INDUSTRIAL SAFETY

MODULE 1

Presented by,
Aravind Appanna K E
Assistant Professor
Dept. of Mechanical Engineering
INTRODUCTION TO SAFETY

 Safety is a very important aspect of any particular activity

 Industrial safety is a branch of management which is concerned with reducing, controlling and
eliminating hazards from industries or industrial units.

 Industrial Safety refers to protection of worker from the danger of industrial accidents.
OBJECTIVES OF SAFETY AND SECURITY MEASURES

 To achieve 100% safety and 100% security of installations, equipment, human life and animal life
 To bring awareness about safety rules
 To educate personnel
 To prevent accidents by reducing the hazards to minimum
 Study of unsafe acts and unsafe conditions leading to accidents. To take corrective measures to eliminate them
 To ensure first aid and emergency help in case of accident
 To understand the cause and effect relationship in accidents associated with any system
 To establish safety management system, safety audit system
TERMS USED

 ACCIDENT: An unpleasant, unexpected, unforeseen or unintended happening sometimes resulting from

negligence, that results in injury, loss, damage, etc., and is caused by mistake or machine failure or natural disaster
 SAFETY: A quality or condition of being safe from ‘danger, injury, damage, loss, accident’.
 HAZARD: To expose to, ‘danger, risk, chance of accident’. Hazard is a term associated with a substance that will
cause an injury in a given environment or situation.
 SAFE: Free from injury, damage, accident, loss’.
 SAFETY DEVICES: Devices which ensure safety against injury or loss.
TERMS USED

 SAFETY GUARD: Any person or thing or devices that prevents injury, loss and ensure safety and security.
 SECURITY: State of sense or safety protection or defence against attack, interference etc.,
 PRECAUTION: Care or measure taken beforehand against possible danger.
 CAUTION: a) A word or sign by which warning is given
b) Act or practice of being cautious.
 APPLIANCE: Device which performs specific task
Example: Stove, Heater etc.
SLIP, TRIP AND FALL

 Too little friction or traction b/w feet and walking surface resulting in loss of balance

 Foot or lower leg hits object, & upper body continuous moving, resulting in loss of balance

 Move from a higher to a lower level, typically rapidly and without control.
LADDERS
SCAFFOLDS
FACTORS THAT CONTRIBUTE TO FALLS FROM LADDERS ARE

 Ladder slips (from top or bottom)

 Slipping on steps
 Defective equipment
 Improper ladder selection for a given task
THE WORKERS SHOULD BE KNOWLEDGEABLE OF THE
FOLLOWING WHEN USING LADDERS

 Visually inspect for structural damage such as, split/bent side rails, broken or missing steps
 Damaged safety devices such as rung locks
 Safety shoes/feet
 Grease, dirt or other contaminants that could cause slip
 Paint or stickers that could hide possible defects
LADDER CLIMBING GUIDELINES

 Wear slip-resistant footwear

 Keep the area around the top and bottom of the ladder clear
 Wear approved fall protection equipment where applicable
 Never carry large objects while ascending or descending a ladder
 Keep both hands free for climbing or coming down
 Face the ladder and maintain three point contact i.e., two hands and one foot or one hand two feet on the ladder
 Do not overload the ladder
HAZARDOUS ENERGY CONTROL (OR LOCKOUT/TAGOUT)

 Hazardous energy is defined by the Canadian Standards Association (CSA) as: "any electrical, mechanical,
pneumatic, chemical, nuclear, thermal, or other energy that can harm people"
 "Lockout/tagout" refers to specific practices and procedures to safeguard employees from the unexpected
energization or startup of machinery and equipment, or the release of hazardous energy during service or
maintenance activities
 A lockout uses a lock to hold an energy isolation device in a safe position and prevents the energization of the
machine or equipment.
 Tagout is when a tag is placed on a piece of equipment to indicate that the equipment being controlled may not be
operated until the tagout device is removed.
LOCKOUT/TAGOUT PROCEDURE

 Notify all affected employees that a lockout is required and the reason therefor.

 If the equipment is operating, shut it down by the normal stopping procedure (such as: depress stop button, open toggle switch).

 Operate the switch, valve, or other energy isolating devices so that the energy source(s) (electrical, mechanical, hydraulic, other) is
disconnected or isolated from the equipment.
 Lockout energy isolating devices with an assigned individual lock.

 Stored energy, such as that in capacitors, springs, elevated machine members, rotating fly wheels, hydraulic systems, and air, gas,
steam or water pressure, must also be dissipated or restained by methods such as grounding, repositioning, blocking, bleeding down.
 After ensuring that no personnel are exposed and as a check on having disconnected the energy sources, operate the push button or
other normal operating controls to make certain the equipment will not operate.
 The equipment is now locked out
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)

 With the Occupational Safety and Health Act of 1970, Congress created the Occupational Safety and Health
Administration (OSHA) to ensure safe and healthful working conditions for workers by setting and enforcing
standards and by providing training, outreach, education and assistance.
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION (OSHA)
MATERIAL SAFETY DATA SHEET (MSDS)

 A material safety data sheet is a technical document which provides detailed and comprehensive information on a
controlled product related to:
a) Health effects of exposure to the product
b) Hazard evaluation related to the product’s handling, storage or use
c) Measure to protect workers at risk of exposure
d) Emergency procedures.
 MSDS are to be provided by Supplier’s with all deliveries, must be Accessible to EVERYONE in the workplace.
MATERIAL SAFETY DATA SHEET CONTENT

 Hazardous Ingredients

 Preparation Information

 Product Information

 Physical Data

 Fire and Explosion Hazard

 Reactivity Data

 Toxicology Properties

 First Aid Measures

MATERIAL SAFETY DATA SHEET
CONTENT
SAFE MATERIAL HANDLING AND STORAGE

 The basic facts with respect to material handling

 Factors influencing selection of handling materials:

 Mechanical aids/equipment

 Unsafe work habits

FIRE SAFETY
MODULE 2

Fires kill several hundred persons and destroy property worth several crores of rupees
every year. More than 85% of fires in various types of plants/ building/hotels/ shops/
godowns etc. are caused by electrical sparks or short circuits
FIRE SAFETY

Several preventive, protection and fighting aspects and human safety aspects should be considered in the
workplace
 Safe escape of personnel in the event of fire
 Fire fighting and minimizing loss to life and property in the event of fires
 Safety of personnel from fire and poisonous gases and smoke
 Minimizing spread of smoke and poisonous gases
 Emergency operations and first aid facilities
TERMS AND DEFINITIONS

Fire: Active rapid burning and oxidation process accompanied by heat, light and poisonous gases/Smoke/ carbon
dioxide gas due to combustion.
Extinction of fire: Putting off of fire by removal of Combustible material
Fire fighting. Action of putting off the fire.
FUNDAMENTALS OF FIRE
INITIATION OF FIRES

Initiation of fire requires

 (1) Heat and hot spot
 (2) Air and
 (3) Flammable material.
CAUSES OF INITIATION OF FIRES

Fires in electrical power station are caused by the following:

 Electric Arcs, Flash Overs, Short Circuits.
 Loose connections resulting in sparks.
 Welding sparks
 Bursting of capacitor cans
 Fires and Explosions in oil filled Equipment.
 Fuels for power generation
TYPES OF FIRES

 According to European and US Standards, Fires are classified into five classes: A, B, C, D, E on the basis of the
material involved in the fire. The type of fire extinguishing technique recommended differs with the class of fire.
 Water is used as quenching medium for class A fires. Water is not suitable for Class B, class C, Class E fires.
TYPES OF FIRES
Fire Class Combustion Material Involved
Class A Fires involving Ordinary solid materials Such as wood,
coal, plastics, cloth, paper, Rags, Rubbish, Construction
and packing materials, Rubber, etc.
Class B Fires involving Flammable Liquids/vapours/ solvents:
Transformer oil, Diesel oil, solvents, Liquid chemicals
Lubricating oils, paints/varnishes/thinners Greases.
Class C Fires involving live Electrical Equipment, in Energised
state If equipment is dead class is A or B.
Class D Fires involving live Electrical Equipment, in Energised
state. If equipment is dead class is A or B.
Class E Fires involving Flammable Gases and Fuels, Hydrogen,
Ammonia, Acetylene, LPG, Petrol, Furnace Oil
Fire Extinguishing Medium
Water or solution with high water content cooling and wetting of
materials helps in quenching the fire
Limiting air or oxygen supply, inhibiting fire Dry chemicals, Foam,
halon. Water is not suitable.
CO2 gas, Dry chemicals. Water is not suitable.
Normal extinguishing media not suitable. Special chemicals and
techniques are used.
Starvation of fire is most useful.
Example: Gas fires can be stopped by closing of gas inlet valve
at supply end
FIRE-EXTINGUISHING TECHNIQUES

 Cooling.
 Water
 Ventilation
 Starvation
 Breaking Chain Reaction of Fire
FIRE HAZARD ANALYSIS

 A detailed fire hazard analysis should be carried out during initial plant design. This analysis should be revised
periodically as design and construction progress and before and during major plant modifications.
FIRE HAZARD ANALYSIS

(a) Concentration of combustible materials, including transient fire loads due to combustible expected to be used in
normal operation;
(b) Configuration of combustible contents, furnishings, building materials, or combinations thereof conducive to fire
spread;
(C) Exposure to fire, heat, smoke, steam that may necessitate evacuation form areas that are required to be attended
for safety functions;
(d) Fire in control rooms or other locations having critical safety related functions;
(c) Lack of adequate access or of smoke removal facilities that impede fire extinguishment in safety related areas;
(f) Lack of explosion prevention measures;
(g) Loss of electric power and
(h) Inadvertent operation of fire suppression systems.
PREVENTION OF FIRE

 Safety documentation for plant and equipment should include safety Instructions related to Fire
Prevention.
 Fire prevention Equipment and subsystems must be a part of plant and Equipment.
Fire should be prevented during storage, civil works, Installation, testing, commissioning and operation maintenance.
Fire prevention is better than fire fighting
PREVENTION OF FIRE

 The prevention of fire aims at not allowing the conditions leading to combination of

(1) Combustible material (2) Air and (3) Heat and local temperature rise (4)Spark/ignition.
PREVENTION OF FIRE
 Inflammable explosive materials should be stored separately and should be handled, stored, used by using
necessary precautions. Such material should be guarded against exposure to flames, sparks, arcs, flash-overs,
intense heat, hot spots, hot air
 Insulating materials in the plant and equipment must not be exposed to (1) high local temperatures (hot spot
temperatures) beyond certain permissible limits (2)sparks (3)Arcs (4) Flash-overs (4)Welding sparks.
 Special precautions should be taken while welding, carrying open flames so that fire is not initiated.
 Smoking, open flames and matchboxes, inflammable materials, explosive materials, open resistor heaters should
not be allowed inside protected area of electrical plant and control room. Smoking must be permitted only in
special areas. Cigarette buts must be carefully extinguished
 Special precautions are necessary while handling, storing, filling, drying-out transformer oil, furnace oil, fuels,
circuit breaker oil, capacitor-fluid, paints, chemicals, explosive gases like oxygen, hydrogen, acetylene. Smoking,
open flames and matchboxes, inflammable materials, explosive materials should not be allowed to be taken inside
protected area of stores and near inflammable materials.
PREVENTION OF FIRE

 LPG cylinder, Acetylene cylinder valves/pipes/tanks should be leak free. Gas cylinders must be stored separately as per
safety recommendations.
 Inflammable material should not be used in electrical equipment as far as possible. Modern non-explosive/ fire-free
equipment must be preferred (e.g. Dry transformer in place of oil filled transformer SF6 circuit breaker in place of oil circuit
breaker. Inflammable material should not be used in civil construction as far as possible.
 Electrical equipment should not be overloaded. Over load protection, over current protection, temperature rise protection,
temperature monitoring must be provided with oil filled equipment and electrical machines having inflammable. Insulation.
 Good housekeeping goes a long way to prevent fires scrap, waste papers, waste wood, waste oil should be disposed off.
Leakage should be attended immediately.
 Precautions are necessary in storage, erection, testing, commissioning, operation and maintenance that fires are not initiated
due to carelessness.
 Precautions are necessary while welding, heating, flame cutting, grinding, drying etc, to eliminate initiation of fires.
FIRE PROTECTION AND LOSS PREVENTION

Civil Works
 The civil design should have following provisions.
 Inflammable material should not be used in civil construction.
 Adjacent rooms should be air tight from each other.
 Fire and smoke from one room should not spread to other room. Heat and smoke should go out of the building.
 Ventilating ducts, air conditioning ducts etc. should have barriers so that smoke and flames do not get transferred from one section to next.
 Space and approach path should be available for firefighting personnel.
 Wiring and switchboards should not initiate fires.
 Provision of Fire Fighting system and Fire Detection system must be made during civil Design and construction.
 Special provision must be made for drainage of oil away from the plant into the oil sump during outbursts.
 Passage, staircase and ladders should be provided for emergency escape for personnel and for Rescue-Fire fighting squad.
 Approach road and space must be provided for Fire Engines and Ladders.
Electrical Plant and Equipment
 Temperatures of current carrying paths and insulating paths are not allowed to exceed above specified limits by
supervision, Monitoring, Automatic over Load protection etc, Temperature monitoring, Gas Leak Monitoring,
Automatic start of Cooling Fans,
 Fire protection systems. Fire/Smoke/Flame/High temperature are detected, portable extinguishers can be used for
small fires, alarms are initiated so that people can immediately vacate the premises, fire extinguishing system is
put into action mode, fire bridge is called.
FIRE PROTECTION

Water system
 Water sprinkler system
 Water mist system
 Fire hydrant system
FIRE PROTECTION

 Fixed Foam system

Fixed foam systems are automatic, totally self-contained and require no manual intervention for operation. These
systems are installed to protect areas where large quantity of flammable liquid is stored.
 Gaseous System

Fire suppression system that uses gas as the extinguishing medium is of two types-Carbon dioxide and halon. The
halons are used as fire extinguishing agents, both in built-in systems and in handheld portable fire extinguishers
 Portable fire Extinguisher
PORTABLE FIRE EXTINGUISHER

 Water is used as the extinguishing medium and is applicable to all fires, Class-A involving ordinary combustible
such as wood, paper, cloth, rubber and the like. Foam, Dry chemical powder (DCP)
 Class-B fire involving flammable liquids, paints, solvents and the like CO 2 and DCP are used as extinguishing
medium for fires
 (Class-C/D) involving fire in gases including liquefied gases. Special type of dry chemical power such as Ternary
Eutectic Chloride (TEC)/Graphite based/Bi-carbonate based powders should be used as extinguishing medium for
fires
STEPS AFTER OCCURRENCE OF FIRE

 Fire Occurs
 Fire is Detected by Observer or Detection System
 Alarm is sounded
 Electric Power supply and Other Fuel Supplies are switched Off
 Immediate Use of portable Fire Extinguishers and Water/sand for Extinguishing small Fires then and there
 Automatic Fire Fighting system Gets Initiated
 Call Fire Brigade.
 Persons vacate the place.
WATER TYPE FIRE EXTINGUISHERS

SODA ACID TYPE-WATER EXTINGUISHERS

 Soda acid type IS:934-1979

 Gas pressure actuated type IS:940-1976
 Constant Air pressure Type IS:6234-1971
 FOAM EXTINGUISHERS

Foam are recommended for class B fires involving flammable liquids like oils, solvents, petroleum products, varnishes,
paints, etc.
 Sodium bicarbonate (NaHCO3, baking soda),
potassium bicarbonate (KHCO3, nearly identical to
baking soda), or monoammonium phosphate
((NH4)H2PO4)

Dry powder fire Extinguishers are suitable for tackling petroleum fires, gas fires, fires in electrical equipments and for
controlling surface fires in textile fibers.
CARBON DIOXIDE FIRE EXTINGUISHERS

CO2 is non combustible and does not react with most substances. Being a gas it can penetrate and spread to all areas
affected by fire.
TYPES OF FIRE DETECTORS

 Fusible glass bulb detectors

 Rate of temperature rise detector
 Heat sensitive cables
 Heat sensitive cables
MODULE 3

Mechanical Safety
 Machine tools
DRILLING MACHINE
POWER SAWS
BAND SAW
GRINDING MACHINE
FORGING MACHINE
WELDING
PRESSING MACHINE
SAFETY WHILE MATERIAL HANDLING

 More than 50% of the total number of accidents resulting injury or property damage are caused during material
handling in engineering industry
 Attempts to be made to reduce material handling to the minimum as it does not add any cost
 Material handling does not add any value
 Material handling accounts for 36% of production costs
 Nearly 50 to 100 tons of material are handled and re-handled for every one ton of finished product
 About 2/5th of manufacturing cycle time is spent on handling
 About 20-80% of the total labour cost go to labour used in handling
 Between 30-40% of industrial accidents are caused while handling materials
Factors influencing selection of handling materials:
 Weight
 Size
 Shape
 Rate of handling
 Distance to be moved
 Purpose of moving
 Obstacles if any in the pathway
Mechanical aids/equipment:
 Hand tools, Example: hook
 Rollers for dragging or sliding
 Trucks and tractors
 Hoisting apparatus
 Overhead travelling cranes
 Conveyors
 Shovels
 Elevators and escalators
 Pipelines/pumps for liquids
Steps for Manual Lifting
 Keep feet apart to give a balanced and stable base for lifting
 Bend the knees so that the hands are as near to the waist as possible
 Keep the back straight, chin tucked-in, lean over the load if necessary [Shoulders in same direction as hips]
 Try to keep the arms within the boundary formed of the legs
 Carry out lifting smoothly without jerk
 Then adjust if precise positioning is necessary
 Give a command to gain group efforts in synchronized ways
FORK LIFT

 Qualified Operators Only

 Daily Inspections
 Plan According to the Operating Environment
 Maintain Load Stability
 Respect Forklift Capacity
 Maintain Clear Visibility
 Follow Company Safety Rules and Procedures
 Cross Pedestrian Areas Carefully
 Refuel Safely
 End the Shift Properly
CHAIN PULLEY BLOCK
ELECTRIC OVERHEAD TRAVELLING – EOT CRANE
COMPRESSED GAS CYLINDERS
ELECTRICAL SAFETY

 Electricity is very useful and has become essential in modern life. Electricity is used in houses,
factories, public places and practically every working place for lighting, operating appliances and
machines, transport etc.
DANGERS FROM ELECTRICITY ARE DUE TO

 Electric shock resulting in burns, injury, deaths

 Explosions in electrical equipment resulting in damage to installations and deaths
 Electric faults resulting in arcing, explosions and fires
 Electric flashovers resulting in fires, damages, deaths
 Fire hazards
SAFETY MEASURES

 The safety inspectors check the design, equipment, installation operation and maintenance from electrical safety
and general safety requirement and recommend necessary modification, improvements before giving safety
clearance.
OSHA STANDARDS ON ELECTRICAL SAFETY

 OSHA standards focus on the design and use of electrical equipment and systems. The standards cover the
exposed or operating elements of an electrical installation such as lighting equipment, motors, machines,
appliances, switches and enclosures requiring that they be constructed and installed to minimize workplace
electrical dangers.
 Also the standards require that certain approved testing organizations test and certify electrical equipment before
use in workplace to ensure it is safe.
BASIC ELECTRICAL SAFETY RULE AS PER OSHA

 Live parts shall be de-energized before working on or near them.

 Even after the exposed parts have been de-energized, they shall still be treated as energized until they are locked-
out and tagged-out
 Competent personnel should carry-out repair or maintenance work

An electrically safe work condition will be achieved and verified by the following process:
 Determine all possible sources of electrical supply to the specific equipment
 Open the disconnecting devices for each source
 Apply lockout/tagout devices
 Use voltage detector to verify they are de-energized
HAZARDS ASSOCIATED WITH ELECTRIC CURRENT AND
VOLTAGE

 Electric Shock
 Falling of persons from height due to shocks or flashovers
 Falling of overhead parts such as conductors, tools, welding sparks, structure members on human body
 Fire caused by electric loose connections, electric arcs, short circuits, electric flashovers
 Release of poisonous liquid/gases
 Natural disaster such as lightning, earthquakes, land-slides
 Sparks in electrical equipment installed in explosive atmosphere (mines)
 Mechanical Accidents due to failure of electrical machines
EFFECT OF ELECTRICAL CURRENT ON THE HUMAN BODY

Electric shock occurs when the body becomes part of an electrical circuit. Shocks can happen in three ways.
 A person may come in contact with both conductors in a circuit
 A person may provide a path between an ungrounded conductor and the ground
 A person may provide a path between the ground and a conducting material that is in contact with an ungrounded conductor

The extent of injury accompanying electric shocks depends on three factors:

 The amount of current conducted through the body
 The path of the current through the body
 The length of time a person is subjected to the current

An electric shock can injure you in either or both of the following:

 A severe shock, can stop the heart beat or results in breathing difficulty
 The heating effects can cause severe burns, at points where the electricity enters and leaves the body
Sl. Part of
PPE to be used Protection against
No. Body
Head i) Fibre Helmet i) Fall of objects, hitting against falling objects
ii) Electrical resistance Helmet ii) Shock when working on electrical lines
1.
iii) Welders leather cap iii) Falling of molten slag during overhead welding

2. Face i) Plastic face shield i) Chemical splashing, striking of dust particles

ii) Welding shield ii) Welding fumes, sparks
iii) Asbestos hood iii) Radiation of heat in furnace work
3. Eye i) Panorama goggles with plastic visor i) Oil and paint splashes, dusts, chip entries
ii) Leather masks, goggles ii) Foreign bodies entering eyes and against smoke
iii) Spectacle type goggles iii) While working on machines
iv) Panorama goggles with green plastic visor iv) Reflected arc during arc welding
v) Gas welding goggles v) Gas welding and gas cutting
vi) Acid and alkali proof rubber goggles vi) Splashes of corrosive substances like acid, alkalies, chemical substances

4. Ear Ear plugs and muffs High noise levels (e.g. 110dbs)
5. Nose i) Dust proof respirator Against dust particles
ii) Heavy fumes mask Against acid fumes, gases
6. Body i) Leather aprons Falling of hot chips
ii) Asbestos aprons Heat radiation
iii) PVC apron Splashing of chemicals
iv) Lead apron X-rays and gamma rays
v) Safety belts Falling of persons from height
7. Hand Leather gloves i) Cuts due to handling
Asbestos gloves ii) Heat radiation
Rubber gloves iii) Burns due to handling of acids
Electrical resistance gloves iv) Electrical shock
Canvas gloves v) Contact with oil, grease and other dirt
Hand sleeves vi) Falling of hot slag during overhead welding
Lead gloves vii) X-rays and gamma rays
8. leg i) Leg guard Welding sparks
ii) Leather safety boots Striking against objects, fall of objects from heights, stepping on sharp and hot objects
iii) Asbestos safety boots Heat radiation, Striking against objects, fall of objects from heights, stepping on sharp and hot objects
iv) Gum boots Mud, dirty floor, chemical liquids
MODULE-5
CHEMICAL SAFETY AND OTHER SAFETY CHECKS

Chemicals are all around us.

 In the food we eat.
 The clothes we wear.
 The vehicles we drive.
 In the products we use every day.
 Chemicals can help us live better lives; otherwise, they can harm us.
The main routes of entry of the chemicals into the human body are:
 Inhalation into lungs.
 Absorption through skin membrane/cuts in the skin.
 Ingestion via mouth into the gastrointestinal system.

Typical examples are sulfuric acid, nitric acid, potassium hydroxide (caustic potash), sodium hydroxide (caustic
soda), bromine and phenol
 Corrosive substances causes destructive burns on the tissue by chemical action at the site of contact.
 Corrosive effect can also occur in the respiratory tract in case of inhalation and in the gastrointestinal tract in case
of ingestion
LABELING OF CHEMICALS

Material Safety Data Sheets (MSDS) are one of the most important tool for providing information, and protection to workers from
hazardous chemicals which are used the workplace
 Identity of the chemical
 Physical and chemical characteristics
 Physical hazards
 Chemical hazards
 Primary routes of entry
 Target organs affected
 Emergency procedures
 precautions for safe handling and use
 Date of preparation
 Name, address and telephone of the manufacturer
HANDLING OF CHEMICALS

 All chemical bottles must be tightly closed after use and must not be placed on edge of the bench or shelf from which they can
fall.
 Bench tops must not be used as storage area to prevent clutter. Keep only chemical bottles that is for immediate use on bench
tops.
 Chemical formulae or short forms must not be used for labeling chemical bottles.
 Labels must include the full name of the chemical, hazard pictogram and a brief description of the hazards and precautions to
be taken.
 It will not be possible to identify the chemical in case of a spill or body contact due to inadequate labeling.
 Worn out labels must be immediately replaced by new ones. Unlabelled chemical bottles can create difficulty at the time of
disposal of chemical bottle.
 Chemicals must not be stored in drinking water bottles.
 Transporting chemicals
EYE WASHERS AND SHOWERS

 An emergency eyewash and safety shower station are essential equipment for every laboratory that uses
chemicals and hazardous substances needs. Emergency eyewash and safety shower stations serve the purpose of
reducing workplace injury and keeping workers away from various dangers. Also, to avoid the chemicals that can
cause further harm to the body.
ACID (FUME) HOODS

 Inhalation is a major route of entry of chemicals into the body. Chemical

fumes and vapours can directly enter our bloodstream and small particles
can lodge in our lungs. A properly designed and operated fume-
hood reduces exposure to hazardous fumes, vapours, gases and dusts.
SAFETY THINKING

A common and simple example has been selected to explain the most desired concept- Safety Thinking
An effort has been made to recall the concepts described in book with modified captions to suit the very purpose of
this guidebook.
We have to LOOK for and THINK of:
 What can go Wrong? Watch and Identify.
 How big the consequences well be?
 How often it will occur?
 What is the remedy?-Solution.
 What should we do?
 How to prevent recurrence?
QUESTIONS TO ASK DURING ACCIDENT INVESTIGATION

What equipment failed?

 How can we prevent failure or make it less likely? What material leaked (exploded, decomposed etc)?
 How can we detect failure or approaching failure?  How can we prevent a leak (explosion, decomposition
 etc.)?
How do we control failure (i.e., minimise
conseguences)?  How can we detect a leak or approaching leak(etc)?
 What does this equipment do?  What does this material do?
 What other equipment could we use instead?  Do we need so much of it?
 What could we do instead?  What material could we use instead?
 What could we do instead?
QUESTIONS TO ASK DURING ACCIDENT INVESTIGATION
Which people could have performed better?
 (Consider people who might supervise, train, inspect, check or
design better as well as people who might construct, operate and 
maintain better)
 What could they have done better?
 How can we help them to perform better?
 (Consider training, instructions, inspections, audits etc . as well
as changes to design.)
What is the purpose of the operation involved in the accident?
 Why do we do this?
What could we do instead?
 How else could we do it?
 How else could do it
 When else could we do it?
 While procuring the answers, the team leaders need to avoid
accepting negative answers such as ‘Nothing’ or “we can’t’.
Instead they can guide the team into constructive thinking by
adding to the question or making the questions more leading.
SAFETY POLICY AND OBJECTIVES OF A COMPANY

 When a person enters a company, he has a right to expect that he will be provided with a proper place in which to
work, safe machines and tools to do his job, and safe methods of operations, so that he will be able to devote his
energies to his work without fear of any danger to his life and health.
 The management should consider no phase of operation or administration as being of greater importance than
accident. Prevention. It will be the policy of the company, therefore, to provide and maintain safe and healthy
working conditions and to follow operating practices that will safeguard all employees and result in safe working
conditions and efficient operation.
 Total safety extends into three important areas-company personnel, products and customers, and the public. The
safety policy should be designed in such a way that it is easy to implement it in these vital areas.
 Lack of knowledge is the root cause for not understanding what is required to be done to prevent an accident or
mishap. Policy provides proper scope for education, training and development for the managers, staff and
employees
 PRINCIPLES, BASIC TO POLICY MAKING, DECLARATION AND
IMPLEMENTATION ARE:

 Safety of the company’s contractors’ employees, the public, and company operations.
 Safety taking precedence over expediency or short cuts.
 Every attempt will be made to reduce the possibility of accidents.
 Compliance with all the possible legal provisions of various acts, rules and laws.
SAFETY, HEALTH AND ENVIRONMENT PROTECTION POLICY AND OBJECTIVES:
A SAMPLE FOR STUDY
POLICY ON SAFETY, HEALTH AND ENVIRONMENT PROTECTION

A.1 Conduct its activities in a manner that ensures the health and safety of its employees and its contractor’s
employees.
A.2 Ensure protection and safe operation to all plants, equipment, machinery and installations.
A.3 Conduct its operations so as to protect the environment and prevent pollution.
A.4 Establish adequate and appropriate norms and systems for safety, health and environment that are essential to
practice and implement.
A.5 Provide safety education and training to bring awareness of programme.
A.6 Fully comply with all the applicable statutory provisions pertaining to safety and health.
A.7 Provide a resume of safety performance of the factory in its Annual Report.
OBJECTIVES FOR SAFETY, HEALTH AND ENVIRONMENT
PROTECTION

B1. Encourage, support and implement methods aimed at continual improvement of safety at work.
B.2 Maintain a safety department to assume an advisory, monitoring and training role in all aspects of Industrial Safety and loss
prevention giving emphasis to participative safety management techniques and training.
B.4 Fix the responsibilities with respect to safety, with accountability for all accidents at departmental head level.
B.5 Ensure by procedures, techniques and surveys that facilities are operated and maintained to a high standard of safety such
that they remain safe and reliable with a practical minimum risk of injury to person, breakdown or damage to property or fire.
B.6 Give due weightage to safety performance while appraising the overall performance of ts employees.
B.7 Integrate health and safety in all decisions including those dealing with purchase of plants, equipment, machinery and
material as well as selection and placement of personnel.
B.8 Encourage, support and promote a high standard of preventive, curative and public health programmes.
B.9 Ensure by design, auditing and quality assurance techniques that facilities are built to comply with national/international
standards for safe production, working and fire and loss prevention.
SAFETY INSPECTION CHECKLIST FOR LP GAS
INSTALLATIONS

Flexible connections
 Hoses for conveying LPG comply with the prescribed standard
 Emergency valves are installed in piping conveying liquid LPG to which hoses are connected, to prevent
prolonged discharge of LPG in the event of failure of hose
Fire Precaution
 Electrical equipment installed near LPG vessels meet the required standards and separation distance
 Plant design and layout take care of adequate water supplies, fire protection, fire fighting equipments
 Facility to call fire brigade
 Fie detecting systems are provided
 Portable firefighting equipment are provided
SAFETY INSPECTION CHECKLIST FOR LP GAS
INSTALLATIONS

Loading and Unloading facilities

 Written instructions are given which clearly define responsibilities for all personnel involved in the loading and
unloading operations
 Competent person is present during unloading
 Excess LPG id removed immediately in a safe manner in the event of overfilling of tanker
 During loading and unloading the tanker, stand on an essential level site to minimize the risk of accidental movement
 For public safety warning, notices are displayed

Maintenance and Examination

 Installation is maintained to acceptable standards by a competent person
 Maintenance has been prepared which includes protective devices and instruments
 Suitable records are kept so that all maintenance schemes are properly monitored
SAFETY INSPECTION CHECKLIST FOR LP GAS
INSTALLATIONS

Operational Procedure
 Written operation procedures are prepared
 Procedure is readily available to the people on site

Training
 Employees concerned with LPG are familiar with its properties and hazards
 Employees are instructed about operation including loading and unloading procedures and emergency shutdown
 Training is a continuous commitment and includes refresher courses appropriately
 Emergency procedures are practiced regularly