EPSILON CARBON

INDUCTION TRAINING
CONTENTS OF TRAINING
 Health & Safety Policy
 Safety Principles and Life Saving Rules
 Responsible care
 What is safety
 Why safety is required
 What is incident & accident
 Causes of incidents
 What is hazard
 Definition of Unsafe act & examples
 Definition of Unsafe condition & examples
 Process hazards
 Sources of hazards
 Sources of hazards
 Incident classifications
 Incident reporting & investigation
 Incident rate
 Personal protective equipment's
 Work permit system
 What is confined space entry
 What is working at height
 What is LOTOTO
 What is Risk & Risk assessment
 How to control hazards
 General safety DO’s & DON’TS
 Toolbox talk
 Mandatory rule for women worker’s
 Ergonomics of safe lifting
 What is co gas
 What is SCBA
 What is NFPA
 Fire safety
 Emergency preparedness & response
 Employee HES responsibilities
Health, Environment & Safety (HES) Policy
Our Vision
 To become market leader & Trusted provider of
High-quality Carbon products
Our Principles
 To ensure Health, well being and safety .
 Emphasis on skills and involvement of employees.
 To provide all resources to achieve our vision
Our Commitment:
 Integrate HES into business strategies and Processes
through out all product life cycle
 Zero injuries
 Regular monitoring and reviewing of HES Performance
 Addressing HES Issues and their impact on processes
 Promote HES Awareness ,verify compliance through
audits
Brief Introduction about Responsible Care
 Responsible Care ( RC )is the global chemical industries voluntary initiative to drive continuous improvement in safe
chemicals management and achieve excellence in Environment, Health ,Safety and Security performance. Indian
chemical council (ICC) is an apex body representing the chemical industry in India and acts as a nodal body pursuing
the global initiative of responsible care program in India. Till June 2021 ,only 72 enlightened company are
Responsible Care logo holders in our country.

7 CODES OF RESPONSIBLE CARE MANAGEMENT PRACTICE.

1.Process safety code
It is related to different aspects of risk in a physical facility and puts them under the control of a management system

2.Employee health and safety code

To protect and promote the health and safety of employees, this code provides management practices by which companies
are able to identify problems before they become work safety incidents

3.Pollution prevention code

The objective of the code is to minimize the environmental effects, this includes reduction of waste and releases, giving
preference to reduction at source leading to recycling reuse and treatment
4.Emergency Response Code
when community and employees have concerns about dangers from production, transportation and distribution of
chemicals ,then it has to be considered in the planning stage of emergency response.
Assessment of potential risk and formulation of a written response plan is required for an emergency. along with
that all stakeholders shall undergo emergency response training based on real and scientifically developed scenarios.
5.Distribution code
Distribution code is designed to prevent or mitigate consequences of incidents during distribution activities.
6.Product Safety and stewardship code
Product Safety is exchanging information with parties regarding product hazards intended users handling practices
exposures and risks
product stewardship is the responsibility to understand manage and communicate the health and environmental
impacts of chemical products
7.Security code
Chemical safety is the prevention and control of the accidental release of hazardous materials or energy
chemical security the prevention and control of the authorized access loss theft misuse diversion or intern
intentional releases of hazardous materials or energy, or the acquisition of dual use equipment that could be used in
the manufacture of chemical weapons.
SAFETY PRINCIPLES
1. Safety is the responsibility of Line Management.
2. We believe that all work-related injuries can be
prevented.
3. Demonstrating safe behavior and attitude while at
workplace is a condition of employment.
4. No job is ever so urgent that calls for compromising
with safety of employees and workmen.
5. No activity shall start without a procedure prepared
after identification of hazards, assessment of risk
and identification & implementation of controls.
LIFE SAVING RULES
1. Drug and Alcohol: Nobody will work under the influence of drugs, cannabis, or alcohol.
2. Safety Interlocks: Nobody will override or interfere or modify without authority with any safety
equipment or device or control.
3. Work Permit: No one will violate Permit to Work system. Written Clearance is to be taken for jobs
requiring isolation of energy.
4. Sources or entry to confined spaces. Verify Isolation and Zero Energy before beginning the work.
5. Working in isolation/prohibited area: Nobody will work or enter an isolated place or prohibited area
without proper approval and a valid procedure.
6. Incident Reporting: All incidents including near misses must be reported to identify and eliminate root
cause(s) to prevent recurrence.
7. PPE: Wear the appropriate PPEs properly since it is the last line of defense.
8. Checklists: All checklists for critical jobs like Work at Height (>2 meters), Lifting Operations, working
near live electrical equipment and working near hazardous areas etc. must be filled in prior to start of
job.
 Any violation related to Life Saving Rules shall be viewed seriously and suitable
disciplinary action as deemed fit shall be initiated.
 EMERGENCY PREPAREDNESS & RESPONSE
1. In case of emergency:
 Use the emergency exits to evacuate the area
 Do not re-enter the affected area
 Assemble with your group in the “Assembly
Point”
2 . In the event of a fire
 Alert co-workers in the immediate area
 Inform to Fire Services immediately
 You must attempt to extinguish the fire with
available fire extinguishers, if you are trained and
confident.
 In the event of a fire in gas handling area,
immediately evacuate the are and move to a
safe place
 EMERGENCY SIREN

• Emergency alert siren : TBD

• Evacuation siren : TBD
• All clear siren : TBD
• Testing of siren : TBD

EMERGENCY CONTACT NUMBERS

S. No Department Contact Number
1 AVP Projects 7028648139, 7620075904
2 GM – Projects 9100833357, 9677065411
3 GM – HR & Admin 7077704535
4 DGM – HES 7036156360
5 AGM – Process 7773087290
6 AGM – Projects 9088812879, 9903022091
LOCATIONS OF ASSEMBLY POINTS AT ECPL

COAL TAR AREA

 TBD
ARIAL VIEW OF ASSEMBLE
POINTS
USE PEDESTRIAN
WALKWAY
 PERSONAL PROTECTIVE EQUIPMENTS

Example of hazard/
Body Part Example of PPE
hazardous condition

Head hard hat Falling object from height

Face face shield Impact from flying wood chips

Eyes safety glasses Liquid chemical splash

Body (torso) leather apron Burn from hot materials

Arms, hands puncture-resistant metal mesh gloves Cut from shellfish processing

Legs, feet knee guards Awkward posture, pressure from carpet laying

body harness/personal fall protection system Work at height

Ears ear plugs Loud noise from machinery

Lungs face mask with cartridge Vapors from cleaning with solvent
PERSONAL PROTECTIVE EQUIPMENT'S

Eye protection Gloves

Face shield
Earmuff & Earplug
 Leather Gloves

Head Protection Welding

Cutting
Grinding

Nitrile Gloves
Respiratory Protection
Chemicals Handling
Rubber Gloves Electrical Heat Resistant Leg protection
Gloves
WHAT IS SAFETY

SAFETY

Freedom from Harm or Loss

WHY SAFETY IS REQUIRED

Industrial Production depends on the following factors: -

Men
Material
Machines
Environment
For efficient production, all the above factors should not have any interruption
WHAT IS INCIDENT & ACCIDENT

INCIDENT ACCIDENT

An undesired and unexpected event An accident is an incident which has given

which may or may not cause injury rise to injury, ill health or fatality .
or property damage.

All incidents are not accidents

All accidents are incidents

Hence report all incidents
CAUSES OF INCIDENTS

Unsafe act - 94%

Unsafe condition -6%

Thus 94% incidents are preventable

UNSAFE ACTS

•Operating without authority

•Bypassing safety devices
•Operating at unsafe speed
•Using wrong tool / equipment
•Unsafe Placing
•Unsafe Loading
•Taking unsafe position or posture
•Working on dangerous or moving
equipment
•Not using PPE
•Horse playing at workplace etc.
UNSAFE CONDITIONS

• Unguarded or inadequately guarded

machines / equipment's.
• Defective conditions of machines,
equipment's, tools etc.
• Unsafe methods of storing, piling etc.
• Inadequate or incorrect Illumination.
• Inadequate Ventilation.
• Improper House Keeping-things not at
their proper places.
• Unsafe design or construction of machines
and equipment etc.
 INCIDENTS CLASSIFICATIONS

Near Miss Case

An event that could have resulted in a loss, but did not have consequences
First Aid Case
A minor injury that calls for only simple treatment and does not call for follow-up treatment by a
health-care professional

Lost Time Injury

If an employee is unable to work on a subsequent scheduled shift because of a work-related injury or
illness, the case is classified as an LTI

FATAL injury case

A work-related injury that results in a loss of life

FIRE INCIDENT
Fire is the rapid oxidation of a material in the exothermic chemical process of combustion, releasing
heat, light, and various reaction products.
 HEINERICH TRIANGLE
Incident statistics are lag indicators and therefore Failure focused
and not Achievement focused.

The aim to is move from Re-active to Proactive

Reactive: Wait until the incident occurs and then respond

Proactive: seek out hazards involving unsafe acts and

conditions and act before they become incidents
SAFETY WORK PERMITS

WORK PERMIT SYSTEM

• GENERAL WORK PERMIT SYSTEM
• CONFINED SPACE ENTRY PERMIT
• HOT WORK PERMIT

CHECKLISTS
• WORKING AT HEIGHT CHECKLIST
• EXCAVATION CHECKLIST
• LIFTING CHECKLIST
• ENERGY ISOLATION CHECKLIST
• SCAFFOLDING CHECKLIST
• ELECTRICAL WORK CHECKLIST
 LOTOTO

Any source energy that, if not controlled, could cause injury to personnel or
damage to property and/or environment

• Electrical • Chemical

• Mechanical • Thermal

• Hydraulic • Nuclear

• Pneumatic • Other
RISK ASSESSMENT
What is risk :combination of the likelihood of an occurrence of hazardous event or exposer &
the severity of injury or ill health that can be caused by the event or exposure

•A risk assessment is an important step in protecting your workers and your business, as well as
complying with the law.
•Accidents and ill health can ruin lives and affect your business too if output is lost, machinery is
damaged
•You are legally required to assess the risks in your workplace so that you put in place a plan to
control the risks.

The law does not expect you to eliminate all risk, but you are required to protect people as far
as ‘reasonably practicable’.
HOW TO CONTROL HAZARDS

Hierarchy of Controls (most to least effective)

• Elimination – Physically remove the hazard.

• Substitution – Replace the hazard.
• Engineering controls – Isolate people from the hazard.
• Administrative controls – Change the way people work.
• Personal protective equipment– Protect the worker with PPE.
GENERAL SAFETY DO’S & DON’TS
Do’s
• Take PTW before work start
• Always use pedestrian walkways
• Switch off the machines when not in use
• Report accidents/incidents immediately
• Safety helmets must be worn when you are in plant
Don’ts
• Enter the site without PPE’s
• Use cell phone at work site
• Smoke inside the plant
• Use tabaco, Gutka alcohol inside the plant
• Violation of safety procedures
TOOLBOX
TALK

What is TBT ?
 It’s a short time training programme which is normally conducted
prior to the shift.
 This is the platform to discuss PPE’s and other safety issues.
 Short talk to detail the health and safety hazards and risks workers
will face.
 Short talks that focus on a specific topic e.g. sheet handling,
Working near automatic machines etc..
 Allow you and your workers to explore the risks of specific health
and safety issues and think about ways to deal with them.
 Help inform inexperienced workers and provide reminders to
experienced workers of correct control measures.
MANDATORY RULES FOR WOMEN WORKER’S INSIDE THE PLANT

• Don’t wear loose cloths when you working inside the plant
• Prohibition of house keeping or any type of work inside the running plant for
women workers.
• Should not enter with loose hair inside the plant
• Use proper mandatory PPE’s before entering plant.
ROUTES OF EXPOSURE

 Inhalation
 Ingestion
 Absorption
 Injection
WHAT IS CARBON MONOXIDE (CO) ?

Carbon monoxide (CO) is an odorless, colorless gas formed

by the incomplete combustion of fuels.

Threshold limit value (TLV): 50ppm for 8 hours of exposure

Immediately Dangerous to Life or Health (IDLH):1200ppm.

EFFECT OF CO IN DIFFERENT CONCENTRATIO

CO Concentration Effects
50 ppm Can work safely for 8 hours exposure.
100 ppm Can work safely for 4 hours exposure.
200 ppm Mild headache after 2-3 hours exposure.
400 ppm Nausea and mild headache after 1-2 hours of exposure.
800 ppm Headache, dizziness and nausea after 3-4 hours of exposure
1. All the above symptoms in 20 minutes exposure
1600 ppm 2. Collapse, unconsciousness and probability of death after 2
hours of exposure.
All the above symptoms in 5-12 minutes exposure and death
3200 ppm
in 30 minutes exposure.
All the above symptoms in 1-2 minutes and death in 15
6400 ppm
minutes exposure
12800 ppm Effect instantaneous, death in 1-4 minutes
CO GAS POISONING SIGNS
WINDSOCKS

Windsocks are used to tell wind speed and the direction

of the wind. Windsocks typically are used at airports to
indicate the direction and strength of the wind to pilots
and at chemical plant where there is risk
of Gaseous leakage They are sometimes located
alongside highways at windy locations.
 MULTIPLE GAS DETECTOR

They detect gases like oxygen (O2 Monitor), hydrogen

sulfide (H2S Monitor), carbon monoxide (CO
Monitor), and lower explosive levels (LEL Monitor) of
a variety of combustible gases.
NFPA(National Fire Protection Association) DIAMOND
NFPA SIGNAGES ON TANKS
GOOD SAFETY PRACTICES

 Inspect work area daily

 Be an observer - stay alert
 Housekeeping, Housekeeping, Housekeeping
 Use your best safety device - THINK
 If you’re not sure - ASK someone!!
 Report Injuries/Incidents/Illnesses
 Report safety issues to the safety committee
CHEMICAL SPLASH
FIRE SAFETY
Types of fire, class & suitability
TYPES OF FIRE EXTINGUISHER
EMPLOYEE EHS RESP. – KEY TO SUCCESS
•Reporting hazards & injuries immediately
•Communicating to supervisor any personal condition affecting the ability to perform work
•Wearing appropriate PPE
•Attending and participating in safety training & meetings
•Practicing off-the-job safety
•Developing Procedures For Performing Work Safely
•Understanding work permits & following requirements
•Maintaining tools & equipment in proper condition
•Practicing lockout/tagout to prevent sudden & unexpected release of energy
•Practicing good housekeeping
•Performing Job Safety Analysis
•Develop subject matter experts
•Perform training
•Participate in development of Safety Program
Thank you!