and
functions,
 Understand the importance of safety education and training in the prevention of
accidents, and
 Know the advantages of safety promotion and publicity schemes.
1.2 SAFETY ORGANIZATIONS IN LOSS PREVENTION
Organization, administration and management are the three important steps
to be taken for the successful outcome of any Industry. Good safety performance is
always the result of well planned and coordinated efforts on the part of enterprise’s
activities or role. It is not achieved by mere compliance with statues, sporadic
campaigns or scattered promotional activities. Safety is directly linked with the
factors like
 The quality of work
 The methods of work
 The working conditions
 The efficiency of work
 The decisions associated with work
 The place of work
 Procedures employed in the work
 Persons involved with the work
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There are three important components in the process of achieving efficient

production without accidents. They can be given as
 The machines, equipments and plant
 The persons performing the jobs and
 The materials manufactured and used
The performance of man and machine and the handling of materials depend
on various factors which are illustrated schematically in the Fig.1 for a good safety
management.
Selection
Design
Maintenance
Operation Machines
& &
Control Equipments
Selection
Training
Placement Man Efficient
Motivation products SAFETY
Discipline
Hazardous
properties
Storage Materials
Transportati
on
Handling
Fig. 1 Illustration of important components in the process of achieving Safety
1.2.1 Objectives of Safety Organizations

The overall objective as well as the essence and philosophy of safety
administration are as follows.
 To provide safe working environment
 To develop safety consciousness amongst employees
 To integrate safety policy with job process
 To ensure compliance and implementation of statutory provisions and
rules as per the factories act
 To ensure and modify(if necessary) the procedures and standards on
identified risks
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 To provide all concerned with the information, intimation, training to

ensure safety
 To invite cooperation and suggestions from the employees in the
matters of safety
 To take measures after accidents(if any) to prevent in the future
In any manner, the effectiveness of the safety management depend on
 The attitude of the top management and
 The competency and ability of the safety professionals
The objectives are attained through the functioning of the safety wing of the
industry by its type.
1.2.2 Types and Functions
Even though safety has been described as everyone’s responsibility, most
functions in the modern plant operations are fulfilled through an organizational
hierarchy. It is up to the principals of every organization to at least review and
approve its long range objectives. Every big or small organization should have a
safety wing which is classified into three types namely
 Line Organization,
 Safety Directorate and
 Committee organization.
In the Line Organization, the entire responsibility fall in line that is from the
top level to the worker level, everyone is responsible regarding safety aspect. Many
of the small scale industries follow this type of organization which does not have a
separate safety department or safety engineer. The weakness in this type of
organization is very often production process preoccupies the employees time and
thinking and hence resulting in the neglecting of safety rules. The other important
factor is the non-availability of safety officer to look after the issues relating to
safety.
Large firms with hundreds of employees follow this type of organization called
Safety Directorate. A Safety Manager directs this organization. The effectiveness
mainly depends on the activities of the Manager. He should keep himself fully
informed concerning the nature of the processes and operations. Apart from this,
his essential duties are creating awareness among the employees, periodic
inspection to locate unsafe conditions and identifying the unsafe act, conducting
safety programmes, maintaining injury and illness records, and investigation of
accidents, etc., This system also has some disadvantages when the top-level
management fails to support the manager’s decision and if the manager is not a
competent person. The success of the safety directorate is mainly depends on the
functions of the directorate in implementing and monitoring the various procedures
in the operation of machines, equipments and handling of materials, training and
motivating the workers towards hazard and accident free industry. The essential
duties of a safety manager are enumerated hereunder.
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1.2.3 Safety Director’s Functions

As the organizer, stimulator, and guide of the safety programme, the
organization’s director of safety performs a number of significant tasks. They
include the following:
1. Understand the company’s policy and programmes, and integrate the
concept of safety and health in all areas of management.
2. Work closely with other mangers and achieve higher standards of
safety.
3. Short and long term planning of safety and health activities and
implementation of plans.
4. Designing and implementing programmes to promote employee
participation in safety.
5. Compliance with legislation, and liaison and coordination with
enforcement agencies.
6. Making available technical information, guidance notes, and training
manuals for use by managers.
7. Conducting training programmes on First-aid, Fire fighting, Material
handling, etc., for all level of workers.
8. The collection and recording of pertinent data on safety-related
operational matters, including work injury causes and statistics.
9. The advisement of supervisors of safety trained programmes.
10. The inspection of the facilities for compliance with federal, state, and
local regulations, as well as the safety program’s established
operating procedures and any insurance company recommendations
that are offered.
11. The participation in the review of purchase specifications, to
ascertain whether danger points in inherently hazardous machinery
and equipment are guarded correctly; and in the design of new
facilities, equipment lay out, or process arrangements to determine
whether all needed considerations for safety have been satisfied.
1.2.4 Safety Committees
A safety committee is standard in many corporate safety organizations found
to be very effective in accident prevention. Committee size should be small enough
for effective work, but large enough to provide the knowledge required to serve the
mission. In larger organizations these two needs are met generally by establishing
one committee at the corporate (overall) level and one or more committees at plant,
departmental, or shop levels.
When starting a committee, a written statement should be prepared stating the
 Mission or responsibility of the committee
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 Authority, including a budget, if any, afforded the committee

 Procedures, i.e., frequency of meetings, start-up times and duration,
agenda, attendance requirements, minutes or records to be kept, and to
whom reports are to be submitted.
Generally, there are three types of sub-committees and a Central Safety
Committee may serve and this vary with the size of the concern, and, as a matter of
fact, widely differing committee setups have been used with equal success in
concerns of the same-size.
The first sub-committee is an Executive committee. This committee acts in
behalf of top management in supervising and controlling the safety efforts. A
company employing several thousand workers, with an outstanding safety record
has an executive committee as shown in the Fig. 2.
EXECUTIVE COMMITTEE
General Manager Works Manager Personnel Manager
Fig. 2 Illustration of Executive Committee

The second is a Technical Committee. A combination of various departmental
heads and managers and supervisory staff will be appointed as members. It has
responsibility in correcting unsafe conditions or unsafe practices that it may
discover. This is illustrated in the Fig.3.
TECHNICAL COMMITTEE
Production
Manager
Maintenance Manager Departmental Heads
Fig. 3 Illustration of Technical Committee

The third is a Workers Committee. Membership includes the foreman and
several workers from each process area form the committee. The small company is
not likely to have these, but where there is a number of departments and each
department is fairly large, they provide a means of holding the employees’ interest
and of securing a continued inspection and consideration of safety by the people
right on the spot.
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A schematic chart showing the Central Safety Committee with the

interrelationship between these three sub-committees is illustrated by Fig. 4.
CENTRAL SAFETY COMMITTEE
Chairman Secretary Members from

(G.M) (Safety Manager) Sub-committees
Fig. 4 Illustration of Central Safety Committee

The major principal functions of the central safety committee shall be
 planning and actions of programmes for safety measures in the field of
working environment
 follow the recent trends and developments in the prevention of accidents
 conducting safety programmes to promote and propagate safety issues
 submitting proposals for necessary investments in improving safety
 must approve the appointment of safety officers and industrial health
officers.
The main advantage of the committee organization lies in the participation of
all level of employees in the central safety committee which takes action in
preventing any kind of unsafe conditions.
1.3 SAFETY EDUCATION AND TRAINING
1.3.1 Safety Education
Safety Education deals primarily in the development of mind, broadening one’s
knowledge in the field of safety by understanding the concept or principle of any
hazardous things on the job activity. The cause for the hazard or the hazardous
property of the material one handles can be ascertained easily through education
and then it can be explained even to the uneducated employees through any kind of
communication technique. This develops the consciousness, awareness and hence
a state of mental alertness among the workers is established to identify and prevent
the hazardous situations.
1.3.2 Safety Training
Safety training is an extension of safety education which lies effectively in the
use of safety work practices and techniques. In safety training, a safe method of
doing a job in the proper sequence of operation is taught in detail. The general
benefits from the safety training shall be
 Training activities indirectly demonstrate company’s interest in employees

which leads to good human relations at work
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 Understanding the importance of safety and hence following safe work

procedures in the operation of machines, equipments and handling
materials
 Training saves the time spent by the supervisor to instruct and correct
 Knowing the techniques of fire fighting, first-aid, lifting, stacking, crane

operation, etc., this helps a lot in the prevention of accidents and during
emergencies.
To meet the training needs it will be necessary to plan and implement a
comprehensive programme for training covering different levels of employees. The
level of people and their training needs are given below:
Level - Training Needs
Helper - Need for safety at work, hazards connected with his work,
ways to safeguard.
Operator - Need for safety, safety requirements of his job,
his responsibilities.
Supervisor - Hazards in the operations supervised and the technical
Skills to identify and prevent them, a broad knowledge of
Company’s policy, techniques of supervision,
Human relations and communication skills.
Managers - Responsibility for safety, company’s policy and direction,
Techniques to identify and control hazards,
Safety engineering and management,
Human relations and communication.
The success of training activities depends on the correct selection of training
modules and its design. One such a module is shown below for a group of graduate
engineer trainees.
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Topic Safety Orientation Training Programme for New Engineers
Level of Participation New Graduate Engineers
No. of Participants Not more than 25

Objective 1) To understand the importance of Safety at work
2) Familiarization with company safety policy and
procedures
Course Content
 Introduction to Safety and company policy
 Common causes of Accidents and their control
 Accident Reporting and Investigating Procedures
 Industrial hygiene and occupational health
 Dos and Don’ts during training
Duration 5 days (30 hours)
Lectures with the help of slides, LCD Projectors, Film shows
Presentation
Faculty
Immediate follow-up Internal

Individual assignment on plant safety inspection
Apart from these, training programmes on specific areas like fire

extinguishing, first aid, noise, industrial hygiene, major hazards control during
emergencies, uses of personal protective equipments must be covered. The
effectiveness of the training also lies in the method of instruction or training which
conveys the message easily by its type. The types involved in the training can be
given by
 On job training
 Lecture method
 Group discussions
 Case studies
 Learning by doing
 Demonstration and visit
A good training programme also depends on the administration of training. It
can be attained through
 Trainers/Faculty
 Enrolment of the employees
 Training material
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 Physical arrangements
 Follow-up on training
 Evaluation
1.3.3 Evaluation of Training
All the participants of the training programme are evaluated through
procedures like answering objective type questions and also they may be asked to
submit an assignment regarding the programme by which the objective of the
training has been met or not may be evaluated. It is also necessary to know their
view about the technical sessions, duration of the programme, presentation, topics
they liked most, etc., through which the design, method of conduction and the
receptiveness are evaluated and if any discrepancy met during the programme can
be rectified in the future.
1.4 SAFETY PROMOTION AND PUBLICITY SCHEMES
Safety Promotion and Publicity largely helps the employees by knowing the
unsafe conditions, hazardous properties of the materials they handle, method of
preventing the hazard, following safe work procedures, etc., which increases the
awareness and alertness. The various techniques involved in the successful
promotion and publicity can be given through
 Lectures
 Practical training in the site
 Posters
 Cartoons
 Slogans
 Caution and sign boards
 Group discussions
 Counseling
 Quiz programmes
 Documentary films
 Safety manual
 News letters
 Reward schemes
 Specialized training on the usage of PPEs
 Involving trade unions in the programmes
 Celebrating safety week
 Safety exhibitions
Materials like posters, cartoons, slogans, caution boards, films must be
prepared to draw the attention of those for whom the message directed and it
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should speak and convey a clear message which should have a strong impact on
the mind of the employees. A sample safety cartoon is shown in the figure. These
kinds of materials must be predominantly displayed at hazardous and critical
locations to remind them to follow the safe methods of doing the job. A good
promotion and publicity resulting in the performance of the industry by
 Good discipline of the workers in following the rules, regulations and
orders
 Broadening the knowledge of the workers
 Understanding and eliminating the hazardous situations.
1.5 SUMMARY
In this unit, we learnt that every big or small organization, where a production
process is carried out should have a safety wing for effective accident prevention
and also the importance of safety education and training to know the various
operation and control techniques of machines and equipments to prevent accidents.
A detailed study is also made on the use of promotion and publicity schemes in
knowing the unsafe acts and conditions in the work place.
1.6 QUESTIONS
1. Discuss the role of Safety Organizations in Industries.
2. What are the objectives of Safety Organization?
3. Describe the different types of Safety Organizations and its advantages.
4. Discuss the role of the Safety Director in the administration of Safety
Department.
5. Write Short notes on a) Committee Organization; b) Safety Directorate
6. Prepare a Safety Training Module for Fresh graduate engineer trainees.
7. Explain the importance of Safety Education and Training in Industries.
8. Explain the different types of training conducted in Industries.
9. Discuss the different modes of safety promotion and publicity schemes.
10. How the safety promotion techniques increase the awareness of the
employee?
SUGGESTED READINGS
1) R. K. Jain and Sunil S. Rao, Industrial Safety, Health and Environment
Management Systems, 1st ed. Khanna Publishers, New Delhi (2006).
2) N. V. Krishnan, Safety Management in Industry, Jaico Publishing House, New
Delhi (1993).

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UNIT – II
CONTENT
2.1 Introduction
2.2 Human factors contributing to Accidents
2.3 Safety and Psychology
2.4 Motivation
2.5 Application of Motivation Theories
2.6 Summary
2.7 Questions
2.1 INTRODUCTION
The human factor is very important for the achievement of the objectives of
any organization. The human with his ability to feel, to think, to conceive and to
plan is most valuable in the prevention of accidents. An industrial accident is
termed ‘unplanned’ because it happens all of a sudden and that more often it may
be beyond the control of the victim. It is unexpected in the sense that its
occurrence is not predictable. Our interest in the study of accidents due to human
factors is to find out the causes and to prevent by specific control measures.
Objectives
After studying this unit, you will be able to:
 know the causes of accidents due to human factors,
 understand the importance of human behaviour and psychology and its
role in preventing accidents, and
 discuss the various theories of motivation and its importance in safety.
2.2 HUMAN FACTORS CONTRIBUTING TO ACCIDENTS
2.2.1 Basic theory of accident factors
The basic theory of accident occurrence with the various factors in their
sequence can be given by two factors. They are
 Unsafe action factors
 Psycho-social and Personal factors
2.2.2 Unsafe action factors
Studies reveal that most of the unsafe actions of the employees are caused due
to various factors. This can be given by
 Failure to use personal protective equipments
 Operating without authority
 Making safety devices inoperative
 Using unsafe equipment and improper tools
 Taking unsafe position or posture
 Working on moving equipments
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 Trying short-cut methods to finish a job quickly

 Distracting, teasing, abusing, quarrelling, etc.
 Inexperience
 Less knowledge and skill
2.2.3 Psycho-social and Personal factors
Psycho-social and Personal factors play a major role in the behaviour of the
workers. The following are some of the reasons leading to accidents due to those
factors.
 Age
 Health condition
 Home environment
 Factory environment
 Financial position
 Addiction to intoxicating substances
 Reckless attitude
 Day dreaming
 Over confidence
 Emotional instability
 Dislike of superior
 Marital status
 Physical problems (vision, fatigue, hearing, reaction time, etc.,)
Preventive measures must be considered and adopted as necessary for each of
the above factors (unsafe action, psycho-social and personal) through various
techniques. In order to avoid the above factors, the industry must take steps to
implement the following methods which enable to prevent the accidents due to
human factors. The methods are
 Proper selection
 Education towards safety
 On job training
 Placement
 Supervision of workers
 Providing safe working conditions
 Motivation
2.3 SAFETY AND PSYCHOLOGY
In the previous topic, it is discussed that many accidents take place because of
psycho-social and personal factors of the employees. A detailed study on the
psychology of the employees is essential in preventing the accidents and also to
13
improve the morale and enthusiasm at work. Psychology is the science of human
mind; the study of human behaviour. The application of psychology to the
industrial situation is known as industrial psychology. Industrial psychology has
been defined as the application and extension of psychological facts and principles
to the problems concerning human beings working in industrial, business, service
and research organizations.
Industrial psychology is a useful aid to the efficient management of people at
work. Its applications can be given as:
2.3.1 Selection and Placement of Personnel
Employment is an important area of industrial management. The
psychologists have designed various systematic tests to select right worker for the
right jobs. Modern industrial concerns use tests like intelligence, aptitude, interest,
dexterity personality tests, etc., These tests help in choosing right type of persons
for the organization. If these tests are properly applied, there will be lower rate of
labour turn over, high productivity and higher job satisfaction among the
employees. The new employees should be properly received, introduced with the
other fellow employees, superiors, subordinates, and the work environment. If he
does not feel comfortable on a particular job, he may be transferred for a better
suited job.
2.3.2 Training and Development
The psychologists help in determining the training needs of employees. They
have devised training programmes for operative work force and for executives. The
important techniques used in industry include, teaching machines, programmed
learning, sensitivity training, role playing etc.
2.3.3 Performance Appraisal
Industrial psychology has helped in replacing the traditional casual approach
to performance appraisal which is more reliable and can be used for certain
decisions like promotions, training, etc.
2.3.4. Determination of Wage structure
Industrial psychologists have developed certain systems of job evaluation to
serve as a scientific basis of basic wage rate fixation. Job evaluation helps in
designing a rational wage structure within the organization. Important job factors
like education, training experience, degree of supervision, degree of risk, etc., are
considered to evaluate different jobs.
2.3.5 Motivation of Personnel
Needs are the starting points in motivating the employees. Industrial
psychologists can help the management in designing the suitable system of
incentives to motivate the employee, to remove the process of fatigue. They also
help in determining the working conditions to be provided to get the maximum
productivity from the employee.
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2.3.6 Vocational Guidance and Counselling

Vocational guidance is important to provide jobs for jobless. Counselling is
essential to find out right type of jobs and to solve personal problems of the
workers.
2.3.7 Improvement of Morale
To maintain high morale of personnel is a great problem of management.
Industrial psychologists can analyze the causes of low morale and improve the
relationship between the attitude of employees, their performance, and group
dynamics.
2.3.8 Human Engineering
Human engineering is concerned with the designing and laying out of
equipment in order to get the greatest efficiency of man machine system. The
industrial psychologists provide data on which management can decide to improve
the design, the product, and comfort of uses, increase the sale and satisfaction of
customers. It also helps to reduce the machine breakdowns, wastage of raw
materials, training time to worker, minimize the accidents and introduce better
performance and job satisfaction.
2.4 MOTIVATION
The term motivation is derived from the Latin word ‘movere’ which means ‘to
move’. The subject of motivation occupies a preeminent position in the field of
theory and practice of behavioural sciences such as psychology, industrial
psychology and organizational behaviour. The objective of our study is to orient the
students in respect to motivation and work in Industry and Society. The study of
motivation will ultimately helps us to understand the forces that explain human
behaviour. It also helps to understand the causes of human behaviour. A
systematic and scientific study of the concept of human behaviour is a pre-requisite
to practice of effective management in industry. The knowledge of motivation is
very helpful in handling various human relations problem in industry as well as our
day-to-day aspects of human existence.
Need and Scope: The application of the concept of motivation is very vast. It
encompasses the entire gamut of human relations. In industries it has application
in work motivation, goal setting and job design. The need and importance of the
study of motivation stems from the fact that people differ in the abilities to perform
and that managers need to realize this difference. Accordingly, the work force has to
be organized. Motivating employees is one of the most consistent challenges any
manager faces today. Before trying to understand the conceptual framework
dealing with motivation and work, it is important to note that there are certain
basic factors that account for human behaviour. These can be classified as
 Psycho-biological factors
 Psycho-social factors
 Social factors
 Organizational factors
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2.4.1 Theories of Motivation

The theoretical treatment of work motivation was a latecomer to the study of
work behaviour. Before the mid-1950s it was generally assumed that people worked
for either economic or social reasons. Personnel practices and policies reflected
these assumptions. Today the situation has changed. There now are several
theories which have a substantial impact on the way work behaviour is conceived.
There are several theoretical positions that provide some useful insights into why
people behave as they do in work settings. With a good knowledge of the theories
that do exist and the support or lack of support for them, intelligent decisions can
be made about the design of jobs and the development of personnel practices to
facilitate desirable job behaviours.
Motivational theories which emphasize needs posit the existence of some
internal state of the individual, labeled a need or a motive. This internal state
usually is described in terms of the conditions that will satisfy the need. Thus, a
need for food is identified by the fact that individuals will seek out objects classified
as food when the individual is believed to be hungry. The need for food, or hunger,
is inferred from the behaviours of seeking food. The following are the three widely
discussed theory of motivation.
 Need Hierachy Theory (Abraham Maslow’s)
 ERG Tehory (Alderfer’s)
 Two Factor Theory (Herzberg’s)
2.4.2 Need Hierarchy Theory
Abrahm Maslow propounded a theory of motivation in terms of need
satisfaction. Maslow proposed that sound motivational theory assumes that people
are continuously in a motivational state, but that the nature of the motivation is
fluctuating and complex. In addition, human beings seldom reach a state of
complete satisfaction except for a short time; as one need or desire becomes
satisfied, another rises to take its place. This never-ending sequence produces a
hierarchy of needs. The theory has two goals. First, it is concerned with identifying
the needs, which are the basis of motivation. These needs provide the content of
the theory. The second goal is explaining how the needs are related to each other.
Maslow also proposed that the needs were ordered in a hierarchial fashion
with all needs lower in the hierarchy having prepotence over those higher. As lower
needs were satisfied, the individual shifted his or her concern to higher order
needs. The hierarchy of needs was often misconstrued to mean that the lower level
needs had to be satisfied before higher order needs began. Now, let us see the
hierarchy of needs. It is given as
 Physiological (or Basic) needs – water, food, shelter
 Security (or Safety) needs – job security, employment position
 Social needs – belongingness, affection, acceptance, friendship
 Esteem needs – status, recognition, appreciation
 Self-actualization needs – the need for realizing one’s own potentialities
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Maslow suggested that the various need levels are interdependent and
overlapping, each higher level need emerging before the lower level need has been
completely satisfied. In addition, he noted that individuals may reorder the needs.
2.4.3 ERG Theory
This theory is propounded by Alderfer, termed Existence, Relatedness, and
Growth (ERG) theory. He offered an alternative theory closely related to Maslow’s
that addresses some but not all the criticisms raised. The name reflects the three
basic needs postulated by the theory. They are:
 Existence – physiological needs, pay, working condition, job security

 Relatedness – social, ego and interpersonal needs
 Growth – personal development, improvement and job advancement
According to Alderfer, the three set of needs are distinct and that they do not
exist in hierarchy. The needs classified under existence needs are concerned with
acquisition of tangible material things for satisfaction. Monetary compensation are
tangible sources of satisfaction, whereas recognition on job is a non-material
reward source of satisfaction.
2.4.4 Two-Factor Theory
The two-factor theory of motivation is a direct result of research conducted by
Herzberg and his associates on job satisfaction and productivity among 200
accountants and engineers. Each subject was asked to think of a time when he or
she felt especially good about his or her job and a time when he or she felt
particularly bad about the job and to describe the conditions that led to these
feelings. The researchers found that the employees named different types of
conditions for good and bad feelings. This led Herzberg to conclude that motivation
consists of two factors. They are
 Hygiene factors(Environment)
 Motivator factors(Work itself)
Hygiene factors: These factors were those associated with negative feelings and are
environmentally related which includes
 Salary
 Technical supervision
 Working conditions
 Company policies and administration
 Interpersonal relations
Motivator factors: These factors were associated with positive feelings and are work
related which includes
 Recognition
 Advancement
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 Possibility of growth
 Achievement
 Work itself
According to the theory, self-realization can be achieved only through the
fulfillment of factors intrinsic to the work itself, in other words, the motivator
factors.
2.4.5 Other Motivation Theories
There are many other process theories of motivation are available, an attempt
to understand and explain cognitive abilities that evaluate alternative behaviours.
Some other important process theories are
 Expectancy theory
 Equity theory
 Goal setting theory
 Reinforcement theory
After a review of the most prominent theories of work motivation, we have
learnt something about its content. People do differ in what they desire or value
from work. These differences occur among individuals across time and across
situations. During certain stages in a person’s development, some factors are more
important than others. For example, the social needs of adolescents may dominate
all others, whereas older workers may be more concerned with security issues. Our
review of motivation theories has identified several content issues. For example,
achievement oriented concerns and an individual’s self-concept seem to be very
important. We also have seen that environmental issues may influence content
factors in the interaction between intrinsic and extrinsic outcomes. All of these
issues illustrate that theories of motivation do offer some cues to issues to consider
when attempting to understand behaviour at work.
2.5 APPLICATION OF MOTIVATION THEORIES
The theories presented here are the major ones influencing
industrial/organizational psychology today. All the theories motivate towards
goals. That goal has the highest motive strength is the one the person will attempt
to satisfy through goal directed behaviour. Having satisfied that goal, the
individual will then go on to the goal with the next highest motive strength with
 Dedication to work
 Loyalty to organization
 Voluntary conformance to rules, regulations and orders
 High degree of interest in the job
 Resistance to frustration
 Team spirit.
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Ultimately, the application of these theories resulting in

a) the attainment of higher level of productivity without accidents,
b) greater confidence and security,
c) low absenteeism,
d) improved mental health and sense of well being,
e) better inter personal relations,
f) freedom from stress and tension and
g) enhanced efficiency.
2.6 SUMMARY
In this unit, we have examined the various human factors contributing for
accidents, the impact of human psychology on industrial safety, many theories on
motivation and their applications in the prevention of accidents and attainment of
high degree of morale at work.
2.7 QUESTIONS
1) Describe the role in the cause of accidents due to unsafe action, psycho-social
and personal factors.
2) Industrial psychology is a useful aid to the efficient management of people at
work – How?
3) Explain the importance and need of motivation in preventing the accidents.
4) Explain the Abraham Maslow’s theory of need hierarchy.
5) What are the various theories applicable to motivate the industrial employees?
6) Discuss the two-factor theory of Motivation.
7) Explain the ERG theory of motivation.
8) Write short notes on: a) Application of theories of motivation; b) Safety and
Psychology.
SUGGESTED READINGS
1) Ernest J. Mc Cormick and Daniel Ilgen, Industrial Psychology, 7th ed.
Prentice Hall of India, New Delhi (1984).
2) Richard M. Hodgetts, Modern Human Relations at Work, 2nd ed. The
Dryden Press, Japan (1984).

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UNIT - III
CONTENT
3.1 Introduction
3.2 Fault Tree analysis
3.3 Event Tree Analysis
3.4 Job Safety Analysis
3.5 Hazard Analysis
3.6 Hazard and Operability Studies
3.7 Failure Mode Effect Analysis
3.8 Five Why Approach
3.9 Summary
3.10 Questions
3.1 INTRODUCTION
This Unit deals on the following topics imperative for all safety professionals to
know. The tools covered in this chapter are Fault tree analysis , event tree analysis,
Hazan, Hazard and operability studies Job safety analysis, Failure mode effect
analysis, Five why Approach. These tools are fundamental requirement (Foundation)
and the students need to be fully aware of when and where these tools to be utilized
in an Industrial scenario. We will cover each and every aspect of these tools but the
student need to practically try and utilize these tools by taking any situation can be
even domestic and working out an Assignment to have complete understanding on
the tools.
What example can a student take when he or she is not exposed Industries? A
road accident or kitchen fire or fall in bathroom or fall from bicycle all are very good
example the student should correlate in having fair understanding of these tools.
Objective
At the end of going through the content of the chapter the student will have an
understanding on significance and how to use these tools ?
3.2 FAULT TREE ANALYSIS
WHAT IS FTA?
FTA is a deductive, TOP DOWN approach to analyzing system design and
performance. It BEGINS by defining an undesirable event, known as TOP
EVENT, (SUCH AS A FAILURE, A FIRE OR A MALFUNCTION) then seeks to
determine all the ways (causes) the top event can happen.
Analysis proceeds by determining how top events can be caused by individual ?
or combined lower level failures or events.
Each immediate cause is analyzed to arrive at BASIC EVENT or other
INTERMEDIATE EVENTS until the BASIC EVENT responsible for each of the
immediate causes are identified.
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FOR EXAMPLE
A specific requirement might state:” Reactor Temperature will not exceed 600C.
The TOP EVENT for the fault tree could be "Reactor temperature exceeds 600C".
Analysis then establishes other events which could permit a temp. greater
than 600C to occur.
As this procedure is continued and laid out in diagrammatic form, a "TREE"
will develop(more like tree roots).
As the tree proceeds downwards from the top event "branches" are created.
Proceeding the tree and branches an analyst can see what the causes of the
occurrences might be.
To perform fault tree analysis the following logic symbols are used
OR GATE
Output event occurs if at least one of the input events occurs.
AND GATE
Output event occurs only when all the input events occur.
INHIBIT GATE
Output event occurs if all input events occur and an additional conditional
event occurs.
DELAY GATE
Output event occurs when the input event has occurred delay time has lapsed
BASIC EVENT
This represents a basic equipment fault or failure that requires no further
development into more basic faults or failures.
INTERMEDIATE EVENT
This represents a fault event that results from the interactions of other fault
events that are developed through other logic gates.
UNDEVELOPED EVENT
This represents a fault event that is not examined further because
consequence is not significant or information is not available.
EXTERNAL OR HOUSE EVENT
This represents a condition or an event that is assumed to exist as a boundary
condition. Annamalai University
TRANSFER SYMBOLS
TRANSFER IN indicates that the fault tree is developed further at the
occurrence of the corresponding TRANSFER OUT symbol
An illustration of the fault tree for a motor system overheating is shown in
Fig. 3.1 (a & b)
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Fuse
Power Motor
Supply
Wire
(a)
Motor Overheats
Primary motor
f ailure Excessive current to
(ov erheated) motor
(1)
Excessive current in
circuit Fuse falls to open
C
Annamalai University Prim ary fuse
Primary power
Prim ary wiring failure (closed)
supply failure
failure (shorted) (2)
(surge)
(3)
(4)
(b)
Figure 3.1 Motor system and fault tree for overheating of the motor:
(a) motor system; (b) fault tree of motor system for top event. Motor overheats
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Defining the problem

Precise definition of the undesirable event or the TOP EVENT forms the basis
of FTA.
The definition should identify the event in terms of,
What are the immediate consequences of the event?(fire/toxic gas
leakage/release of inflammable material).
Location of the event within a system(reactor/distillation column/compressor).
and the condition under which the event is expected to occur (runway
reaction/normal operation/fire in adjacent unit).
Hence to be meaningful the event description should encompass
"what/where/when" of the event.
Simple explanation on MINIMAL CUT SETS
Fault tree provides information on interactions of equipment failures that
could result in a TOP EVENT.
It is however difficult to identify directly from the fault tree all combinations of
failures that can lead to an accident.
The method adopted to do this is known as MINIMAL CUT SETS.
Minimal Cut Sets are "combinations of failures" that can result in the top
event.
Useful for ranking ways accident may occur.
Allows quantification of Fault tree if appropriate data are available.
A Large Fault tree needs computer program support.
MINIMAL CUT SET
FT method creates a diagram with gates and basic events representing logical
description of a system failure, known as TOP EVENT.
On creating FT diagram user assigns failure characteristics of the system
components.
On completion of the model system analysis is performed.
To do this it is necessary to determine the minimum combinations of failures
that will cause a system failure.
These minimum combinations are known as MINIMAL CUT SETS.
Finally calculate the quantitative parameters such as system unavailability
and failure frequency
FAULT TREE SOLUTION METHOD
HAS FOUR STEPS
1. Uniquely identify all gates and basic events (FT DIAGRAM).
2. Resolve all gates to (sets of) basic events.
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3. Remove duplicate events within sets.

4. Delete all supersets (sets that contain another set as a sub set).
Result is list of minimal cut sets for the FT.
Second step is done in a matrix format.
Top event is always the first entry in the matrix in the first column of the first
row.
Two rules have to be followed:
'and gate' rule.
'or gate' rule.
'Inhibit' and 'delay' gates are resolved as if they were 'and gates'.
'AND GATE' RULE:
When resolving an 'and gate' in a matrix, the first input to the 'and gate'
replaces the gate identifier in the matrix.Other inputs to the 'and gate' are inserted
in the next available column,one input per column,on the same row that the 'and
gate' appeared on.
'OR GATE' RULE:
The first input of the 'or gate' replaces the gate identifies inputs to the 'or gate'
are inserted in the next available row of the matrix.
HISTORY OF FTA
It is a technique for reliability and safety analysis. Bell Telephone Laboratories
developed the concept in 1962 for the U.S.Air Force and later adopted and
extensively applied by the Boeing Company. It is one of many "analytical logic
techniques" found in operations research and in system reliability.
The students need lot of practice to gain expertise in this tool.
3.3 EVENT TREE ANALYSIS
This technique is complementary to Fault Tree, but in reversed direction.
Whereas a fault tree starts from a final event and works from the top down an
Event Tree begins with an initial event such as a power failure and explores all
possible outcomes by working from the bottom up.
Some sample initial (bottom) events for Event Tree Analysis are :
1. Failure of pump in a chemical industry supplying feed to process plant.
2.
3.
Failure of stirring of agitator in reactor.
Failure of water/cooling media/heating media in process.
4. Stoppage of motor at assembly line.
3.4 JOB SAFETY ANALYSIS
Identification of Hazards
An illustration of the event tree for a overfilling of surge tank is shown in
Fig. 3.2 (a & b).
24
LC
FC
(a)
Controller dam aged High voltage in power

by m an s upply
Flow controller falls

Cri ti cal event
Flow controller f ailure causes

pump ov erspeed, Flow
increase
Level in tank ris es
(b)
Flow from tank Level m easuri ng i nstrum ent
increas es operates correctl y
Wire broken Valve seized

Level Controlleropens valve
No Yes
Tank ov erf lows Tank does
not ov erf low
Figure 3.2 Surge tank system and cause consequence diagram for overfilling of the
surge tank (a) Surge tank system; (b) cause consequence diagram of surge tank
system for critical event ‘Flow controller fails’
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Introduction
Occupational injuries and fatalities occur every day in the workplace.These
injuries often occur because employees are not trained in the proper job procedure.
One way to prevent work place injuries is to establish proper job procedures
and train all employees in safer and more efficient work methods.Establishing
proper job procedures is one of the benefits of conducting a Job Safety
Analysis(JSA)-carefully studying and recording each step of a job,identifying
existing or potential job hazards (both safety and health),and determining the best
way to reduce or eliminate these hazards.A JSA is used to review job methods and
uncover hazards that:
May have been overlooked in the layout of the plat or building and in the
design of the machinery,equipment,tools,workstations,and processes;
Result of changes in work procedures or personnel;
May have developed after production has started.
When preparing a JSA the basic steps of the job are listed in the order in
which they occur.For each step list all of the hazards that can occur during the job
step.Also include the safe procedure that should be followed to guard against the
hazards and ways to prevent potential accidents(see Appendix 1.JSA, for an
example of a Job Safety Analysis).
The benefits of performing a JSA are many,including:
Giving individual training in safe and efficient work procedures;
Making employee safety contats;
Preparing for planned safety observations;
Intrusting new worker on the job;
Giving pre-job instruction of irregular jobs;
Reviewing job procedures after accidents occur;
Studying jobs for possible improvements in job methods ;
Identifying what safeguards need to be in place;
Supervisors learn about the job they supervise;
Employee partcipation in workplace safety;
Lowered workers compensation costs;
Reduced absenteeism;
Increased productivity ;and
Positive attitudes about safety.
Developing a JSA
A) Select The Job
Jobs with the worst accident history have priority and should be analyzed
first. In selecting jobs to be analyzed and the order of analysis, top supervisors of a
department should be guided by the following factors:
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1. Frequency of Accidents: A job that has repeatedly caused accidents is a

candidate for JSA.The greater the number of accidents associated with
the job, the greater its JSA priority.
2. Rate of Disabling Injuries: Every job that has disabling injuries should
be given a JSA.
3. Severity Potential: Some jobs may not have a history of accidents but
may have the potential for a severe injury.
4. New Jobs: A JSA of every new job should be made as soon as possible.
Analysis should not be delayed until accidents or near misses occur.
5. Near Misses: Jobs where near misses or close calls have occurred also
should be given priority.
After the job has been selected, the three basic steps in making a JSA are:
Break the job down into successive steps or activities.
Identify the hazards and potential accidents.
Develop safe job procedures to eliminate the hazards and prevent the potential
accidents.
Break the Job Down into multiple tasks
To do a job breakdown, select the right worker to observe. Select an
experienced, capable, and cooperative worker who is willing to share ideas. Explain
the purpose and the benefits of the JSA to the worker.
Observe the employee perform the job and write down the basic steps.
Videotaping the job can also be used for review in the future. To determine the
basic steps, ask,”what step starts the job?”Then,”what is the next basis step?” and
so on.
Completely describe each step. Any deviation from the regular procedure
should be recorded because it may be this irregular activity that leads to an
accident.
Number the job steps consecutively in the first column of the JSA.Each step
should tell what is done, not how it is done. The wording for each step should begin
with an action verb like insert,open,or weld.The action is completed by naming the
item to which the action applies,for example “insert board”,”weld joint”.Be sure to
include every step of the job from beginning to end.
Identify Hazards and Potential Accidents
The next step in developing theJSA is the identification of all hazards involved
with each step. Identify all hazards, both those produced by the environment and
those connected with the job procedures. Ask yourself the following question about
each step:
Is there a danger of striking against,being struck by,or otherwise making
harmful contact with an object?
Can the employee be caught in by, or between objects?
Can pushing, pulling, lifting, bending, or twisting cause strain?
27
Is there a potential for a slip or trip?

Is there a fall hazard where the worker can fall to a lower level?
Can the worker come in contact with electrical power and become part of the
electric circuit?
Is the environment hazardous to safety and health? Are there concentrations
of toxic gas, vapour, mist, fume, dust, heat, or radiation?
Is there a danger of fire or explosion?
Close observation and knowledge of the particular job are required if the JSA
is to be effective. The job observation should be repeated until the worker and
observes are comfortable that all hazards and potential accidents are identified.
Listed below is a list of question that should be asked and answered when
inspecting a particular machine or operation?
Is it possible for a person to come in contact with any moving piece of machine
equipment?
Are rotating equipoment,set screws, projecting keys,bolt,burrs,or other
projections exposed where they can strike at or snag a workers clothing or skin?
Is it possible to be drawn into the in runing nip point between moving parts,
such as a belt and sheave, chain and sprocket, pressure rolls, rack and gear,or gear
train?
Do machines or equipment have reciprocating movement or motion where
workers can be caught on or between a moving part and a fixed object?
Is it possible for a workers hand or arms to make contact with moving parts at
the point of operation where work is being performed by the machine?
Is it possible for material to be kicked back or ejected from the point of
operation, injuring someone nearby?
Are machine controls located and safeguarded to prevent unintended and
inadvertent operation?
Are machine controls located to provide immediate access in the event of
emergency?
Do machines vibrate, move, or walk during operation?
Is it possible for parts to become loose during operation, injuring operators
and others?
Are guards positioned or adjusted to correspond with the permissible
openings?
Is it possible for workers to bypass the machine guard?
Do machines,equipment,and tools receive regular maintenance?
Do workers have sufficient room to work safety?
Are all possible hazardous energy sources controlled during maintenance
operations?
Are energy sources heat controlled for protection?
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Is housekeeping satisfactory with no debris and tripping hazards?

Are chemical and product spill cleaned up immediately?
Is the operator properly using personal protective equipment (PPE)?
Is ventilation adequate?
Does the worker have good visibility during operation of machines or
equipment?
Is the work area well illuminated with specific point of operation lighting where
necessary?
Are all ignition sources (static electricity, sparks, arcs, open flame, etc)
eliminated before using flammable liquid?
Are flammable or combustible vapors or gases present during operation?
Is the worker exposed to any source of electric shock or electrocution?
All of these questions can be incorporated into an inspection form that can be
filled out at regular intervals. Even if the question may not apply at first it may
become relevant if there is change from the standard operating procedures. Using a
checklist is a good way to be sure nothing is overlooked. Employers should develop
checklist for each operation.
Develop Solutions
The last step in a JSA is to develop a recommended safe job procedure to
prevent occurrence of potential accidents. There are several solutions that should
be considered.
Find a new way to do the job.
Change the physical conditions that create the hazards.
Change the work procedure.
Reduce the frequency of job or task.
If a new way to do the job cannot be found then try to change the physical
conditions (tools, materials, equipment, layout, or location) of the job to eliminate
the hazards.
When changing the work procedure is the best solution, find out what the
employee can do during the job to eliminate hazards or prevent potential accidents.
The employee should be able to suggest ways to improve the safety on their
worksite. Annamalai University
Often a repair or service job has to be frequently repeated because a condition
needs correction again and again. To reduce the need of such a repetitive job find
out what can be done to eliminate the cause of the condition that makes excessive
repairs necessary.
Reducing frequency of a job contributes to safety only in that it limit’s the
exposure. Every effort should still be made to eliminate hazards and to prevent
potential accidents by changing physical conditions or revising job procedures or
both.
29
List recommended safe operating procedures on the form, and also list
required or recommended personal, protective equipment for each step of the job.
Be specific, say exactly what needs to be done to correct the hazard. If the hazard is
a serious one, it should be corrected immediately. The JSA should then be changed
to reflect the new condition.
Appendix 1. Example JSA
Job Safety Analysis Job Title: Bander Date: 00/00/00
Company/Organization: Person Who Does Job: Bander Supervisor:
ABC Company Department:

Analysis By: Approved By:
Personal Protective Gloves, eye protection, long sleeves,
Equipment Required: Safety boots
Position portable- Cart positioned too close Leave enough room
banding cart and place to pallet (strike body between cart and pallet
strapping guard on top of &legs against cart or to feed strapping-have
boxes. pallet, drop strapping firm grip on strapping
gun on foot.) gun.
Withdraw strapping and Sharp edges of strapping Wear gloves, eye

bend back about 3 (cut hands, fingers, protection, and long
inches. &arms).Sharp corners on sleeves-keep firm grip on
pallet (strike feet on strapping- hold between
corners). thumb &forefinger.
Walk around load while Projecting sharp corners Assure a clear path
holding strapping with on pallet (strike feet on between pallet and cart-
one hand. corners). pull smoothly-avoid
jerking strapping.
Pull and feed strap under Splinters on pallet Wear gloves-eye
pallet. (punctures to hands and protection-long sleeves.
fingers).Sharp strap Point strap in direction of
edges (cuts to hands, bend-pull strap smoothly
fingers, and arms.) to avoid jerks.
Walk Annamalai University
load.Stopdown.Bend
around Protruding corners of
pallet splinters
Assure a clear path-
watch where walking,
over, grab strap, pull up (punctures to feet and face direction in which
to machine, and ankles). walking.
straighten out strap end.
Insert,position,and Springly and sharp Keep firm grasp on strap

tighten strap in gun. strapping (strike against and on gun-make sure
with hands and fingers). clip is positioned
properly.
30
3.5 HAZAN
Hazard Analysis is simply the application of numerical methods to obtain an
understanding of hazards in terms of:
1. How often a hazard will manifest itself?
2. with what consequences? for people, process and plant.
HAZANS is therefore the essential prerequisite for the complete risk
assessment process, i.e. first analyze the hazards and then go on to assess the
risks they present and determine what, if any, ameliorating measures should be
taken.
Methods of HAZAN
A number of techniques, referred to in other Health and Safety Briefings,
including HAZOP and FTA, could form the basis of a Hazard Analysis.
Whatever techniques is used, it is important to have the practical advice of
those who understand the system being modeled. An expert analyst, who is
unfamiliar with the specific system may be unware of some factors that are taken
for granted by the operators.
In the end, what management is reviewing the analysis, it is important to
confirm that the assumptions that have been made are reasonable and that the
outcome appears to accord with experience. A thoroughly conducted hazard
analysis provides a sound quantitative basis for decisions on ameliorative measures
that it will be reasonable to take crucial decisions
3.6 HAZARD AND OPERABILITY STUDIES ( HAZOP)
Historical background of HAZOP:
Hazard and operability studies were developed in the 1960’s by Imperial
Chemical Industries (ICI) in England. It was recognized that for new, large, novel,
single unit, complex continuous processes, the historical methods of design
checking were not enough. A procedure called “Critical Examination” was developed
where a team reviewed a process one line at a time, writing down and analyzing its
purpose.
In the 1970’s, the method was speeded up by carrying out this design check at
the process and Instrumentation drawing (P&ID) stage. The method was further
expanded and applied to batch operation and projects at the conceptual stage.ICI
the published information on it for possible by other industries.
The basic concept developed, was that a multi disciplinary team, guided by a
leader, systematically and creatively reviews a process, line by line. Using
guideworks, they look for causes and consequences of changes (deviation) from the
design intent for each line and make recommendations for follow up before
incidents occur.
In the 1980’s, a general acceptance of the methodology grew with the
availability of training courses and increasing regulatory demands. An incentive
was also provided by a series of process disasters across the world: Flixborough-
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1974,Three mile island-1979,Bhopal-1984,Mexico city-1984,Chernobyl-1986.It was

recognized that the causes o the incidents were not a surprise, but a better way of
problem identification and management was required.HAZOP provided a
structured, creative method for finding problems before they ocured.This was
different to the more traditional methods that relied on experience(checklists, codes
of practice)which were developed after incidents had happened.
Today, more and more companies are realizing and applying the benefits of
HAZOP.
The HAZOP study concept:
There are only seven ways an activity can deviate from the way it is supposed
to happen. These are summarized by the guidewords:
-No
-More
-Less
-As well as
-Part of
-Reverse
-Other than
After a team member has defined intent of a line, the team leader applies these
guidewords to different parameters such as flow, pressure,and temperature. He
asks the team “How can you get no flow……..More flow…?”.The team identifies all
practical causes and consequences. The team also identifies how the operator can
recognize that the deviation is occurring. The information is recorded, and once all
the potential hazards/operating problems are identified, on all the systems, the
results are analysed and follow up recommendations made.
The multi disciplinary team members selected to carry out the study are
choosen on the basis they already know the system well and because they have a
vested intrese in its success.That is,they will be responsible for the system’s
operation after the study is complete.This defines the key team members as
representatives from operations,maintenance and technical support.Other specialty
members are called on as needed.
As a result of doing the study,the team members will have an even greater
knowledge of the process.This can be applied to all aspects of operation and safety
management.
Benefits and constraints:
HAZOP studies take time.The benefits must therefore be apparent beforehand
to ensure the proper commitment to them.It is difficult to measure something that
does not happen. Preventing incidents or accidents is the objective.ICI monitored
new projects over an eight year period, comparing ones that received HAZOP
reviews with ones that had not and the data proved that the project with hazop had
fewer failures
Where does HAZOP fit in Process Safety Management System?
32
HAZOP fits in the Process Safety Management System in two areas:

a. One of the elements of the Process Safety Management is Hazard
Analysis.HAZOP will be used to do this analysis.The Process Hazard
Analysis standard requires a HAZOP to be done of the entire plant once
every 5 years.
b. Another element of the Process Safety Management System is called
Management of change.The Mnagement Of Change suggested to the areas
storing/handling or processing hazardous chemicals.If the committee needs
a HAZOP study to be done,then the on site HAZOP team will do that study
and submit the reports containing suggestions,if any.
HAZOP INFORMATION FOR THE STUDY TEAM MEMBER
Hazop Studies - the General Approach
The Hazop concept is that a Multi disciplinary team systematically and
creatively review a process,line by line.Guided by the team leader,applying guide
words,the team identifies deviations from the process design intent,together with
the causes and consequences.These are recorded for later follow up.Not all the
guidewords may be relevant to the part of the system being considered,or there will
be some guideword interaction.This is normal.An overview of what is happening in
the study,is shown below:
GUIDE WORDS
No, Not,none,don’t
More
Less
As well as
Part of
Reverse
Other than
Design Intention / Real Deviation / Possible Causes/ Consequences/ Recomm
-endation.
The team members already know the system to be reviewed.The members will
want the study to succeed because they will be using the results in their jobs
afterwards.
Hazop studies are not limited to chemical process,they can be Applied to any
activity.The only requirement is that the design intent is clearly defined for that
activity.
The “Design intent”is a very specific function statement (a description where
something is being done).
The function statement defines:
-The Material (and its operating parameters).
-The Activity (eg.Transfer,heat,filter…).
-The Source (where the material is coming from).
-The destination(where the material is going to).
33
The team examine deviations on a process section which has a design intent
small enough to visualize completely,but large enough to contain a complete
activity.There may be more than one activity defined in sequence in the function
statement
(eg.transfer and cool….)
The material definition will contain the following:
-Specific operating conditions (Temperature,pressure,level,viscosity…)
-The operating phase:Gas/Liquid/Soid(or the phase combination).
-Specific composition(chemical and physical).
The Activity defined may be:
-Transfer
-Condense
-Evaporate
-Heat
-Cool
-React
-Vent
-Drain
-Mix
-Separate
-Filter
-Raise
-Lower
-Measure
(flow,pressure,temperature,level,pH,density,viscosity,concentration)
-Control
(flow,pressure,temperature,level,pH,density,viscosity,concentration).
Note:-.Activities are “Doing”words.
-Activities often have opposites e.g.”Heat vs. Cool”.These opposites are
examined in the study.
An example of a function statement giving the design intent might be,”To
transfer 100 usgpm of clean condensate from Tank # 2 at 250 ‘F/15 psig,through
cooler HX123 giving an outlet temperature of less than 80’F,let down the pressure
through LV 123 to atmospheric before draining the water to the storm water sewer.
How Hazop is applied by the team - A Summary schematic.
Hazard / Potential problem Identification and Follow up to comply with suggested
recommended recommendations.
(Analysis/recommendations)
- Select line
- Define design intent
- Use Guideword to identify first / next deviation
34
Check the operator can know the deviation is occurring.

Identify all cause of Hazardous / inefficient operation.Record.
Will prevent,reduce,protect,
Against the consequences.
Identify all Consequences.Record.
Identify existing Protective Systems.Record.
Last Guideword?
Agree the cost/effective
Change,responsibility,
Yes
And followup.
Review next section.
Problem identification ./ analysis are separate activities carried out by the
same team.The analysis /recommendations are made after problem identification is
completed.
TEAM DYNAMICS
The Team Leader needs to make work effectively on an ongoing basis.There
may be initial resisance to overcome such as:
-I don’t need this because I don’t make mistakes.
-Its great but takes too long.
The team leader needs to ensure effective preparation takes place.Every hour
of preparation by one person can save an hour of team time.Note that enough data
and accurate data are required.The study should stop if necessary until it is
available.The Hazop study should check the design not create it.
During the study sessions,the leader needs to minimize interruptions,lateness
and absenteeism.At the same time the leader needs to establish a structure and
routine for the meetings,apply the guidewords in the same order,set the ground
rules for recording (minimizing the discussion on how things should be written).
The leader needs to optimise the pace of the study,neither too slow that
members get bored,nor too fast that items are missed (5 - 25 minutes per
guideword sequence per line).
The team should not be finding too many problems.Zero to three or four per
guideword application.More than that will suggest the design is suspect and should
be reviewed outside the study.
During the recommendation review the team will decede that 10 - 30% of the
items will not need follow up,then the leader should think about whether items
have been missed.
Team problem solving and side debates should be minimized during the study
itself.The study purpose is to identify potential problems.This focus must be
retained while still keeping the team stimulated.
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Follow up will take most the members time in a study (about 60%).Preparation
accounts for about 15% of the study time (on a continuous process review) and the
study itself,about 25% of the total time.
Problems can occur during the study itself:
- Difficulty translating the guidewords into practical
deviations.: The team leader must be careful not to
provide answers to his own questions,otherwise the
team will soon come to expect him to do this as a
matter of routine.A silence from the leader after the
question is asked will stimulate the
- discussion…He need only clarify for team / secretary
understanding.
- Clarification: The team leader needs to understand the items that are being talked
about to ensure the proper recommendations and record are made.It is reasonable
for the team members to recoginise he is not the process expert,and often other
members benefit from the clarification too.
Recycling back to previous guideword: The leader need to encourage team
members to make the effort at the time.However a small amount of recycle is
reasonable given that the study sessions are about creativity.
Lack of understanding of the methodology: The leader should prevent this by
discussion at the initial information meeting.He will take corrective measures as
necessare.
Fatigue / Motivation: The team will tire at the constant demand on their creative
skills.It is important to take regular breaks (say 10 minutes an hour),to carryout
the studies in the mornings,and to minimise the number of sessions in a
week.(Ideally,no more than 3 sessions on alternate days,each session lasting not
more than 4 hours).Occasionally,the team leader should encourage
digressions.Discussions of previous incidents will let the team relax while keeping
their minds on a related topic which itself may stimulate identifying other potential
problems.
Deliberate Omissions: There may be a temptation not to study apparently low
hazard items,particularly if there is a time constraint.This must be resisted.The
detail of the review may be chosen to be lower in a low hazard area.An identical
system may be reviewed in isolation in less detail.The system must still be
examined.
Forcing the pace : The leadre should not compress the study to meet a taret date.If
the original date proves unsatisfactory then it should be changed or the meeting
frequency changed.Otherwise the team will sense the study becoming superficial
and will become less effective themselves.
The team leader needs to remember that the members are people too.He needs to:
- Be sensitive to their feelings and ensure they respect each others views.
This means the leader needs to control the group discussions and differences
of opinion.
- Ensure every member participates including the specialists who only attend
when needed.
-Keep his role clear (say if he is contributing to the technical discussion from his
experience,for example)
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-Request occasional critique of the HAZOP process the team are applying and its
place.
The leader needs to keep track of the objective that the study needs to be
successful.
Of fire protection methods.The guide has been updated several times but still
only covers process units rather than auxiliary plant such as power generators.The
Mond Index was developed by ICI for the chemical industry,after the Flixborough
disaster.It expands on the Dow Index to include wider consideration of continuous
and batch processes,loading and unloading and storage.It provided a more
comprehensive treatment of hazards from materias,reactions and toxicity.In
summary:
3.7 FAILURE MODE EFFECT ANALYSIS
Failure Mode Effective Analysis (FMEA)
What is FMEA?
An FMEA is a systematic method of identifying and preventing product and
process problems before they occur.
FMEA are focused on preventing defects,enhancing safety and increasing
customer satisfaction.
Ideally,FMEAs are conducted in the product design or process development
stages,although conducting an FMEA on existing products and processes may also
yield huge benefits.
History of FMEAs
The first formal FMEAs were conducted in the aerospace industry in mid-
1960s,specifically looking at safety issues.
Before long,FMEAs became a key tool for improving safety,especially in the
chemical process industries.
The goal with safety FMEAs was,and remains today,to prevent safety accidents
and incidents from occurring.
An Example of FMEA
An aircraft engine manufacturer conducted an FMEA on its engine assembly
operation. A cross-functional team was formed that included individuals from
outside of the assembly department,although all were familiar with assembly to
some extent.
Key ingredients of FMEA (Evaluating the Risk of Failure)
The relative risk of a failure and its effects is determined by three factors:
Severity- the consequences of the failure should it occur.
Occurrence- the probability or frequency of the failure occurring.
Detection -The probability of the failure being detected before the impact of the
effect is realized.
Risk Priority Number (RPN)
It is a numerical and relative “measure of overall risk” corresponding to a
particular failure mechanism and is computed by multiplying the Severity,
Occurrence and Detection numbers.
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RPN = S O D
The RPN provided priority levels to potential failure mechanisms in terms of
which need to addressed first,second and so on.
Assessing the Risk Priority Number
Using data and knowledge of the process or product,each potential failure
mode and effect is rated in each of these factors on a scale ranging from 1 to 10,low
to high.
By multiplying the rating for the three factors (severity occurrence
detection),a risk priority number or RPN will be determined for each potential
failure mode and effect.
The risk priority number (which will range from 1 to 1,000 for each failure
mode) is used to rank the need for corrective actions to eliminate or reduce the
potentisl failure modes.Those failure modes with the highest RPNs should be
attented to first,although special attention should be given when the severity rating
is high (9 or 10) regardless of RPN.
Assessing the Risk Priority Number.
Once corrective action has been taken, a new RPN is determined by
reevaluating the
Severity,Occurrence and Detection ratings.This new RPN is called the
Resulting RPN.Improvement and corrective action must continue until the resulting
RPN is at an acceptable level for all potential failure modes.
10 Steps for an FMEA
All product/design and process FMEAs these 10 steps :
Step 1: Review the process
Step 2: Brainstorm potential failure modes.
Step 3: List potential effects of each failure mode.
Step 4: Assign a severity rating for each effect.
Step 5: Assign an occurrence rating for each failure mode.
Step 6: Assign a detection rating for each failure mode and /or effect.
Step 7: Calculate the risk priority number for each effect.
Step 8: Prioritize the failure modes for action.
Step 9: Take action to eliminate or reduce the high risk failure modes.
Step 10:Calculate the resulting RPN as the failure modes are reduced
or eliminated.
3.8 FIVE WHY APPROACH
Five why is a typical root cause analysis widely followed in many multinational
and other process industries. This is a simple technique involved in drilling down
the causes identified at different stages.
A simple observation with children is asking why for anything they are asked
to do ? This provokes the thought processes and leads to actual cause.Individuals
find it difficult to think or they do not know the answer or do not want to revealk
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the thought the questioning is not appreciated and this why has left us over a
period of time again to question we have to train individuals.
A simple format with the end event would enable 5 why approach. It has been
learnt that the root cause would get exposed within the five why and so this
approach is widely applied.
3.9 SUMMARY
In a simple way Fault tree analysis is drilled down from the end event , event
tree analysis top down approach which would forecast the likelihood of event that
could lead to potential incident or accident.
Job safety analysis is a tool to break down activities into task and evaluate the
hazard associated with each task and control measure recommended are followed
to ensure that hazards are in control
Hazard analysis is a quantitative method to analyze and quantify the various
rate such as failure rate, etc
Hazard and operability is a brain storming approach done in a structured
manner which enables to surface out hazards in processes, this approach is one of
the receommended approach for process engineers during process design and
process modification done in industries.
Failure mode effect analysis considers key issues that might probably occur
during any operation and analyzing the effect in term of numbers based on data by
professionals. This technique is quantitative and robust approach
Five why approach usually is carried for incidents / process failures which
also brings out the root cause for any incident happening.
3.10 QUESTIONS
a) Make job safety analysis for any one of the following industrial activity
1. Brick loading and unloading in a red brick industry
2. Loading of 50 kg cement bags 10 metric tonne in a lorry from a
conveyor.
b) Apply Fault tree analysis for the following
1) Fire incident in coal storage yard
2) Failure of a lift in a High raise building ( 20 floors) 2 personnel injured
c) Make a simple HAZOP for a Hydrochloric acid transfer from a storage tank to two
plants A and B .Draw a simple sketch and explain
d) Carry out an FMEA for High pressure steam pipe line with relief valve.The steam
is transported from Sulfuric acid plant to Captive power plant
e) Explain HAZAN for an Engineering industry with examples
SUGGESTED READINGS
 Hazard analysis By Trevor Kletz
 Industrial safety by K.U Mistry
 Industrial safety by RR Blake
 Industrial accident prevention by H.W Heinrich
 Factories Act 1948

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UNIT - IV
CONTENT
4.1 Introduction
4.2 Plant Safety Inspections
4.3 Safety Audit
4.4 Summary
4.5 Questions
4.1 INTRODUCTION
Plant safety inspection which is a method of discovering potential accident
risks is one of the oldest of accident prevention techniques. Development of the
statutory regulations covering safety and inspection by Factory Inspectors have
given stimulation to in-plant inspections and guarding programmes.
Just as, inspection in quality control of the product manufactured, plant
safety inspection plays a vital role in accident prevention. Its purpose is to find and
remove hazards in jobs before accidents occur. It may not be possible to spot and
remove all the unsafe conditions or unsafe practices in the entire plant in one
stroke. But the ultimate aim is to make all the operations safe and efficient.
Plant safety inspection is some times wrongly construed as being confined only
to direction of unsafe physical or mechanical conditions. This is probably so in view
of the emphasis on statutory requirements alone. As unsafe action is causative
factor in all accidents and as it may not be possible to make the physical conditions
safe and fool proof in all circumstances, it is very important that unsafe action or
work practices are also carefully noted during plant safety inspections.
Inspections properly carried out contribute to safety by its incidental benefits.
The Safety Officer, Plant Superintendent or other supervisory personnel making the
inspections could achieve the purpose of inspection better by consulting the
persons concerned in the shop and thus enlisting their co-operation. Consultations
with the employees besides revealing the practical aspects of the problem, often
brings out useful suggestions from the employees. Such consultations and
implementation of suggestions is a sure way of creating employees’ interest in
safety.
Objectives
A system of discovering the hazards in various jobs and taking prompt
corrective measures to eliminate accidents serves indirectly to demonstrate
management’s interest in safety of the employees and thereby motivate them. The
employees in turn are encouraged to report the hazards in their jobs
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4.2 PLANT SAFETY INSPECTIONS

Responsibility for Inspections
Obviously safety inspections cannot be done effectively by any one individual
or agency. The responsibility should be shared by all those concerned. Within the
plant it is important that all personnel at the various levels should clearly
understand their responsibilities and functions so that management’s objectives in
this respect are implemented through their co-ordinated efforts.
Safety Officer
Industries of a fairly large size normally have a Safety Department with one or
more qualified Safety Officers but in smaller units, safety is normally under the
charge of a senior person of the Personnel or Production Department. Though
safety inspection will have to be carried out by all levels of personnel, the Safety
Officer and his assistants have a special responsibility in this respect. The
inspections made by the members of the Safety Department could bring out many
unsafe conditions, methods and actions which are not reported by those in charge
of the departments concerned. Being solely concerned with safety they have the
necessary time for carrying out these inspections. Further, the critical eye of these
specialists easily detects the accident potential in the various jobs or process.
Line Management
Safety being principally a line management function, persons from the line
management should themselves take the main responsibility for plant inspections.
Senior Plant Management
Interest at all levels in safety can be stimulated and maintained, if the Senior
Management makes it obvious that they are keen on safety. For example, while
going round the department the action of the part of a Plant Superintendent who
notices an unsafe condition or unsafe action which is contrary to the approved
practice, to stop and point it out to the Supervisor, will go a long way in educating
all those under him. Indeed, it is the Senior Plant Management who have to set
pace in accident prevention. In addition to the type of the inspections mentioned
above, the Senior Plant Management should make thorough Safety Inspections of
the plant or the sections of the plant in their charge to locate all hazards conditions
and practices.
First Line Supervisors
The duties of the supervisor require that he should continuously look out for
hazardous conditions and unsafe practices on the part of the men in his section. In
addition to these inspections of continuous type, he should make periodic
inspections at regular intervals to see that all the hazards have been properly
safeguarded and that the safe procedures are being followed. He should also make
periodic and special inspections of equipment in his department.
Maintenance Department
Supervisory personnel both of senior and first line levels of the above
department could make effective contribution to safety by making frequent safety
inspection and taking necessary steps for maintaining the plant and equipment in
safe condition.
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Workers
It is workers who ultimately carry out the various operations using the
machinery and equipment. Since they come into close contact with the machinery,
equipment, tools and other parts of the plant during working they can easily detect
the defects associated with the above. They should be encouraged to report defects
or hazardous condition which can cause accident to themselves or others.
Type of Inspection
Safety Inspections can be of the following types:
 Periodic inspections,
 Intermittent inspections,
 Continuous inspections,
 Special inspections.
Periodic Inspections
These inspections are well planned and made at regular intervals. Machinery
equipment tools and all parts of the plant should be inspected periodically. Their
periodicity should be decided according to the requirements. While making
periodical general inspections, efforts should be made to cover the entire plant,
particularly the inconspicuous places. For periodic inspections of pressure vessels,
cranes, hoists, elevators, chains, cables, ropes, power trucks etc. a pre-arranged
schedule as required by law should be followed and these should be carried out by
competent persons. All concerned persons should be notified well in advance of
such inspections, for necessary arrangements.
Such inspections should be aimed at assisting the Supervisor to fulfil his
responsibility for maintaining health and safety standards at his work place and
therefore the Supervisor should be involved or he should carry out his own
inspections, possibly with the help of others.
Intermittent inspections
These are unannounced inspections made at irregular intervals. These may be
made by safety department personnel, supervisors safety committees, or individual
workmen and may cover a particular department, place of equipment or work area.
Continuous Inspections
In a system of continuous inspection, some selected employees spent all their
time on serving certain equipment or operations. Maintenance men, electricians,
etc. fall under this category. Continuous inspection of tools are done by stores staff
in some factories. Continuous inspection of personal protective equipment to keep
in good shape is especially desirable.
Special Inspections
Special inspections are those, which are occasionally made to locate hazards
that are suspected to be present in certain situations or processes. Example of such
inspections are:-
 Inspections during special campaigns such as fire prevention, waste
elimination.
 Inspections of new buildings, installations and process.
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 Inspections for investigation of accidents to determine causes.

 Health surveys to determine the extent of the suspected hazard and the
necessary preventive measures.
 Inspections of hand tools, scaffolds, personal protective equipment, point of
operation guards, lighting facilities, general ventilation equipment,
excavations and construction work.
Inspection Procedures
The persons making inspections should be familiar with the equipment, tools,
the processes and operations and should have adequate knowledge of the hazards
associated with these. They should also be familiar with the company rules and
policies and also the various statutes dealing with safety and health. The
inspections should be equipped with data based on a detailed analysis of previous
accidents in the plant. An inspection check list often proves to be very handy and
will eliminate the chances of overlooking some of the sources of accidents. A
specimen of a broad check list is a given separately. Detailed check list could be
drawn up for individual plants or sections.
The inspection should be systematic, thorough and cover all the operations,
equipment tools and parts of the plants so that no hazard is overlooked. The
inspector should not depend on his memory and make complete notes of the unsafe
conditions and practices which are discovered at the time of the inspection. All
pertinent data should be recorded and this can be used at the time of writing the
inspection report.
The implementation of the suggestions arising out of inspections is to be
carried out by the various departments concerned with production, engineering,
maintenance etc. and therefore, it is important that the recommendations are
discussed, wherever necessary with the concerned persons.
Work Site Inspections
It can be undertaken by an individual or as a team and as such have very
valuable contribution to maintain and improving safety in the work place. The
purpose of the inspection is to give some examples of the various types of
inspections that can be undertaken, suggested frequency and duration, the
recording of observations, recommendations and subsequent follow-up action.
A very important point to remember is that inspections are similar to
investigations in that they are conducted for the purpose of ‘fact finding’ and should
not seek to find fault or lay blame.
Scope and Frequency
Supervisors have many demands on their time and may find difficulty in
making time available for formal inspections. When obviously hazardous operations
such as lifting and handling the load by awkward posture, they probably do a
specific inspection because of the obvious dangers, but the need for inspection is
not always apparent during the more routine operations.
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Frequent safety inspection will not only overcome complacency, it will discover
unknown or unrecognized hazards before they cause an accident. By their nature
continuous process operations need this attention and weekly frequency is
probably the minimum. It may not be essential or possible to conduct a
comprehensive inspection on every occasion. But the activity should be planned
and scheduled so that full coverage is achieved over a period of weeks.
Techniques
Most Supervisors are required to perform inspecting task as applied to plant
maintenance or process faults. It is likely therefore that they will have acquired a
degree of skill in such tasks. Techniques of safety inspection can assist the
development of existing skill applied to the task of accident prevention.
A common technique is the inspection check list which encourages a
procedural approach although it may restrict the attention causing certain unsafe
conditions to be overlooked. It is, however, desirable to use a classified list for the
recording of the safety problems which are identified during the inspection.
Formal Inspections
These should be planned in advance in liaison with the Installation Manager
and the frequency and areas to be inspected should be agreed. Formal inspections
may involve several persons and therefore must be systematic and undertaken at a
frequency dependent on the risk presented by the activities involved.
Inspections may take the following forms:
 Safety Tour – a general inspection of any part of the installation where the
interest of the members of the constituency might be involved.
 Safety Sampling – a systematic sampling of particularly high risk activities,
processes or areas.
 Safety Surveys – a general inspection of the particularly high risk activities,
processes or areas.
Informal Inspections
These can be undertaken at any time and usually involve a walkabout to view
various job activities. Some of the issues looked for are: housekeeping, job specific
hazards, conflicting activities, substandard acts and conditions etc.
Some considerations before beginning an inspection are:
 The number of persons to be involved.
 Areas and activities to be covered
 Use of a standard form of written record and report
 Arrangements for remedial action and notifications
 Arrangements for re-inspection following remedial action
 Arrangements for viewing and being supplied with relevant documents
kept under statutory provision
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 Action to be taken in the event of a noticeable incident

 Obtaining advice from people on the installation or elsewhere
Method of Recording Information
Numerous methods exist to record the finding during an inspection. It may be
acceptable to rely purely on recorded observations. There is the use of a checklist,
which should be structured and reviewed periodically to ensure that it is as
complete as possible and is modified to reflect changes made to plant and
equipment. The use of a checklist can be very beneficial, as it channels the
thoughts and concentrates the mind along the right direction, ensuring that little or
nothing is overlooked if they are not specially referred to in the list.
Ultimately, whatever type of pro-forma, checklist or other form is used, it
should provide a record of what has been observed, who observed it, and the
suggested remedial action necessary.
Without doubt there will be a need for remedial action and subsequent follow-
up and provision should be made to record this on the form, with a date of action
and by whom. The inspection report should be clear and concise with enough
explanation to make it understandable.
Types of Observation
It is essential for the observer to be able recognize two basic factors:
 Unsafe or potentially unsafe condition at the workplace.
 Unsafe acts by people at the workplace
Within these two basic factors there is the need to consider and observe the
following:
Workplace
Housekeeping, Fire precautions, Work methods, Safety notices, Working
environment, Condition of plant, machinery, tools and materials.
The Worker
Behaviour, Hazard and activities, Handling of materials, Use of safeguards,
Personal protection/
The accommodation, messing facilities, changing area, laundry and its
associated facilities are should not be over looked.
Observation Techniques
The techniques involves five basic sets:
Preparation Annamalai University
Select a suitable area for the inspection ensuring that you have not just been
preceded by another team. Brief the team members ensuring that they clearly
understand the objective of the exercise.
Observation
At the work site stop for a few minutes and observe people activities. Look for
the “evaporative act” the action that stopped immediately employees were aware of
the inspection team. Look for the unsafe acts, but also note the tasks which are
being carried out correctly.
45
Discussion
Approach the employees with a positive attitude, discuss with them on a
practical basis the way they were tackling the job. Using the premise that the right
way is the safe way, encourage them to identify ways to improve carrying out the
job. Do not forget to record compliance at job procedure and positive suggestions
and comments made.
Recording
List all the unsafe acts identified and the result of conversations with
employees.
Follow-up
The content of the completed forms should be passed to the Supervisor
responsible for the work site inspected. Analysis of the forms should indicate
strengths and weaknesses and identify where procedures may need reviewing or
training of employees is required.
Submission of findings
In most cases the record or checklist will be submitted “as is” to the next level
of management. If properly and clearly presented it will need little or no discussion.
There may, however, be occasions when discussions are necessary, in which it is
important to follow a few basic rules.
 Get facts right. Ensure you have necessary information and understand it.
 Present the problem. Stick to the main theme, balance bad news with good
news and be logical.
 Be relevant. Use understandable language, give examples, use charts,
documents etc.
 Anticipate questions. Encourage them, treat them with respect, be honest-
if you don’t know, say so.
 Ensure the problem is understood. Be clear in your own mind. Reinforce
and re-explain – but only if necessary. Don’t repeat yourself unnecessarily.
 Request action. Don’t demand action.
A planned method of Safety Inspection
 Determine the physical boundaries of the area to be inspected and the time
available for inspection.
 Prepare a checklist.
 Decide the route to use, which will give the best coverage of the area.
 Follow the route first time and focus attention on the boundaries (eg. Floor,
walls and roof) of the area.
 Follow the route a second time with the focus on the major contents of the
area. (e.g. machines, stored materials, plant, vessels etc.) which will
usually be static.
 Follow the route a third time directing attention to the movement of people,
materials, vehicles etc. and include the often invisible flow of fluids, gases,
electricity, air, water etc. (do further tours as necessary).
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 Interrupt the tour whenever a hazard or safety problem is recognized, to

ask questions, exercise control, examine more closely, give instructions or
record future action required.
 Look into situations and assess the risk potential, the probability of
accidents, particularly those which are unexpected or unfamiliar.
 Review the information arising from the inspection, priorities your finding
and plan improvement action.
 Report in writing, making recommendations and stating action already
taken or planned.
 Compare current report with previous reports.
 Keep a record of the inspection.
 Plan and implement follow up action.
Essential Steps in a Safety Inspection
Plan, Conduct the inspection, Draw information, Draw conclusions, Make
recommendations, Record.
Planning & Set up
Time available, Determine area (area plan), Ascertain layout, Determine route,
Establish checklist. Recording procedure, Reporting procedure.
Conduct of the Inspection
Take the following Action During the Inspection on Discovering:
An unsafe act, an unsafe condition.
Unsafe Acts
Stop it immediately, Discuss with those involved, Ascertain reasons, Explain
need for change, Implement safe behaviour, Observe safe working, Report incident,
Record finding and action taken
Unsafe Conditions
Take immediate action to control if necessary. Observe and record
observations. Discuss situation with those involved or at risk. Correct the situation
finally if possible. If not possible, ensure temporary control is effective to make the
situation safe.
Report soonest stating: Situation found, Action taken, Any possible solutions.
Draw Information
Continue to monitor the situation. Follow chosen route. Physical boundaries &
Fittings. Plant/machinery/storage etc. People/process, systems and procedures.
Note: Repeat route as often as needed to cover all aspects thoroughly.
Take time to observe/note: Acts/omissions/deviations. Situations: Actual/
otential. Use all senses. Be systematic. Be thorough. Involve the work group.
Analyse Information
Implication. Priorities.
Draw Conclusions
What need to be done? Determine the alternative.
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Make Recommendations
Detail findings. Outline implications. Outline confusions. Make
recommendations with practical alternatives Identify additional resource
requirements (if possible).
Record
Findings. Action taken. Recommendations. Further / later action.
Example of a checklist
Safety Notice Boards
Is there one in or near your workplace?
Is the Company Safety Policy displayed?
Are boards well sited, clean, tidy?
Are the up to date minutes of the Safety Committee posted up?
Are the safety posters kept up?
Are recent changes in rules and procedures displayed?
Housekeeping
Is the site kept clear of waste?
Is flammable waste stored in metal bins?
Is waste removed daily?
Are there leaking joints (i.e. oil, steam, water)?
Is the lighting adequate, positioned correctly and kept clean?
Chemicals and Dangers Substances
Is handling equipment in good order?
Is protective equipment/clothing available?
Are chemicals stored in a defined area?
Are eye wash bottles / eye fountain / safety shower available?
Are non-combustible substances properly segregated?
Fire
Are exists clear and unobstructed?
Flammable liquids (if used), only kept in work area for current use?
Are the extinguishers readily accessible and properly maintained?
Do the staff know how to use the appliances?
Are the no smoking rules adhered to?
Access
Are ladders, stairs, steps and corridors in good repair?
Are walkways marked out and unobstructed?
Are the outside areas (roadways) kept clear of obstruction and adequately
maintained?
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Material Handling
Are all forklift trucks and mechanical equipment well maintained?
Are the operators qualified to drive?
Are there any excessive oil leaks?
Are the overhead and/or toe guards fitted and in good repair?
Are all loads safety stacked?
Are all staff trained in good handling techniques?
Machinery / Plant
Are the guards in good condition and in position?
Do the interlocks operate?
Are machines locked off when being set up or adjusted?
Are safety systems/procedure adhered to?
Hand Tools
Are all hand tools in good condition?
Portable electric tools – are they inspected, stored correctly – of approved type?
Unsafe Practices (Examples)
Vehicle exceeding speed limits?
Personal wearing protective equipment and clothing?
Wearing unsafe clothing (loose cloth, short sleeves, non-safety foot wear)?
Using unsecured ladders?
Are guards replaced after maintenance or adjustment is completed?
Horseplay in working areas?
Smoking in non-smoking areas?
Not following safe work procedures?
Health and Hygiene
Are the toilets and washing facilities well maintained clean and tidy?
Personnel
Do staffs know the safety rules for the work they are required to do?
Are staffs properly trained?
Are the manning levels sufficient?
Welding in pressure vessel
Is it free from under cut, cracks, blowholes, craters?
Is it in correct profile?
Is the appearance smooth, even finish?
Is the joins are smooth where now electrode have been started?
Is the penetration at the root of the weld is good?
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Vessel
Is there any internal corrosion, surface defects, weld defects, wear defect,
deposits and debris and external corrosion?
Is the drainage adequate?
Is the following protective devices are available and working properly?
(pressure relief valve, bursting disc, tank vents and filters, other pressure relief
devices, non-return valve, mechanical and instrument trips, alarm system, fire and
gas detection system, sprinkler and fire water system)
Is the support of the vessel in tact?
Pipeline
Is the pipe line rest on support?
Is the flanges provided with all bolts and nuts of correct size?
Is the expansion slippers safe?
Is the drain fitted at the lowest point and vent at highest point?
Note: More items can be included in the checklist as appropriate.
Revision Points
Plant safety inspection is a method of discovering potential risk in the accident
prevention. Safety officer, Line Management, Senior plant manager, Supervisor and
workers can do the inspection. The inspection can be carried out on need base.
Before conducting inspection, the area and the job activities to be inspected are to
be chalked out. A check list will be a handy one. All the findings are to be recorded
and presented in a self explanatory manner.
4.3 SAFETY AUDIT
Introduction
Safety Audit, like financial audit, should be part of the management practice to
ensure that critical business operations are carried out in a profitable, efficient and
safe way. Just as, the management would not accept the financial statement as
accurate reflection of organisation’s position unless the accounts had been audited,
effectiveness of safety programme cannot be judged by mere reduction in the
frequency or severity rare of accidents.
Safety Audit is a systematic, independent and critical examination of safety
activities and related results to determine whether they comply with planned
arrangements. It should aim at evaluating the effectiveness of all matters related to
safety such as research and development, design, occupational health and hygiene,
environmental control, product and public safety, emergency procedures, training,
housekeeping, personnel attitudes etc.
The audit system should be organized by a senior executive, who is vested with
necessary power for implementing the proposed recommendations. Depending upon
the nature of industry he shall launch the auditing either through internal or
external agencies. The officials having the requisite training in auditing shall form
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the team of internal agency. Factories having high potential hazards may call for
experts from external agencies.
The audit system will begin with the designing of objective, scope, frequency
and elements. It should also contain the methods of auditing. For conducting
proper and effective audit and for saving time the audit team shall make use of a
checklist. A typical checklist for safety audit is given. The team shall record each
observation in the checklist and a concise report shall be prepared indicating the
defects and deficiencies noticed. The report shall contain three main elements viz.
the observations, the attributes and the explanations. The observations should be
precise and must be accurate. The attributes shall be indicated against relevant
standards or procedures. The explanation for the defects noticed shall be indicated.
List of defects and deficiencies shall be passed on to respective sections for
corrective actions. The corrective action plan and the progress in respect of time
etc. shall be monitored by a senior management personnel. After correcting the
deficiencies noticed in the audit, the respective files shall be closed and recorded.
Need for Safety Audit
“First duty of business is to survive and the guiding principle of business is
not maxmisation of profit – it is avoidance of loss”.
Any simple measurement of performance in terms of accident frequency rate or
accident incidence rate is not seen as a reliable guide to the safety performance of
an undertaking. There is no clear correlation between such measurements and
working conditions, in injury potential or severity of injuries that have occurred. A
need exists for more accurate measurement so that a better assessment can be
made and efforts taken to control foreseeable risks. More meaningful information
could be obtained from systematic inspection and auditing of safeguards, systems
of work, rules and procedures and training method than on data about accident
experience alone.
Objectives
To critically evaluate the safety programme.
To analyse and apprise critically the company’s efforts to identify, evaluate and
control all potential accidental losses.
To critically evaluate the level of occupational safety and health standards and
their compliances, as per legal requirements and those of company’s SHE policy.
The instrument used should include evaluation of the following;
Prevention and control of occupational injury and disease.
Prevention and control of fire and explosion.
Prevention and control of toxic release.
Prevention and control of accidental damage to tools, equipment and
buildings.
Prevention and control of production delays and interruptions due to all types
of incidents.
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Developing a Programme
To develop one’s own safety audit programme, the following steps could be
followed:
Programme elements common to the industry should be listed.
Each element is divided into various sub-elements taking into account the
critical factors which will affect the safety programme.
A series of objectively structured questions is prepared for each sub-element.
Each of the question should be given a value factor. This must be based on the
contribution this particular sub-element will make to the whole programme.
Types and Elements
Before undertaking any full-fledged audit, the management should ensure that
al least basic elements of a safety programme are in operation. They must analyse,
qualitatively, their achievements in the areas of policy statement on safety, safety
set-up, hazard identification, job procedures, education and training and record
keeping. This is ‘Basic Audit’. After being satisfied with the result of ‘Basic Audit’,
the management can take up “Self Audit”. The “Self Audit” should normally be done
by a management staff team. They should have professional training in the
disciplines of safety, fire, environmental monitoring, control and occupational
health. The team can be drawn from maintenance, process, instrument
engineering, training, medical etc. The team should preferably be from corporate
office since they are unlikely to be biased and are directly accountable for the
results. The Safety Audit must necessarily contain the following elements.
Leadership and Administration Emergency preparedness

Training Rules and Regulations
Inspection Procedures Group Safety Meetings and Communication
Inventory of critical jobs and job analysis Community Education
Investigation of accidents and incidents Documentation
The next stage of audit is a “Professional Audit”, conducted by outside
auditors. This audit will be analysis of the safety system at micro level. Since, this
will be done by an external agency, the extent of influence of the management and
bias on the part of the auditor can be expected to be minimal and will consider all
the elements of the audit.
Procedures Annamalai University
After developing the audit or safety programme rating instrument,
consideration must be given to its application. The basic steps in conducting the
audit.
Pre-Audit Preparation and meeting
Planning and organizing necessary steps to ensure that the external or
internal audit is carried out in the most efficient manner.
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Opening meeting
The purpose of an opening meeting is to ;
 Introduce the members of the audit team to the auditee’s senior
management.
 Review the scope and the objectives of the audit.
 Provide a short summary of the methods and procedures to be used to
conduct the audit.
 Establish the official communication links between the audit team and the
auditee.
 Confirm that the resources and facilities needed by the audit team are
available.
 Fix a schedule of visit to individual plants/departments.
 Discuss the auditee’s senior management; the areas of concerned and
suggested areas of focus by the audit team.
 Confirm the time and date for the closing meeting and any interim
meetings of the audit team and the auditee’s senior management.
 Clarify any unclear details of the audit plan.
 The Chief Executive and Senior Managers of the unit under Audit must be
involved to get their support in the audit process and the related follow up
action.
Familiarisation Tour and Interview
The audit team must make a tour of the facility to get themselves familiarized
with the nature of operations, exposure of the people and property with various
kinds of energies, barriers provided, safety climate and physical conditions.
To get the answers to the questions of the audit by interviewing concerned
personnel who are most knowledgeable.
Eg: Typical questions to be asked for the standard “Safety Policy, attitude and
assignment” are:
 Is there a written SHE Policy?
 Is it oriented toward injury prevention only?
 Is it oriented toward accident prevention, environment protection etc?
 Is it oriented for total loss control?
 Are all supervisory personnel familiar with it?
 Are contract workers familiar with it?
 How does management support the policy: Strong commitment / Nominal
support / Lip service / Indifference.
 General attitude towards safety workers / supervisors / management.
 Do senior management meetings include safety?
 What are the safety objectives?
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 Current Year
 Last Year
 Is success in accident prevention recognized?
 Promotions
 Appraisals
 Others
 Is responsibility for safety defined in writing?
 Do those responsible understand?
 Do all levels understand their responsibilities?
 Is safety included in job descriptions?
 Are accidents and their costs charged against the department?
 Are first line supervisors required to submit periodic safety reports to
management?
Verification of Information
The information received verbally, through forms and related materials are to
be verified by established techniques like;
Actual Count, Random Sampling, Physical Measurement, Professional
Judgement Techniques.
Employees at all levels, should also be interviewed by the auditors to check the
correctness of the information provided by the Management on the questionnaire.
Cross Verification at the Site
Tour of the facility to cross check the information collection on the audit
questionnaire.
Close of Meeting with Chief Executive
An overview of the incomplete audit findings may be discussed with the Chief
Executive and Senior Managers in order to satisfy the Mangement’s desire to know
the results.
Writing audit report
Analysis and evaluation of audit findings and report preparation. The audit
report is prepared under the direction of lead auditor, who is responsible for its
accuracy and completeness.
Report Content
The audit report should faithfully reflect both the tone and content of the
audit. It should be dated and signed by the lead auditor. It should contain the
following items as applicable.
 An executive summary of the report presenting, introduction, objectives
and methodology, overview of the site, plant description, managements
OS&H system, worker’s perception of management’s commitment towards
safety and the major conclusions and recommendations.
 The scope and objectives of the audit.
 Details of the audit methodology, the identification of audit team members
and auditee’s representative, audit dates.
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 Identification of the reference documents against which the audit was

conducted (safety system standard, safety manual etc)
 Observations of conformities as well as good practices.
 Audit teams’s judgement of the extent of the auditee’s compliance with the
applicable OS&H system standard and related documentation.
 The system’s ability to achieve defined objectives.
 The recommendation for improvement.
Submission of Report
A detailed audit report along with required forms and findings should be
submitted within reasonable period after the audit, but not later than a month.
This will facilitate the Management to review their safety system and effect changes
faster.
Advantages
The benefits of a valued measurement of safety activity are many. It provides a
vehicle to convey to management in understandable, concrete terms the status of
the safety effort. A measurement “score” is easily understood.
A valued measurement will bring into proper perspective the various loss-
control measures. On a continuing basis, this enables the safety professional to
promote through plant management, in an understandable way, those loss-control
measures which are considered to be the most effective.
The evaluation process incorporated in the technique requires a degree of
guided self-evaluation. The local plant management must examine their own
operation under the guidance of an evaluator to determine the status of safety
activities. Weaknesses and areas needing additional emphasis are readily
recognized.
By participating in the evaluation process, the local management group
becomes familiar with the expectations of the company, and they are motivated to
strengthen those activities in need of strengthening.
A measurement which provides a basis for comparative evaluation is achieved
in the above technique. A comparison of the scores from one year to the next is
valid to determine progress. Within a multi-plant operation a comparison of the
various plants can be made.
The criteria are known in advance and the weighted values are provided. Thus,
a plant knows ahead of time what is going to be measured, how it is to be
measured, and that the results will be compared with previous results. The local
management is also quite aware of the comparisons with other plants which might
be made at the corporate level.
Needless to say, the evaluation should be guided by the safety professional
who has a good grasp of the operations and the expected safety activity.
While the technique outlined tends to maintain objectivity, the evaluator must
also be objective in his assignment. His ability to be objective in guiding local
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management through the self-evaluation portions of the measurement process will

enhance the whole effort and make it a useful tool for future control of accidents.
Specific Limitations
Safety Audit is a particular technique which should not be construed as a
substitute for other techniques. Its specific limitations are as follows:
 In depth hazard identification or accident analysis is not covered under
Safety Audit which can be carried out using Hazop and Hazan studies.
 Basic measurement of physical and chemical hazards, i.e. noise levels,
vibrations, ventilation quality, concentration of air borne contaminants etc.
is not a part of the Safety Audit. However the Audit would identify areas
where, the intent of such hazards necessitates a detailed study including
measurements where such study has been done, the Audit would review
the completeness and effectiveness of the study.
 Conducting medical check up is not a part in the safety audit. However the
audit would recommend the departments/workers to be covered and even
in industries where pre-employment and periodic medical examinations are
done the Safety Audit could comment on their effectiveness, coverage and
periodicity etc.
 Safety Audit is not a method to control hazard and not a substitute for a
comprehensive safety programme by Management. Safety audit is to review
the adequacy and effectiveness of the Safety programme.
The quality and effectiveness of recommendations arising out of the audit may be
determined by the following steps.
 Existence and easy availability of detailed technical documents listing the
norms and standards drawn up by the professional institutions of bodies.
 Existence of a programme to train and certify by safety auditor.
 Auditor’s qualification, background and experience of safety as well as of
conduction audits.
 Auditors familiarity with published standards and his advance preparation
before undertaking the audit as well as use of references while writing the
report.
Standard Activities in which Attention are to be given
 Safety Policy, Responsibilities Assigned attitude.
 Safe Operating Procedures
 SHE Organisation
 Plant Safety Rules
 Employees Selection and Placement
 Emergency and Disaster Control Plans
 Direct Management Involvement in Safety
 Availability of P & I Diagram, Flow Chart etc.
 Housekeeping – Storage of Materials, Drainage
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 Machine Guarding
 General Area Guarding
 Maintenance of Equipment, Guards, Tools etc.
 Material Handling – Manual & Mechanised
 Personal Protective Equipment – Safety Showers, Resuscitators etc.
adequacy and use.
 Chemical Hazard Control Reference
 Flammable and Explosive Materials Control
 Ventilation – Fumes – Smoke and Dust Control
 Skin Contamination Material
 Fire Control Measures, Fire Fighting Training, Fire Fighting Manual and
Fire Fighting Equipment – Alarm System.
 Pollution Control Air, Water, Land & Noise
 Supervisor Safety Training, Training for new Entrant
 Job Hazard Analysis
 Hazop Study
 Training for Specialised Operation & Safety
 Internal Self-inspection
 Safety Promotion and Policy, Safety Organisation
 Employee/supervisor Safety Contact and Communication Safety Meeting,
Safety Suggestion.
 Loss Prevention
 Safe Work Permit
 Process Safety Device Reliability
 Process Maintenance – Pressure Relief Valve, Vessel, Alarm.
 Corrosion Problems in the Plant – Critical Look
 Major Modification Done – Safety Point Review
 Colour Coding, Slip Plate Procedure
 Stability of Structure
 Fulfilment of a Statutory Requirement
 Lighting System – Emergency Lighting, Explosion Proofs, Interlock System
in Equipment.
 Earth Grid Resistance, Earthing of Equipment.
 Electrical System – Safety Angle
 Annamalai University
Instrument System – Safety Angle
 Review of the Past Major Accidents
 Accident Investigation by Line Staff
 Accident Cause and Injury Location Analysis and statistics
 Investigation of Property Damage.
 Proper Reporting of Accidents and Contact with Victim
 Fulfilment of Statutory Requirement
 First aid Facilities
 Communication System
 Unsafe Practices
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 Involvement of Employees in Safety Activities.

 Waste disposal systems.
Revision point
Safety audit is like financial audit. It is a systematic independent and critical
examination of safety activities. The safety audit is to be started with opening
meeting and target for completion of audit is to be spelt out. Standard activities as
per IS 14489:1998 are to be audited. The detailed report is to be submitted to the
Management of the factory with suggestions wherever possible. All deviations from
statutory obligations are to be noted and recorded.
4.4 SUMMARY
Accident do not happen and they are caused by unsafe condition or unsafe act
or combination of both. To prevent the accident, it is to be discovered the causative
factors and apply adequate corrective measures before the accident occurs. Well
planned plant safety inspection procedure thoroughly and systematically applied is
an effective means of discovering hazardous conditions. Inspection to discover
conditions that if uncorrected, may lead to accident and injuries is similarly
essential to first rate safety performance. Inspection should not be limited to search
for unsafe physical conditions but should also try to detect unsafe practices.
Safety Audit is important as part of company’s control system. It checks to
ensure any deteriorating standards are detected and the entire organisation is in
good standard with specific reference to safety, loss prevention and fire protection.
It helps management to achieve efficient and profitable operation. Check and re-
check is still the responsibility at all levels in day to day operation in spite of Safety
Audit. Industry while instituting safety Audit must define the objectives, scope of
system, its frequency, the elements and method to be adopted. Safety Audit should
be on going plan and should be carried out periodically.
4.5 QUESTIONS
 Short notes on: Safety inspection, Safety Audit, Opening meeting in safety
audit, Limitations in safety audit.
 What are the types of safety inspection and explain in short?
 What is the area of inspection? Prepare a check list for 5 areas?
 What is the need for safety audit, and its objectives?
 What are the standard activities in which attention are to be given in the
safety audit?
SUGGESTED READING
Loss prevention in the process Industries – Frank P. Lees, Butterworth –
Heineman Publications, London.

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UNIT - V
CONTENT
5.1 Introduction
5.2 Accident Investigation
5.3 Steps of Investigation
5.4 Investigation Report
5.5 Types of Investigation Analysis
5.6 Accident Reporting
5.7 First Aid
5.8 Questions
5.9 Asssignment
5.1 INTRODUCTION
The studies on accident causation have swept off the misconcept that accident
is just a chance happening. It is an undesired event, which can be brought under
control through excellent planning and untiring efforts. For a scientific approach to
accident prevention it is necessary to control even the no-injury and the no-loss
accidents, which is termed as ‘incident’. Hence accident can be defined as “Accident
is an undesired event or an unplanned incident which could (or does) downgrade
the efficiency of a business operation and result in loss”.
According to the Multiple Causation Concept “an accident is an unexpected,
unplanned event in a sequence of events that occur from a combination of causes
and which result in or having a potential of resulting in physical harm leading to
injury or danger to property, equipment, building etc.
In some cases uncontrolled release of energy can cause accidents and in some
other situations deficiency of a particular energy below the requirement limit could
also cause accidents. “Accidents are events which occur from contact with sources
of energy such as chemical, kinetics, thermal, radiation etc. above the threshold
limit of body or structure or that which occur due to deficiency of particular energy
source such as oxygen or any other chemical substances.”
Thus various definitions are given to accident by researchers. But all of them
agree in one point that accident is an unwanted occurrence which can be put under
control. The Bureau of Indian Standards has defined accident as “unintended
occurrences arising out of and in the course of employment of a person, resulting in
injury”, which is incorporated in IS 3786-1983. This definition is a guideline for all the
industrial concerns to compare one another and to analyse accidents in the same
direction in order to control them in a scientific manner like accident investigation.
5.2 ACCIDENT INVESTIGATION
Classification of Accidents
The principal factors related to classification of accidents are:
 Classification according to agency : Agency is the object or substance which is
most closely associated with the accident causing the injury and with respect to
which adoption of a safety measure could have prevented the accident
Eg. Machine, Means of transportation and moving equipment, Other
Equipments, Materials, Substances, Radiations, Working Environment, Other
agencies – Mining and Tunneling, Other agencies not elsewhere classified.
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 Classification according to unsafe material or physical conditions. This identifies

the unsafe mechanical or physical condition or conditions related to the agency
which contributed to the causation of accident.
Eg. Improperly guarded agency, Defects in agency, Improper illumination,
Improper ventilation, Unsafe dress etc.
 Classification according to unsafe act. This identifies the deviation from the
accepted and laid down safe procedure which contributed to the causation of
accident.
Eg. Operating without authority, operating at unsafe speed, making safety
devices in operative, using unsafe equipment, unsafe loading, placing mixing etc.
taking unsafe posture etc.
 Classification according to unsafe personal factor. This identifies the anatomical,
physiological, or the psychological characteristic which permitted or occasioned
the selected unsafe act.
Eg. Unsuitable anatomical, physiological or psychological characteristics, Lack
of knowledge or skill, unsuitable mechanical or physical condition, social
environment etc.
 Classification according to type of Accidents: The type of accident is the manner
in which the object or substance causing the injury comes into contact with the
injured person.
Eg. Fall of persons, Fall of objects, steeping on, striking against or struck by
object, caught in between objects, over exertion or wrong movement, exposure to or
contact with extreme temperature, exposure to or contact with electric current,
explosions etc.
 Classification according to nature of the injury : This identifies the injury interms
of its principal physical characteristics.
Eg. Fracture, Dislocations, Sprains and strains, wounds, superficial injuries,
Burns, Poisoning, Asphyxia, Effect of current, radiations, etc.
 Classification according to the location of the injury: Location of injury identifies

the part of the injured person’s body directly affected by the injury identified.
Eg. Head, Eye, Ear, Trunk, Upper limb, Lower limb etc.
Objectives of Accident Investigation
The primary object of investigation is to find facts and not faults. If the
investigator is being upon finding faults, material informations may be suppressed
and this would do more harm than good. The investigator therefore, should conduct
his enquiry in a manner as to bring out all facts. He should follow the general
principle of factories inspections, to be polite but firm in his dealings. He may take
the help of such persons as may be able to assist him in eliciting information and
should, unless otherwise needed, keep all such information confidential. It may at
times, be necessary to collect information from workers in the absence of
management representatives or even from management personnel in the absence of
his supervisors. Investigations have to be taken up immediately as a delay of even a
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few hours may allow material information to be erased intentionally or

unintentionally. Putting off investigation for a short time as in case of some fatal
accidents when the mob is agitated may be considered as prudent. No opportunity
should however, be lost in taking note of the situation under which the accident
occurred and collect other information without offending the informants.
Cases to be investigated
Any accident is worth investigating, as it reveals lack of preventive measures.
All fatal and serious accidents should be investigated thoroughly and sample
cases (say 10%) of the non-fatal accident should also be enquired into. All
dangerous occurrences should be investigated, and if time and facilities permit,
‘near accidents’ and other non-reportable accidents, especially those of repetitive
types, should also be investigated.
The principal purpose of Accident investigation are:
To learn accident causes so that similar to that can be prevented by
mechanical improvement, better supervision and instructions.
To publicise the particular hazard among employees and their supervisors and
to direct attention to accident prevention in general. The need is for full information
of the causes, all the contributory causes that led to the accident and not just the
major causes.
Since the sole purpose of accident investigation and analysis is for designing
accident prevention strategies and further, since the investigation report is the base
on which the entire accident investigation rests, it is but essential that the report is
complete and accurate. The reporting has to be prompt and it should not miss any
detail so as to avoid in difficulties in collecting the information later.
Investigation Officer:
The chief value of investigation lies in uncovering contributory causes. No one
should be assigned the investigation work unless he has a reputation for fairness
and experience in gathering information. The shop supervisor is the man on the
spot and he is in a position to be physically present and ascertain all facts
immediately. No one probably knows more about the accident than him. He is
therefore most suited to enquire into the event and in most cases he is the one to
take corrective steps to prevent recurrence.
The safety officer by virtue of his qualification and training and unbiased
approach is the most appropriate person to enquire into the important accidents
and make reports. His interest is nothing beyond prevention of similar accident in
future and his ability is best put to test in investigating an accident.
Department Committee of an organization may be entrusted with the task of
investigation of a serious accident when it is of greater concern to the management.
Such Committee may be adhoc ones or standing committee but it should be so
composed that an unbiased report should come.
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At times, in view of the public interest, statutory committees may be set up to

go into causes and effect of an accident. These committees may exercise the power
of civil courts in matters of investigation.
The qualifications needed by the members of the accident investigation team include:
Technical knowledge
Objectivity
Familiarity with the job, process or operation
Tact in communicating with others
Intellectual honesty
An analytical approach to problems.
5.3 STEPS OF INVESTIGATION
The form taken by an investigation depends somewhat on the accident, but is
likely to be broadly as follows:
 Letter for investigation
 Preliminary site visit
 Collection of background information
 Examination of damage
 Interviewing of witnesses
 Research and analysis
 Final report
The purpose of the investigation should be clearly defined from the outset and
a clear letter for investigation obtained. If in the course of investigation, it proves to
be necessary, the letter should be renegotiated the general circumstances of the
accident including all details about the process, materials used etc.
For a major investigations the accident investigation team should:
 Visit the accident scene before the physical evidence is disturbed.
 Take sample of unknown chemical spills, vapours, residues, dusts and
other substances, noting conditions that may have affected the sample.
 Make comprehensive visual records. No one can predict in advance which
data will be useful, so photographs should be taken from many different
angles. Accurate and complete sketches or diagrams should be made
before the accident scene is restored.
 It may be helpful to obtain an overview of the site by viewing it from a
distance, perhaps the window or a nearby building.
 Determine which accident-related items should be preserved. These may
become critical evidence if there is litigation later. When the investigation
reveals that an item may have failed to operate properly or was damaged,
arrangements should be made either to preserve the item as it was found
at the accident scene or to document carefully any subsequent repairs or
modifications.
 Identify the people who were involved in the accident. Also identify all eye-
witnesses, including those who saw the events leading to the accident,
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those who saw the accident happen and those who came upon the scene
immediately following the accident. Identify others who may have useful
information.
 These people should be interviewed as soon as possible. The validity of
their statements is highest immediately after the accident. Immediate
interviews minimize the possibility that witnesses will subconsciously
adjust their stories to fit the interviewer’s concept of what occurred or to
protect someone involved. Witness should be interviewed individually and
in private so the comments of one do not influence the response of others.
 The interviewer should avoid the use of leading questions and should seek
to cross check details given.
 Conduct interviews with everyone who was involved or can provide
information. Tactful, skilled investigators usually get uninhibited cooperation
from employees by eliminating any apprehension they may have about
incriminating themselves or others. Witnesses must be convinced that the
investigators want to find the cause of the accident and don’t want to place
blame. If witnesses provide misleading information, the purpose of the
investigation is thwarted and a similar accident may occur again.
 Allowance needs to be made for the fact that the statement given by a
witness may be defective by reason of the initial observation, memory or
descriptive powers.
 Carefully document the sources of information. This documentation avoids
an unwarranted impression that information actually obtained from third
parties is based on the investigator’s own observations or analysis.
Documentation of information sources can prove valuable if the accident
investigation is expanded at some point or reopened later. Note any
contradictory statements or evidence and attempt to resolve discrepancies.
If resolution is not possible, indicate which statements or evidence are
considered most reliable.
 Review all sources of potentially useful information. These may include
original design, design specification; drawings, operating logs; purchasing
records; previous reports; procedures; equipment manuals; verbal
instructions; maintenance; inspection and test records; alteration or
change of design records; design data; job safety analysis; records
indicating the previous training and job performance of the employees and
supervisors involved; computer simulations; and laboratory tests.
 There may be some issues which can be resolved only by physical tests. In
some cases small scale tests are adequate, but frequently the only tests
capable of providing results which will carry major punishment are
relatively large scale, time consuming and expensive. The decision as to
whether to call for tests is often one of the most difficult which an
investigator has to take.
 A report is then written. This may will be best cast in the form of a
chronological account of the steps by which the investigator came to a
conclusion.
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5.4 INVESTIGATION REPORT

The report must be presented in such a way that key points are easily
established and the conclusions easily drawn. Its format should follow a logical
sequence which could be:
Title - To say what is about
List of contents - But only if the report is long enough to warrant
it.
Summary - So that the top management can quickly get the
gist of the report content and findings.
Introduction - To give background to the report.
Findings - Recording the information gathered during the
investigation.
Conclusions - Drawn up from the findings.
Recommendations -
Appendices - May be necessary for supporting material, such
as tables, sketches, test reports, photographs etc.
Note: Before issue the report either on its title page or the last page should be
signed and dated by the investing team members.
Facts must be separated form opinion, direct evidence from circumstantial
evidence, and eye-witnesses statements from speculative testimony. Investigators
should divide the data they collect into the following categories:
Hard Evidence
Data that usually cannot be disputed, such as the time and place of the
accident, logs and other written reports and the position of physical evidence
(provided investigators can establish that it has not been moved).
Witness statements
Statements from persons who saw the accident happen and from those who
came upon the scene immediately following the incident.
Circumstantial evidence
The logical interpretation of facts that leads to a single, but unproved,
conclusion.
Investigators must understand that the accuracy and thoroughness with
which they obtain and record data will largely determine the quality of the final
report and the effectiveness of the corrective actions.
Interviewing tips for Investigators
Interviews are of critical importance in conducting investigations. Each
interviewer uses his own variety of skills and styles, but the following common
denominators apply across-the-board.
 Have another person present in the room during questioning. They should
keep a record of each session containing the names of the interviewers and
interviewee; place; date and time of the interview; and any significant
comments or actions during the interview.
 Conduct the interview in private with no interruptions.
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 Protect the reputation of the people you interview. Don’t discuss the
purpose of the interviews with anyone other than your immediate staff and
appropriate management personnel. Interview several persons to divert
attention from one or two witnesses.
 Set a casual, informal tone during the interview to put the individual at
ease. Tell them that you are simply searching for information and it is their
turn to be questioned.
 Communicate in language the interviewee can understand. Repeat
responses to questions to make sure you understand the answer correctly.
This also enables him to hear his own response and correct his statement,
if necessary.
 Do not, under any circumstances, clandestinely tape record an interview
without proper authority.
 Don’t come to conclusion by jumping and need to keep an open mind.
 After the interview, summarise the individual’s comments in a written
statement and have them sign it. This will avoid any misunderstanding of
what was said during the interview.
Essential question to ask
In order to obtain the right information, and thereby establish the direct
indirect and root causes of an incident, we have to ask the right questions. A line of
questioning should certainly include the following:
Who was injured?
Who saw the incident?
Who was working with the injured?
Who had instructed and/or assigned the job?
Who else was involved?
Who knows what happened immediately prior to the incident?
What was the incident?
What is the injury or injuries?
What is the damage?
What is the effect of the damage?
What is the approximate cost of the damage?
What was the employee doing?
What had he/she been told to do?
What machine/installation/equipment was involved?
What instruction had been given?
What specific precautions were necessary?
What specific precautions were taken?
What protective equipment should have been used?
What protective equipment was used?
What problems or hazards were encounted?
What training had the employee received?
What did the employee or witness see?
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What safety rules were violated?

When did the incident occur?
When did the damage become evident?
When was the equipment last inspected/checked?
When did the job start?
When was the equipment last maintained/repaired?
When was it planned to start the job?
When did the supervisor last visit the job site?
When were all potential hazards identified or reported?
Why was the unsafe act committed?
Why were instructions not understood?
Why was he/she in the position that they were?
Why was that tool or machine being used?
Why didn’t he/she check with his supervisor?
Why was the supervisor not there at the time?
Where is the damage?
Where did the incident occur?
Where was the supervisor at the time?
Where were other persons at the time?
Where were witnesses when the incident occurred?
How did the employee get injured?
How did the damage occur?
How could the incident have been avoided?
How could the damage have been avoided?
How could the injury have been avoided?
How could the supervisor have prevented the incident?
How long had the specific circumstances exited?
The Incident Investigation Kit
In order to aid a swift response the following items should be kept readily
available for effective investigation:
 Chalk, pens, pencils, coloured markers (permanent and non permanent)
 Graph paper, plain drawing paper, steno pad, clip board, incident report
forms, photo log book and the investigation procedure manual.
 Large and small envelopes for evidence, self-adhesive labels, tags with
string ties.
 Measuring tape (50m), short measuring tape, ruler.
 35 mm camera with telephoto feature, auto-focus, light meter and auto-
flash, additional film, camera bag, batteries etc.
 Fluorescent flagging tape
 Torch and spare batteries
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 Copies of any rules or procedure which may apply

 Warning signs to isolate area (if needed)
 Personal protective equipment for each team member
Investigation of accidents can produce these remedial measures:
 Identify and locate the principle sources of accidents by determining, from
actual experience, the material, machine, and tools most frequently
involved in accidents and the job most likely to produce injuries.
 Disclose the nature and the size of the accident problem in departments
and among employees.
 Indicate the need for engineering revision by identifying the principal
unsafe conditions of various type of equipment and material.
 Disclose inefficiencies in operating processes and procedure, poor layout,
which contributes to accidents, or where outdated methods or procedures
which overtax physical capacities of the workers can be avoided by using
mechanical handling methods.
 Disclose the unsafe practices which need special attention in the training
of employees.
 Disclose improper placement of personnel in which inabilities or physical
handicaps contribute to accidents.
 Enable supervisors to use the time available for safety work to the greatest
advantage by providing them with information about the principal hazards
and unsafe practices in their departments.
 Permit an objective evaluation of the progress of a safety programme by
noting in continuing analysis the effect of different safety measures,
educational techniques and other methods adopted to prevent injuries.
5.5 TYPES OF INVESTIGATION ANALYSIS
There are several types of investigation analysis and that one is to be chosen
depends on the circumstances and objective in each case.
Type of Analysis:
 Failure Mode and Effect
 Fault Tree
 Cost effectiveness
 Statistical method
 Critical incident method
 Systems safety
In the failure mode and effect method, failure or malfunction of each
component, the mode of failure and its ultimate effect on the overall performance is
evaluated. This is a straight forward method provided that the analyst has a
thorough knowledge of the system. It’s draw back is that it considers only one
failure at a time and some possibilities may be overlooked. It could be very useful
for investigating situations where large complex inter related machines and
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procedures are involved but may be of limited value in the investigation of accident
involving hand tools.
In the fault tree method, an undesired event is selected and all the possible
happenings that can contribute to the event are diagrammed in the form of a tree.
The branches of the tree are continued until independent events are reached.
Probabilities are determined for the independent events and after simplifying the
tree, both the probability of the undesired event and the likely chain of events
leading upto it can be computed. This is a very powerful analysis technique but
requires complex mathematical calculations. This method yields good results if
management procedure and communications and their relationship to accidents is
of interest.
In the cost effectiveness method, the cost of system change made to increase
safety are compared with either the decreased cost of lower serious failures or the
increased effectiveness of the system to perform its task to determine the relative
value of these changes. This method helps in selecting the most economical method
yielding same results.
The statistical method is the conventional one. The defects are grouped
together based on say, 4 M’s i.e. man, machine, media and management of 3 E’s i.e.
Education, Enforcement and Engineeing. Accidents are distributed among these
categories and problem components identified for preventive action.
The critical incident technique consists of selecting at random a number of
workers from major plant departments and interrogating them to seek errors they
might have committed or observed for similar jobs in the past. The incidents
described are classified into various categories and accident problem areas are
seen. This technique can identify mechanical and human error which may have
contributed to an accident or have accident potential.
The system safety method believes in a complete view of interrelationship of
various events that can lead to an accident. When an astronaut can be brought
back home safely from space why not a worker form the plant? The difference is
that in the former case, the system in toto made safety (though at a huge cost)
whereas the totality is not taken into account in the later case. The systems
approach to safety has recently been conceived. The system can cover a wide range
including machines, tool, materials, environmental factors, people, documents,
(operating instructions training manuals) etc. As accidents will rarely have one
cause, the system safety method may identify more than one problem areas where
counter measures are necessary. It has the advantage of application to new
processes and plants and can be applied before accident can occur.
Any one can use the profit from the systems approach to safety. Being forced
to visualize the impact of malfunctioning/failure of each component this approach
helps to bring most accident possibilities into consideration automatically and in an
orderly manner. It transforms the safety profession from an art to a science by
codifying the knowledge. It discards a piecemeal attack of the problem to safety
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designed operation. A question can be put as to how different departments of the

system may be affected if a particular component fails and the precise answers in
respect of each can be had before accident occurs. This therefore is a versatile
investigation technique.
5.6 ACCIDENT REPORTING
Use of Records
Reporting of accidents is very essential for determining hazard potentiality and
also for controlling accidents in future. Hence accident report forms are important
documents for mobilizing accident prevention activities.
Records of accidents are essential for efficient and successful safety work. The
completeness and accuracy of the entire accident record system depend on the
information transmitted in the individual accident reports. Therefore, simple forms
which contain all essential information should be used for reporting. They are of
two types –
a. First Aid Report
b. Supervisors Accident Report
In case of reportable accidents or dangerous occurrences, the management
shall send notices to the concerned authorities in prescribed formats.
The First Aid Report
The collection of injury data generally begins in the First Aid Departments. The
First Aid Report is filled by the First Aid Attendant for each new case.
Supervisor’s Accident Report
The line supervisory makes a detailed report about each injury. The primary
purpose of the accident report is to give complete and unbiased information on the
cause of an accident and not to fix blame. Information on unsafe acts and unsafe
conditions is important in the prevention of future accidents.
Rehabilitation / Evacuation
The principal event where evacuation may be in question is a large release of
toxic gas. In this case an alternative means of mitigation is shelter within factory.
This is to be considered by the model for the toxic gas concentrations outdoors and
indoors during the passage of a toxic gas cloud, and for the associated toxic loads.
A building with a ventilation rate 2 air changes/hour offers a degree of protection
which reduces the toxic load for a person indoors compared with that for some one
outdoors by atleast an order of magnitude, although protection is much reduced if
the ventilation rates are higher. A high degree of protection can therefore be
achieved by advising people to stay indoors and shut doors and windows. A further
reduction in the overall toxic load can be obtained if at the approximate time
persons indoors leave the still contaminated indoor space and come out doors into
the fresh air.
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The degree of protection provided by shelter in such that it should be policy for
a toxic gas release to use shelter rather than evacuation, except in certain special
circumstances.
As regards evacuation, the following three cases may be distinguished
 Evacuation after toxic gas release taken place
 Evacuation when a toxic release is expected
 Evacuation after the toxic gas cloud has passed.
Taking these cases in turn, it needs to be appreciated that once a toxic leak
has occurred, the cloud may travel quite rapidly. Even at a low wind speed a 2 m/s
the cloud will travel 1.2 km in 10 minutes, whilst at the higher wind speed of 5m/s
it will travel 3 km.
The event in which evacuation is most likely to be considered is where a tank
or vessel is under threat, usually from fire, and there may well be a loss of
containment, but only after some time has elapsed. This is the situation for which
evacuation is most often considered to be an option. Even here, there are a number
of difficulties. The decision to evacuate is unlikely to be made with in the first half
an hour.
Even when the decision has been taken, its implementation by the police is not
effective, unlike the fire brigade, the police are not normally equipped with
respiratory protection.
It cannot be assumed that people at risk will necessarily need the advice to
evacuate. There will be problem in getting people to move. Although the off site
emergency plan will normally include an evacuation plan, it is likely to recognize
that shelter rather than evacuation to the preferred option.
Making a Decision on Evacuation
The first evacuation consideration determining whether an evacuation is
necessary involves a comprehensive effort to identify and consider both the nature
of and circumstances surrounding the released hazardous material and its effect on
people. The exact safe exposure levels have not been established for the extremely
hazardous substances and therefore it is not possible to calculate evacuation
distances accurately. But the hazardous condition and inherent properties of the
released materials can be taken into account to decide the evacuation distances.
Hazardous conditions Affecting Evacuation Decisions
Numerous factors affect the spread of hazardous substances into the area
surrounding a leaking/burning container or containment vessel. The conditions
created by the release, the areas that have been or will be affected and the health
effects on the people, amount of released materials, health hazards, dispersion
pattern, atmospheric conditions, dispersion medium, rate of release and the
potential duration of release etc.
The most important factor among this is the physical and chemical properties
including
Physical state; solid, liquid or gas, odor, colour, visibility, flammability, flash
point flammable limits, ignition temperature, specific gravity, whether the material
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sinks or floats in water. Vapour Density – whether vapour rises or remains near
ground level. Solubility – whether it readily mixes with water. Reactivity – whether it
reacts with air, water or other materials. Crucial temperatures – boiling point,
freezing point.
Other Considerations
Does the release follow the contours of the ground. Is it plume/vapour cloud
from a point source? Does the release have circular dispersion pattern (dispersing
in all directions)
Atmospheric Conditions
Wind, Temperature, Moisture (precipitation, humidity), Air dispersion
conditions (Inversion or normal), Time of the day (Day or night)
Nature of Release
Whether the hazardous material is being released into air, land or water and
the concentration. Size and potential duration of the release. Rate of release of the
material as well as projected rate (the rare of release may change during the
incident).
Life Safety Factory to Consider During Evacuation
The number and types of people that need evacuation; whether the people are
actually located in an area that contains hazards or in an area that is only
threatened by hazards. The resources need for a safe and effective evacuation.
Population in a Hazardous Area
When considering people who are actually located within a hazardous area the
question remains whether they should remain in doors, rescue a few others or a
general evacuation.
To remain indoors option can be considered when the hazards are too great
and risky during the exposure while evacuation. It may be necessary to rescue
people from the hazardous area, but this would involve supplying, of required
personal protection gadgets to ensure their safety. In case of general evacuation
proper transport has to be arranged to a safe location. Other important factors for
evacuation:
For a safe and effective evacuation the following additional points are to be
taken into account
No of people involved. Where they are located. Their degree of mobility.
Communication facilities. Transportation facilities/barriers. The type of people
whether they are aged, children, women handicapped, prisoners.
Required Resources for Evacuation
Evacuation assistance personnel.
Transportation facilities, like buses, ambulances etc.
Protective gear eg. gas masks, face shield etc. as applicable
Communication equipment (Portable and mobile phones radios, public address
system, bull horns etc.)
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Evacuation tags to the places evacuated and identify cards for the evacuated
personnel.
Emergency Medical Care facilities.
Security requirement
Place for sheltering at safe location
The activities on Evacuation
Information required by Evacuation Assistants.
Specific area to evacuate
Protective gear to be worn
Information to evacuees
Exact transportation arranged
Assistance to exceptional evacuees
Security for evacuated area, the arrangement
Traffic and pedestrian control arrangement
Communicative arrangement
Monitoring the progress arrangements
Emergency medical care arrangements.
Revision points
Bureau of Indian Standards give details of classification accidents based on
agency, unsafe material and physical condition, defects in agency, unsafe act,
unsafe factor. All accidents can be investigated. But for want of time fatal accident
and reportable accidents can be investigated. The purpose of investigation is not to
find fault but to find out the causes of the accidents. Qualified and experienced
officer can investigate the accidents and prepare the report and submit it to the
management. If, in a factory, the release of chemicals or fire are beyond the control,
the workers and nearby factory people are to be evacuated and rehabilitated in a
safe location till the emergency is over.
Preliminary Accident Report
(to be filled in triplicate : 2 copes to be sent to the Medical Officer along with
the injured person and one copy to be retained by the concerned department)
1. Branch or Department and exact
place where the accident or the
dangerous occurrence happened. -----------------------------------
2. Annamalai University
Injured person’s name and address -----------------------------------
3. Injured person’s a. Sex, Age -----------------------------------
b. Occupation -----------------------------------
4. Date and hour of accident or
dangerous occurrence -----------------------------------
5. Hour at which he started work
on the day of accident -----------------------------------
6. a. Facts leading to accident
or dangerous occurrence -----------------------------------
b. if caused by machinery. -----------------------------------
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i. name of the machinery and

part causing the accident -----------------------------------
ii. whether it was moved by
mechanical power or otherwise -----------------------------------
c. what injured person was doing
just before and at the time of
occurrence. -----------------------------------
d. Name of the persons who
witnessed the accident & who
can explain the cause of the accident -----------------------------------
7. Weather first aid given -----------------------------------
I certify that to the best of my knowledge and belief the above particulars are
correct in every respect.
Supervisor/Foreman of the Department (to be filled by the Medical Officer of the
Company)
(One copy of the report is to be retained in the Health Centre and one copy to
be sent immediately to personnel Dept. through the concerned HOD)
1. Nature and extent of injury
(e.g. fatal, fracture or
any disablement or otherwise) -----------------------------------
2. Location of injury (e.g. right leg,
left hand etc.) -----------------------------------
3. Date and time of injured person
reporting at the Dispensary. -----------------------------------
Signature of the Medical Officer

5.7 FIRST AID
Introduction
It is often very difficult to render medical care to victims of injuries, occurring
at industrial environment, construction area etc. The nature of injuries and
infliction may vary widely. This may lead to grave complication and can some times
be fatal. It is therefore necessary to render aid to the victims as soon as possible on
the spot itself and send them for further treatments to hospital. Often proper and
prompt first aid will be the most essential saving factor. Every management should
feed knowledge of first aid methods and facilities to a good number of personnel in
the organization. First Aid boxes, First aid room are to provided as per the
requirement.
Objectives
“First Aid is the immediate and temporary care given to the victim of an
accident or sudden illness by a bystander until effective medical aid arrives”.
First aid person
Suitable persons with adequate numbers and appropriate in the
circumstances, for rendering first aid to the employees if they are injured or become
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ill at work, are to be employed as first aider. For this purpose a person shall not be
suitable unless he has undergone:
 Such qualification and trained (he must be approved by the site incharge).
 Such additional training if any, as may be appropriate in the circumstances of
that case. In practice, (a) refers to trained first aider and (b) to an occupational
first aider. In addition, a person who holds a current first aid certificate issued
by a registered medical association or the Indian Red Cross Society will be
classed as a “suitable person” for the purpose of regulations.
 It must be ensured that atleast one first aider is present when the number of
employees at site is between 50 & 150. Providing additional first aider for
every addition of 150 employees. The first aider must be spread in all shifts for
the coverage of 24 hours.
 In the absence of infirmaries, clinics, hospital, in the proximity to the work
site, properly trained and certified first aid personnel must be available with
first aid supplies.
 Appropriate vehicle for the transportation of injured personnel to a physician
or hospital shall also be provided.
Training:
The first aiders must be given sufficient training atleast in the following:
To determine the nature and severity of injuries
To take urgent steps to control disturbances of heart action and breathing
To stop external bleeding
To bandage wounds
To immobilize injured body parts in case of fractures
To lift the victims properly
To remove the cloths of the victims
To shift the victims to the ambulance
To handle the victims properly
To utilize the materials available in a skilled way at the work site
To handle emergy situation when the affected persons are more.
First aid Box
Regardless of the number of employees there must be atleast one first aid box
on site. Every first aider or occupational first aider should have easy access to first
aid equipment and provision shall be made for every employee to have reasonably
rapid access to first aid box. Each box shall be placed in clearly identified and
readily accessible location and contain a sufficient quantity and suitable first aid
materials and nothing else. Boxes are to be checked frequently to ensure that they
are fully stocked and all items are in a useable condition. Sufficient qualities of
each item should always be available in every first aid room. The first aid box or
cupboard should protect the contents from dampness and dust and be clearly
marked with a white cross, in red back ground. First aid equipment like stretcher
in sufficient numbers may be kept in the first aid room in tip top conditions for use
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at any moment. De dusting at the time of usage is not safe for the victims
movement.
First aid room
Where there are 250 or more persons at the site, a suitably staffed and
equipped first aid room shall be provided.
 Be under the charge of occupational first aider, the names and locations of
all first aiders displayed.
 Be readily available for use and only for rendering of first aid.
 Be clearly identified and of sufficient size to allow access for a stretcher,
wheel chair etc. and to hold a table (cough) with space for people to work
around it.
 Sufficient and all type of dressings must be made available.
 A sink with hot and cold running water, drinking water, towels,
impermeable work surfaces, clean garments for use by first aider, clinical
thermometer, a cough with pillow and blankets (all to be cleaned regularly)
 The room should be kept clean with good ventilation.
 Keeping one medical oxygen cylinder in a usuable condition.
 The approach to the first aid room should not get obstructed or slippery
floor or with bushes etc.
 All the equipments and furniture used in the room must be sturdy so that
at the time of emergency they will not create any further hazard to the first
aider.
First aid treatment
When a first aider is called to an accident spot, there are many important
details, which he must consider immediately and the method he adopts may
considerably influence the future welfare of the patient. His actions must be
modified according to the circumstances and surroundings of the accident. He
must be able
 To determine the nature of the case by carefully considering history,
symptoms and signs.
 To decide on the character and extent of treatment, depending upon the
circumstances and the facilities which are available.
 To arrange for the disposal of the casualty. The speed with which a
casualty is brought under medical care is of tremendous importance in his
recovery.
The first aider must always
 Respond quickly to calls for assistance. The saving of a life may depend on
promptness of action.
 Adopt a calm and methodical approach to the casualty. Quick and
confident examination and treatment will relieve pain and distress, lessen
the effect of injury and may save life. Time spent on long and elaborate
examination of a casualty may be time lost in his ultimate recovery
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 Treat obvious injuries and conditions endangering life such as failure of

breathing, severe bleeding and severe shock before making a complete
diagnosis.
 Whenever possible, the cause of the accident should be removed without
delay.
 Study the surroundings carefully for these may influence the action to be
taken.
 Tactfully control the crowds and make use of bystanders to the best
advantage.
 Reassure the casualty by speaking encouragingly to him.
Golden rules of first aid
 Do first things first, quickly, quietly and without fuss or panic;
 Give artificial respiration, if breathing has stopped; every second counts;
 Stop any bleeding;
 Guard against or treat for shock by moving the casualty as little as possible
and handling him gently;
 Reassure the casualty and those around and so help to lessen anxiety;
 Do not allow people to crowd around as fresh air is essential;
 Do not remove clothes unnecessarily;
 Arrange for the removal of the casualty to the care of a doctor or hospital
as soon as possible.
The advise of a first aider is often sought for a number of ailments and
accidents. They are not a substitute for attention by a doctor or a trained nurse.
First aid treatment of cuts and lacerations
Two of the most common types of injuries, suffered on the job of various
activities in the construction and other industries are cuts and laceration. It does
not take much imagination to visualize most of the sources of such injuries. Each
job has its own hazards that produce these injuries. This is even true of office
personnel, who can be cut by paper edges and punctured by staples, scissors etc.
However, there are more serious injuries. Of these, perhaps, the most likely to
become infected is the deep puncture wound; this is even more likely than the torn
edges of a laceration. But here antiseptics can reach and generally cleanse the
wound. The sources of these wounds may be the protruding nails, screws,
splinters, steel bands, binding wire. Flat metal sheet can have very sharp edges and
the scarp left after cutting sheet metal can cause cuts and punctures.
Hand tools like hammer, chisel, punches, saws, files, drills, screw driver, knife
etc can puncture and cut. Machine tools like grinding wheels, circular saws, stone
cutters, polishers etc. can also cut and lacerate. While doing bending the rods,
straightening rods, handling the rods there are every possibility of laceration.
Probably the most common “cutter” of all is broken glass. The best safety
device for dealing with that hazard is don’t handle any glass pieces with hands. If
they are broken use a broom and sweep it up. Dispose of it in a safe place where no
one else can be injured by it, in addition warn the house keeping crew.
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Good common sense and the rules above will usually keep us safe from cut,
laceration and puncture injuries.
Any injury, however small, must receive prompt treatment. Delay may result in
a minor injury becoming a major one due to infection in the case of a slight wound
or scratch. The first aider must wash his hands thoroughly before treating the
casualty suffering from a cut or wound. The wound should be covered as soon as
possible with a sterlised dressing. If the skin around the wound is dirty or is
contaminated with a water soluble chemical substance, careful washing with clean
water should be carried out. If the wound area is contaminated with a water
insoluble chemical, careful swabbing with cotton wool and surgical spirit should be
carried out, followed by application of a dressing. Sometimes stitching of the wound
may be necessary, hence medical attention must be obtained.
General rules for first aid treatment of wounds accompanied by haemorrhage
(or bleeding):
 The casualty must be placed in a suitable position, bearing in mind that
the blood escapes with less when the patient sits and still less when the
patient lies down.
 Except in case of fractured limb, the part can be raised;
 The blood clot already formed should not be disturbed.
 Any foreign bodies which are visible and can be easily picked out, are to be
removed;
 Pressure must be applied and maintained;
 A dressing, pad and bandage must be applied;
 The injured part has to be immobilized;
Control of bleeding by direct pressure
Direct pressure is applied with the thumbs or fingers, over a pad if available.
When a foreign body or projecting broken bone is present in the wound, the
pressure is applied along side it and not over it. A suitable sized dressing and pad
is applied over the wound, pressed firmly down.
Control of bleeding by indirect pressure
 On a pressure point
 By constrictive bandage (rubber)
When bleeding cannot be controlled by the application of direct pressure, or
when it is impossible to apply direct pressure successfully, indirect pressure is
applied to the appropriate pressure point. A pressure point is one, where an artery
can be compressed against the underlying bone, to prevent the flow of blood beyond
that point.
Rubber constrictive bandage
If it is necessary to maintain indirect pressure for more than a short time, a
constrictive bandage is applied around the limb. It is preferable to use a rubber
bandage, about 1 meter long and about 1 cm wide, with a tape attachment at the
end for fastening. It must only be tight enough to control the flow of blood to the
bleeding part. The bandage can be retightened, immediately if bleeding has not
stopped. When used, the constrictive bandage should never be covered by other
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bandages. A note should always be attached, indicating the time of its application
or last release.
First aid treatment of fractures
 No attempt must be made to move the casualty until the injured part has
been immobilized.
 The injured parts must be steadied and supported at once, so that the
movement is impossible.
 The fracture is immobilized by the use of bandages and by the use of
splints; the bandage should not be applied over the site of fracture. It is
fastened above and below the site of fracture. Ideally, the joints
immediately above and below the fractures are included in immobilization.
The first aider must be prepared to improvise available; hand kerchiefs or
some other suitable material for dressings; firmly folded newspaper,
corrugated paper, broom handles, walking sticks, and odd pieces of wood,
plastic or tubular steel for splints.
First aid treatment of burns and scalds
A burn is often caused by dry heat such as fire or hot metal, contact with any
object charged with electric current, chemicals acids and alkalis, etc. General rules
for the treatment are;
 To avoid handling the affected area more than is necessary;
 To cool the burnt area as quickly as possible by showering in cold water;
 Not to remove burnt clothes except in cases of burns caused by corrosive
chemicals;
 To immobilize the affected area by suitable means.
First aid treatment of asphyxia
 The cause must be removed if possible or the casualty must be removed
from the cause;
 The casualty must breathe freely and to ensure that there is a free passage
for air
 To apply artificial respiration immediately;
 If the heart is not beating, closed chest cardial massage is given in
addition.
In all cases of respiratory failure, immediate first aid action is imperative.
When the respiratory system has failed, life can only be saved by introducing air
(oxygen) into the lungs artificially.
Technique of exhaled air resuscitation, (kiss of life) mouth to mouth (or to
nose) artificial respiration:
Position
The casualty is quickly turned on his back. His head is tilted back to open the
air passages. If a cushion or folded dress or blanket can be placed under the
shoulders without delay, this should be done.
78
Inflation
The casualty’s nose is kept closed by pinching. The operator takes a deep
breath, applies his mouth to the casualty’s mouth and inflates the lungs by blowing
air into the mouth.
Exhalation
When the casualty’s chest rises, the operator removes his mouth and turns his
head to one side to allow air to escape from the casualty’s lungs. The inflation and
exhalation cycle is repeated 10-12 beats per minute, until there are signs of
returning normal respiration. The operator adjusts his breathing to coincide with
the casualty’s returning respiration.
With the mouth to nose method, the mouth is closed during inflation and may
with advantage be opened during the expiratory phase. Where injuries to mouth
and face are apparent, or where cyanide poisoning is known or suspected, then
resuscitation by manual methods such as Sylvester brosche method (chest
pressure arm lift method) or holger vielser method or schafer’s method on artificial
respiration must be done.
First aid treatment of cardiac arrest
The maintenance of life depends on continuing circulation of blood which is
kept flowing by the pumping action of heart. Once a heart has stopped, only
minutes are available before death occurs and no time should be wasted before
taking positive action. The recent introduction of closed chest cardiac massage
offers a real chance of saving the lives of casualties suffering from cardiac arrest.
Technique
If the casualty is not breathing and if there is no improvement after six
inflations by exhaled air resuscitation or other method of artificial resuscitation
used, then closed chest cardiac massage combined with mouth to mouth (or to
nose) resuscitation should be commenced. (Silvester method of respiratory
resuscitation – chest pressure arm lift method – can be combined with external
cardiac resuscitation)
The casualty must be on his back on a hard surface. The first aider feels
quickly for the lower end of the sternum and places the ball of the hand on it, with
the second hand covering the first. After each inflation of the lungs, the first aider
has to apply six to eight sharp presses at the rate of one per second.
Closed chest cardiac massage combined with mouth to mouth (or to nose)
First aid treatment of eye injury
Eye is a most delicate organ and even a slight injury is liable to be followed by
unpleasant complications. Therefore all cases need medical attention.
Foreign body in the eye
There are two kinds of foreign particles which get into the eyes on jobs. One
kind is the material carried by the wind – saw dust, sand cement dust flakes of iron
dust etc. These are not too trouble same. Then there are high-speed chips, which
79
result when one hard material comes in contact with another hard material. Here is
where one need eye protection.
 Driving hardened nails in concrete.
 Running an electric hammer in concrete.
 Drilling, reaming or chipping metal.
 Hammering on a chisel or a steel pin.
 High wind conditions.
 Using solvents etc.
If the foreign body is seen in the conjunctiva and does not appear to be
embedded or adherent to the eyeball, then it can be removed with the corner of a
clean hand kerchief, preferably white, moistened with water. In all other cases, the
person is instructed not to rub the eye. The eyelids must be closed, a soft pad of
cotton wool is applied and secured by a bandage. Medical aid must be obtained.
When a solvent or acid is suspected
Vigorous treatment must be started at once. The eye is irrigated freely with
copious amounts of running water for atleast 10 minutes or till it is felt all solvent
or acid is removed. For this both the eyelids can be kept open and pour good water
at the middle point at the top of nose so that water will irrigate both the eyes
simultaneously. Then the eye should be covered with a pad and bandage and the
patient is sent to hospital.
First Aid Treatment of Fainting
Sudden, temporary loss of consciousness owing to rapidly developing anaemia
of the brain is a frequent complication of various injuries. Fainting occurs with
strong emotional strain and with pain caused by clumsy manipulations during
bandaging or shifting or jolting during transportation.
When the patient faints, he suddenly turns pale, loses consciousness and does
not respond to such external stimuli as calls or pricks. The pulse accelerates and
weakens, the pupils are dilated and when fainting is deep do not respond to light.
Remove the victim from crowds or a stuffy atmosphere. The victim should be
laid flat on his back with his head lower than his feet and his clothings loosened so
as to provide a free circulation of air. He may be allowed to sniff of smelling salt.
Water should be sprinkled on the face. Artificial respiration can be applied.
First Aid Treatment for Bites
Animal Bites: Cleanse the wound immediately with liberal amounts of soap
and running water. Paint with antiseptic, bandage, and see a doctor promptly.
Unpleasant rabies-preventing injections will be necessary unless the animal is
found not to be “mad”. Identify, catch and confine the biting animal if possible. If
the animal dies or is killed, preserve the head. Notify health authorities at once and
follow their directions.
Snake Bites: A victim of poisonous snakebite should be taken immediately to a
medical center where specific antivenom injections can be given.
80
Immediate first aid: make victim lie down and cease all activity. If bite involves
an extremity, tie a constricting band (belt, cloth strip, bandage) above the bite.
Tighten only enough to slow blood flow but not stop it completely. To make sure
circulation is not completely stopped, the band should be entirely loosened for 1
minute every 30 minutes. Apply icepacks or immerse part in ice water if available
(may ease pain and slow spread of venom). Remove the constricting when ice pack
or ice water is applied. Transport the patient to hospital with bitten part hanging
down.
If much time will elapse before expert medical treatment, sterilize a knife and
make small cross-cut incisions about 3mm deep into and around the site of venam
deposit. Apply mouth suction (venom is not poisonous if swallowed). Incision-
suction must be prompt to be helpful. If possible, capture or kill snake for doctor’s
identification.
Insect Stings and Bites : General relief of pain and itching; Hold part under
cold water, apply wet dressings, or cover site with a paste of baking soda. Put the
victim of massive stings by swarms of insects into bath water in which a package of
baking soda is dissolved.
“Stingers” left in flesh by some insects may continue to pump venom. Remove
stinger by scrapping with fingernail in direction opposite to which stinger entered.
Scorpions, Spiders: Apply ice packs to bites. Keep patient quiet, comfortably
warm. Call doctor.
First Aid Treatment for Poisoning
Any substance not used as a food or beverage may cause poisoning when
swallowed. All medicine can be dangerous when accidentally swallowed by children
or adults. This also applies to household cleansers, fuel, garden chemicals and
insect sprays.
Swallowed Poisons: Immediate first aid if patient is conscious: Give large
amounts of water or milk to dilute poison. Then call doctor. If poison is known, tell
doctor and follow his directions pending his arrival.
If poison is unknown or medical help delayed; induce patient to vomit unless
he has swallowed corrosive poisons, probably indicated by burns of mouth.
Warm water usually is the quickest available substance to encourage vomiting.
A teaspoon of salt or a teaspoon of dry mustard to a glass of water enhances emetic
action. Give fluids until vomited material is clear. Put finger in throat to make
patient gag and vomit. Keep head of patient low.
If patient has swallowed strong acids or alkalis, do not induce vomiting. Give
fluids to dilute the poison. If poison is known to be acid, give milk of magnesia or
baking soda in water in weak solution. If poison is an alkali, give vinegar, lemon or
orange juice.
Lebels of poison containers may list antidotes. Give the antidote if it is
immediately at hand, but do not waste time looking for it. For quick action, use
81
common household materials that dilute or neutralize many kinds of poisons: Milk.
Raw egg whites beaten into water. Thin mixture of flour and water. Save the poison
container for the doctor’s information.
Gas Poisoning: The most common cause of inhalation poisoning is carbon
monoxide, an odorless gas, faulty heaters, wood and coal fires. Toxic amounts
accumulate quickly in closed or badly ventilated quarters. Victims become
headache, dizzy, weak, unconscious.
Get the victim into fresh air immediately. If breathing has stopped or is
irregular, give continuous artificial respiration. Have someone notify authorities
that oxygen equipment is needed.
Protect yourself in removing the victim of any gas poisoning to safety.
First Aid Treatment for Electric shock
There are emergency and first aid measures which can minimize the severity of
injury and can even save a life. Shock received by a person can lead to fatal,
paralysis of the body, stoppage of breathing, burns and other impairments. First
and fore most thing to do is free the person from the electrical contact with care. If
a circuit breaker is nearby shutoff the electricity. If this is not possible, use a
electricians rubber gloves, use a stick or woolen blanket or rope or dry paper to
push the victim out of electrical contact. At no time should the victims body come
into contact with your own. Normally electrocuted person will have sweating. If the
victim’s shirt is dry and free, the victim can be pulled out very cautiously.
If the victim is conscious, keep the victim lying down with head turned to one
side, feet up and body in an inclined position. Tightly cover the victim to conserve
body heat. It is better to call a doctor. If the victim is unconscious and has difficulty
in breathing or has stopped breathing, he has probably suffered ventricular
fibrillation. It is essential that life saving steps be undertaken immediately.
Ventricular fibrillation, paralyzes the heart muscle, stopping the pumping of blood.
Brain damage results when the brain is deprived of oxygen.
Following steps are to be taken immediately:
 Loosen all clothing at waist, chest and neck. Remove false teeth, tobacco, etc.
from the mouth, if any, to make the tongue free.
 Support the casualty’s head with palm and tilt it backwards. By this action,
tongue may come to the position and the victim may begin to breathe.
 If breathing is not received, resort to mouth-to-mouth resuscitation.
 If the above is not possible due to injury in the face, call a doctor or trained
person to give artificial resuscitation.
For superficial burns, apply water or dip the affected part in cold water till the
pain subsides. Remove jewellery or metal worn near the affected part, before it
starts swelling. Do not bust open the blisters. Never apply oil, ointment or home-
made medicine. For serious burns, arrange medical aid immediately.
82
Revision
First aid is the care given to the victim by the available person nearby till
medical assistance is got. Person with qualification and training can give first aid
treatment. The first one hour after accident is the very vital period. The treatment
given within one hour after the accident is the golden hour of treatment. The
important golden rules of first aid is “Do first things first, quickly, quietly and
without fuss or panic and speaking encouraging words to the victim.”
Summary
Accident investigation report will contain the event, the elements and sources
from which accident developed, analyzing the accident factors to find out causes
and remedial measures to eliminate such even in future.
First aid is indeed a most important branch of medical science, one in which
the layperson has a worthwhile and rewarding part to play. The growing publicity in
recent years associated with accidents on the roads, in the factories, at home and
at play, is arousing the public conscience and increasing the demands for first aid
training. Gone are the days, when first aid training was a dreary process of learning
about tourniquets, pressure points bandages and splints only. Today it is learning
about the human body, how it works and what can be done to protect it from the
hazards of its environment and safeguard it from further damage, when things go
wrong. Every accident is different and every injured human being responds
differently to injury or illness. There is no rule of thumb procedure in first aid; just
certain basic principles which must be learnt and adapted with compassion and
understanding to each occasion.
It must be clearly understood that the first aid has its limitations, and any
attempt at more ambiguous treatment may prove harmful to the patient. However,
there is still and enormous field in daily life for valuable and useful service in the
practice of first aid. Knowledge in first aid is progressive achievement; basic first aid
must be taught to all and the medical profession must ensure that the training in
first aid is in keeping with modern techniques of treatment for injury and sudden
illness.
5.8 QUESTIONS
1. Write short notes on : Accident, Reportable accident, Non reportable
accident, Near Miss.
2. What are the classifications of accident and give examples?
3. What is the Principal purpose of accident investigation?
4. What are the steps to be followed in the accident investigation?
5. List out essential question can be asked while investigating the accidents
6. What are the various types of analysis? Explain each of them
7. Prepare a model accident report.
8. At what circumstances evacuation of workers and near by people are to be
done?
83
9. What are the required resources and information for the evacuation
assistants?
10. Write short notes on : First aid box, First aid room, First aid treatment.
11. What are the golden rules for First Aid?
12. What is the First aid treatment for Cardiac arrest?
13. What is the First aid treatment for Electrical Shock?
5.9 ASSIGNMENT
 Prepare a model of plant safety inspection of sulphuric acid plant.
 Prepare a check list to conduct a safety audit in a Thermal Power Station.
 Discuss Case study to conduct an accident investigation.
Accident in a Packing Section
The accident occurred in a Packing Section of a firm.
The packing processes carried out in this section involved the use of paper,
straw, woodwork, glue and all the items which contributed making a messy sort of
shop.
A worker was available for cleaning in the section. He was used for other works
also, but this was regarded as his main job.
The shop was constantly getting dirty and was frequently being cleaned by the
worker.
He swept the rubbish & kept into small piles in the gangway.
He then showelled the rubbish into a wheel barrow which he normally wheeled
to the end sliding door and emptied into the bin kept there.
This end door was rarely used by any person other than this worker.
Over a period of fifteen days, the sliding door became increasingly difficult to
open. The worker reported this to the supervisor.
One Monday morning at about ten 0’clock, the supervisor heard that the
General Manager, accompanied by some visitors, would visit the section in the
afternoon.
He took a quick glance around the section and noted that there was a pile of
rubbish at the end of the shop.
He told the worker to get rid of its quickly as the General Manager would be
coming at “any moment”.
The worker told the supervisor not to worry, he would move the rubbish right
away.
He went to work with a will and overloaded the wheel barrow in order to get
the rubbish out in one barrow load.
While the barrow was being loaded the supervisor noticed something else i.e.
an empty box case in the central gangway.
84
The supervisor then looked for a packer named Sri Govind who has been told
to remove the case on the previous day evening. Sri Govind had gone to the
canteen, so the supervisor decided to await for his return.
While he did so, he noticed the worker hurrying through the central gangway
with a barrow load of rubbish.
The worker looked like having grievance and the supervisor concluded that it
was because he had failed to repair and open the end door and was having to use
the longer route to the bins. He made a mental note to get something done to repair
the door as soon as the visit of VIP is over.
When Sri Govind returned from the canteen, the supervisor reminded him that
he had been told on the previous day to remove the box. Would he please do it now
before someone tripped over it?
Sri Govind, quite apologetic about it, lifted the box, in order to carry it to his
bench.
After taking about two steps, his feet slide, in trying to save himself, his left
hand trapped in between the box and a bench.
Immediately the supervisor asked him to go the hospital with another worker
in a cycle. His hand was lacerated and bruished Sri Govind did not go immediately
& told he will go after the visit of General Manger. The visitors came in the
afternoon at about 3 p.m. Sri Govind then went to the hospital for treatment. He
was off the work for the next three days.
It was quickly seen that he had stepped on a small glue brush which had
previously been part of the load of rubbish at the end of the shop.
 Enumerate what will be the role of first aider in a chemical factory accident in
which more number of workers injured.
REFERENCE BOOKS
Loss prevention in the process Industries – Frank P. Lees, Butterworth
Heineman Publications, London.
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SRIVATSAN: Re-print on 15.10.

Diploma in Industrial Safety

LOSS PREVENTION TECHNIQUES AND

DIPLOMA IN INDUSTRIAL SAFETY

DIPLOMA IN INDUSTRIAL SAFETY

UNIT PAGE NO.

There are three important components in the process of achieving efficient

1.2.1 Objectives of Safety Organizations

 To provide all concerned with the information, intimation, training to

1.2.3 Safety Director’s Functions

 Authority, including a budget, if any, afforded the committee

General Manager Works Manager Personnel Manager

Fig. 2 Illustration of Executive Committee

Fig. 3 Illustration of Technical Committee

A schematic chart showing the Central Safety Committee with the

CENTRAL SAFETY COMMITTEE

Chairman Secretary Members from

Fig. 4 Illustration of Central Safety Committee

 Training activities indirectly demonstrate company’s interest in employees

 Understanding the importance of safety and hence following safe work

 Knowing the techniques of fire fighting, first-aid, lifting, stacking, crane

Topic Safety Orientation Training Programme for New Engineers

Level of Participation New Graduate Engineers

No. of Participants Not more than 25

Immediate follow-up Internal

Apart from these, training programmes on specific areas like fire

 Trying short-cut methods to finish a job quickly

2.3.6 Vocational Guidance and Counselling

2.4.1 Theories of Motivation

 Existence – physiological needs, pay, working condition, job security

Ultimately, the application of these theories resulting in

Defining the problem

3. Remove duplicate events within sets.

Controller dam aged High voltage in power

Flow controller falls

Flow controller f ailure causes

Level in tank ris es

Wire broken Valve seized

1. Frequency of Accidents: A job that has repeatedly caused accidents is a

Is there a potential for a slip or trip?

Is housekeeping satisfactory with no debris and tripping hazards?

ABC Company Department:

Withdraw strapping and Sharp edges of strapping Wear gloves, eye

Insert,position,and Springly and sharp Keep firm grasp on strap

1974,Three mile island-1979,Bhopal-1984,Mexico city-1984,Chernobyl-1986.It was

HAZOP fits in the Process Safety Management System in two areas:

Check the operator can know the deviation is occurring.

4.2 PLANT SAFETY INSPECTIONS

 Inspections for investigation of accidents to determine causes.

 Action to be taken in the event of a noticeable incident

 Interrupt the tour whenever a hazard or safety problem is recognized, to

Leadership and Administration Emergency preparedness

 Identification of the reference documents against which the audit was

management through the self-evaluation portions of the measurement process will

 Involvement of Employees in Safety Activities.

 Classification according to unsafe material or physical conditions. This identifies

 Classification according to the location of the injury: Location of injury identifies

few hours may allow material information to be erased intentionally or

At times, in view of the public interest, statutory committees may be set up to

5.4 INVESTIGATION REPORT

What safety rules were violated?

 Copies of any rules or procedure which may apply

designed operation. A question can be put as to how different departments of the