HAZARD AND RISK MANAGEMENT IN INDUSTRY INCLUDING ICH GUIDELINES FACTORY ACT AND RULES PHYSICOCHEMICAL MEASUREMENT OS EFFLUENT, BOD, COD

1. Hazards and Risk Management
Prepared by :
Harshada Khude
Tushar Naikware
QA 1st year
M.pharma
Guided by :
Prof. Mukesh Patil Sir
At Shri D.D. Vispute College
of Pharmacy and Research
Centre.

2. Content
• Introduction
• Self-protective measures against workplace hazards
• Critical training for risk management
• Process of hazard management
• ICH guidelines on risk assessment and Risk management
methods and Tools
• Factory act and rules
• Physicochemical measurements of effluents
• Determination of contaminants
• Effluent treatment procedure
• Role of emergency services

3. Introduction
• Hazard is the potential for harm or an adverse
effect (for example, to people as health effects,
to organizations as property or equipment
losses, or to the environment).
• Risk Management, in the context of occupational
safety and health (OSH), is the process of
identifying OSH hazards, determining the risk
based on likelihood and severity of work injuries,
ill health and property damage, prioritizing the
implementation of preventive measures to
mitigate these risks and communicating the risk
assessment to workers.

4. Self-protective measures against
workplace hazards
Employers must protect employees:
• Assess the workplace
• Eliminate and reduce the hazards found using
engineering and administrative controls
• Then use appropriate personal protective equipment
• Remember, Personal Protective Equipment is
the last level of control.

6. Elimination/substitution:
• Highest level of protection
• Eliminate hazard from the workplace
• Substitute
– Use safer item/substance
– Use same chemical but in a different form; as particle size of a substance
decreases, hazard level increases
Engineering controls:
• Physical changes to workplace
• Examples
o Isolation
o Ventilation
o Equipment modification
o Others

7. Administrative controls/work practice control:
• Requires worker or employer to do something
• Examples
o Written proper operating procedures, work permits
and safe work practices
o Inspection and maintenance
o Housekeeping
o Monitoring the use of highly hazardous materials
o Supervision
o Training
o Alarms, signs and warnings
o Regulated areas
o Limit exposure by time or distance

8. PPE controls:
Requires worker to wear something.
Types of PPE
Head protection:
Classes of hard hats:
– CLASS G (General)
– CLASS E (Electrical)
– CLASS C (Conductive)

9. Eye and face protection:

10. Respiratory protection:
Types of respirators
– Air-Purifying (APR) –
remove contaminants from
air
• Particulate respirators
• Chemical cartridge/
gas mask respirator
• Powered Air-Purifying
Respirator (PAPR)

11. – Atmosphere-Supplying – provide clean, breathable
air
• Self-Contained Breathing Apparatus (SCBA)
• Supplied-Air Respirator (SAR)

12. Hearing protection:
• Examples of hearing protection:
– Disposable foam plugs
– Molded ear plugs
– Noise-cancelling ear plugs
– Ear muffs

13. Hand protection:

14. Body protection – protective clothing:
• Provide protective clothing for those parts of the
body exposed to possible injuries
• Types of body protection
– Laboratory coats
– Coveralls
– Vests
– Jackets
– Aprons
– Surgical gowns
– Full-body suits

15. Critical training for risk management
Train workers on their specific roles and
responsibilities in the safety and health
program
Instruct workers with specific roles within the safety
and health program on how they should carry out
those responsibilities.
Provide opportunities for workers to ask questions
and offer feedback during and after the training.
As the program evolves, institute a more formal
process for determining the training needs of
workers responsible for developing, implementing,
and maintaining the program.

16. Train workers on hazard identification and controls
 Train managers and workers on techniques for
identifying hazards, such as job hazard analysis.
 Have workers demonstrate that they can recognize
hazards they may encounter in their own jobs, as well
as more general workplace hazards.
 Ask workers to show that they recognize the measures
being used to control hazards in the workplace.
 Provide additional training, as necessary, when a worker
is assigned a new task or given a new assignment.
 Provide training where required by specific OSHA
standards, such as Hazard Communication, Lockout/
Tagout, Confined Space, or Blood borne Pathogens.

17. Process of Hazard Management
Steps for Hazard Management
I. Hazard Identification
II. Risk Assessment
III. Controls
1) Eliminate
2) Isolate
3) Minimize
IV.Monitor and Review

18. Hazard Identification
All hazards in the workplace need to be
identified. Once identified, they need to be
recorded on a hazard register.
Examples of potential hazards include:
• Dangerous equipment
• Chemicals
• Stacked shelving
• Repetitive jobs that may cause strains
and/or fatigue from lifting,

19. Hazard Assessment
Using the Risk Matrix, assess each hazard for
risk. Once you have determined the hazards
that would cause the most harm you will need
to deal with these first.
When assessing each hazard, consider the
following:
• Likelihood – What are the chances the
hazard could occur
• Consequence – If the hazard did occur,
what would be the potential outcome

20. Hazard Control
Hazard controls are put in place to keep people safe from
harm. The Health and Safety in Employment Act 1992,
requires all employers to put hazard controls in place.
The steps to follow are:
• Eliminate the hazard (e.g. remove it, remedy it, etc), or,
• Isolate the hazard. If it is not possible to eliminate the
hazard, then, all practicable steps should be taken to
isolate the hazard. An Isolating control measure may
include, the placing of barriers around the hazard, confining
the hazard to a specific area etc, or
• Minimise the hazard If the hazard cannot be eliminated or
isolated, you must minimise the hazard. Minimisation
control measures may include e.g. providing personal
protective equipment; (gloves, earmuffs, aprons), develop
safe work procedures, provide training etc.

22. ICH guidelines on risk assessment
and Risk management methods and
Tools
Risk Assessment
According to ICH, Risk assessment consists of the identification of
hazards and the analysis and evaluation of risks associated with
exposure to those hazards.
Quality risk assessments begin with a well-defined problem description
or risk question.
When the risk in question is well defined, an appropriate risk
management tool and the types of information needed to address the
risk question will be more readily identifiable.
Three fundamental questions are often helpful:
• What might go wrong?
• What is the likelihood (probability) it will go wrong?
• What are the consequences (severity)?

23. Risk management methods and Tools
Below is a list of some of these tools as per ICH:
• Basic risk management facilitation methods
(flowcharts, check sheets etc.);
• Failure Mode Effects Analysis (FMEA);
• Failure Mode, Effects and Criticality Analysis
(FMECA);
• Fault Tree Analysis (FTA);
• Hazard Analysis and Critical Control Points
(HACCP);
• Hazard Operability Analysis (HAZOP);
• Preliminary Hazard Analysis (PHA);
• Risk ranking and filtering;
• Supporting statistical tools.

24. Basic risk management facilitation methods
Some of the simple techniques that are
commonly used to structure risk management by
organizing data and facilitating decision-making
are:
• Flowcharts;
• Check Sheets;
• Process Mapping;
• Cause and Effect Diagrams (also called an
Ishikawa diagram or fish bone diagram).

25. Failure Mode Effects Analysis (FMEA)
• FMEA provides for an evaluation of potential
failure modes for processes and their likely
effect on outcomes and/or product
performance.
• Once failure modes are established, risk
reduction can be used to eliminate, contain,
reduce or control the potential failures.
• FMEA relies on product and process
understanding.
• FMEA methodically breaks down the
analysis of complex processes into
manageable steps.

26. Failure Mode, Effects and Criticality Analysis
(FMECA)
• FMEA might be extended to incorporate an
investigation of the degree of severity of the
consequences, their respective probabilities
of occurrence, and their detectability, thereby
becoming a Failure Mode Effect and
Criticality Analysis.
• In order for such an analysis to be
performed, the product or process
specifications should be established. FMECA
can identify places where additional
preventive actions might be appropriate to
minimize risks.

27. Fault Tree Analysis (FTA)
• The FTA tool is an approach that assumes
failure of the functionality of a product or
process.
• This tool evaluates system (or sub-system)
failures one at a time but can combine multiple
causes of failure by identifying causal chains.
• The results are represented pictorially in the
form of a tree of fault modes.
• At each level in the tree, combinations of fault
modes are described with logical operators
(AND, OR, etc.).
• FTA relies on the experts’ process
understanding to identify causal factors.

28. Hazard Analysis and Critical Control Points
(HACCP)
HACCP is a systematic, proactive, and preventive tool for assuring
product quality, reliability, and safety (see WHO Technical Report
Series No 908, 2003 Annex 7).
HACCP consists of the following seven steps:
1. conduct a hazard analysis and identify preventive measures for
each step of the process;
2. determine the critical control points;
3. establish critical limits;
4. establish a system to monitor the critical control points;
5. establish the corrective action to be taken when monitoring
indicates that the critical control points are not in a state of
control;
6. establish system to verify that the HACCP system is working
effectively;
7. establish a record-keeping system.

29. Hazard Operability Analysis (HAZOP)
• HAZOP (see IEC 61882) is based on a theory that
assumes that risk events are caused by deviations
from the design or operating intentions.
• It is a systematic brainstorming technique for
identifying hazards using so-called “guide-words”.
“Guide-words” (e.g., No, More, Other Than, Part of,
etc.) are applied to relevant parameters (e.g.,
contamination, temperature) to help identify potential
deviations from normal use or design intentions.
• It often uses a team of people with expertise covering
the design of the process or product and its
application.

30. Preliminary Hazard Analysis (PHA)
PHA is a tool of analysis based on applying prior
experience or knowledge of a hazard or failure to identify
future hazards, hazardous situations and events that
might cause harm, as well as to estimate their
probability of occurrence for a given activity, facility,
product or system.
The tool consists of:
1) the identification of the possibilities that the risk
event happens,
2) the qualitative evaluation of the extent of possible
injury or damage to health that could result
3) a relative ranking of the hazard using a combination
of severity and likelihood of occurrence, and
4) the identification of possible remedial measures.

31. Risk ranking and filtering
• Risk ranking and filtering is a tool for comparing and
ranking risks.
• Risk ranking of complex systems typically requires
evaluation of multiple diverse quantitative and
qualitative factors for each risk.
• The tool involves breaking down a basic risk question
into as many components as needed to capture factors
involved in the risk.
• “Filters,” in the form of weighting factors or cut-offs
for risk scores, can be used to scale or fit the risk
ranking to management or policy objectives.

32. Supporting statistical tools.
Statistical tools can support and facilitate quality risk management.
They can enable effective data assessment, aid in determining the
significance of the data set(s), and facilitate more reliable decision
making.
A listing of some of the principal statistical tools commonly used in
the pharmaceutical industry is provided:
• Control Charts, for example:
 Acceptance Control Charts (see ISO 7966);
 Control Charts with Arithmetic Average and Warning Limits (see ISO
7873);
 Cumulative Sum Charts (see ISO 7871);
 Shewhart Control Charts (see ISO 8258);
 Weighted Moving Average.
• Design of Experiments (DOE);
• Histograms;
• Pareto Charts;
• Process Capability Analysis.

33. DEFINITION – Factory:
According to the Factories Act,1948, under section 2(m) a ‘Factory'
means "any premises including the precincts thereof
(i) whereon ten or more workers are working, or were working on any
day of the preceding twelve months, and inany part of which a
manufacturing process is being carried on with the aid of power, or is
ordinarily so carried on, or
(ii) whereon twenty or more workers are working, or were working on
any day of the preceding twelve months, and in any part of which a
manufacturing process is being carried on without the aid of power, or
is ordinarily so carried on; but this does not include a mine subject to
the operation of the Mines Act, 1952 , or a mobile unit belonging to the
armed forces of the union, a railway running shed or a hotel, restaurant
or eating place."
Factory Act and Rule ,

34. Manufacturing Process: Sec.2(k)
‘Manufacturing process’ means “any process for
(i) making, altering, repairing, ornamenting, finishing
packing, oiling, washing, cleaning, breaking up
demolishing, or otherwise treating or adapting any article
or substance with a view to its use, sale,transport,
delivery or disposal,
(ii) pumping oil, water, sewage or any other substance; or
(iii) generating, transforming or transmitting power; or
(iv) composing types for printing, printing by letter press,
lithography, photogravure or other similar process or
book binding; or
(v) constructing, reconstructing, repairing, refitting,
finishing or breaking up ships or vessels; or
(vi) preserving or storing any article in cold storage”.

35. Worker : Sec.2(l)
'Worker’ means ‘‘a person employed ( directly or by
or through any agency including a contractor ), with
or without the knowledge of the principal employer,
whether for remuneration or not in any
manufacturing process or in cleaning any part of the
machinery or premises used for a manufacturing
process or in another kind of work incidental to or
connected with the
manufacturing process or the subject of the
manufacturing process’’ ( but does not include any
member of the armed forces of the Union ).

36. Occupier: Sec.2(n)
‘Occupier’ of a factory means “the person who has
ultimate control over the affairs of the factory ; and
(i) in the case of a firm or other association of individuals,
any one of the individual partners or members thereof shall
be deemed to be the occupier;
(ii) in the case of a company, any one of the directors shall
be deemed to be the occupier;
(iii) in the case of a factory owned or controlled by the
Central Government or any State Government, or any
local authority, the person or persons appointed to
manage the affairs of the factory shall be deemed to be the
occupier

37. Section 11 to 20
of the Factories Act, 1948, deals
with the provisions relating to
the health of the workers in a
factory

38. Provisions regarding health :
• Cleanliness (sec.11)
• Disposal of Wastes & Effluents (sec.12)
• Ventilations & Temperature (sec.13)
• Dust & Fumes (sec.14)
• Artificial Humidification (sec. 15)
• Overcrowding (sec.16)
• Lighting (sec.17)
• Drinking Water (sec.18)
• Latrines & Urinals (sec.19)
• Spittoons (sec.20)ng

39. Cleanliness (Sec.11)
➢ Accumulation of dirt shall be removed daily.
➢ The floor of every workroom shall be cleaned at least once in a week.
➢ All inside walls, partitions, ceilings must be repainted or varnished once in every
five years.
➢ All doors and windows frames other wooden or metallic framework and shutters
shall be kept painted orvarnished.
Disposal of Wastes & Effluents (Sec.12)
➢ Every occupier of a factory shall make effective arrangements for the treatment of
wastes and effluents due to the manufacturing process carried on in the factory so
as to render them innocuous and for their disposal.
Ventilations & Temperature (Sec.13)
➢ Adequate ventilation by the circulation of fresh air.
➢ Reasonable temperature must be maintained.
Dust and Fume (Sec.14)
➢ The exhaust fumes of internal combustions enginesmust be conducted outside of
the factory.
➢ Injurious or offensive dust and fumes not be inhaled

40. Artificial humidification (Sec.15)
(1) In respect of all factories in which the humidity of the air is artificially
increased, the State Government may make rules, prescribing standards
of humidification; regulating the methods used for artificially increasing the
humidity of the air; directing prescribed tests for determining the humidity
of the air to be correctly carried out and recorded; prescribing methods to
be adopted for securing adequate ventilation and cooling of the air in
theworkrooms.
(2) In any factory in which the humidity of the air is artificially increased, the
water used for the purpose shall be taken from a public supply, or other
source of drinking water, or shall he effectively purified before it is so used.
For example:
• In certain industries like cotton, textile, cigarette, etc.,higher degree of
humidity is required for carrying out the manufacturing process. For this
purpose, humidity of the air is artificially increased. This increase or
decrease in humidity adversely affects the health of workers.

41. Overcrowding (Sec.16)
➢ The overcrowding affects the workmen not only in the discharge of duties but also
their health.
➢ The working space should be 9.9 cubic meters of spaceper worker in every workroom
before thecommencement of this Act.
➢ And after the commencement of this Act, the space per worker is 14.2 cubic meter
➢ Roof shall be 5 mts (14ft.) above the floor.
Lighting (Sec.17)
➢ There shall be provided and maintained sufficient and suitable lighting, natural or
artificial, or both, in every part of the factory.
➢ In every factory all glazed windows and skylights be used and workrooms shall be
kept clean on both the inner and outer surface.
➢ In every factory effective provision shall, so far as ispracticable, be made for the
prevention of glare,either directly from a source of light or by reflection
from a smooth or polished surface
Drinking Water (Sec.18)
➢ The place of drinking water shall not be situated within six meters of any washing
place, urinal, open drain or any source of contamination.
➢ Effective arrangements shall be made to provide a sufficient supply of wholesome
drinking water.

42. Latrines and Urinals (Sec.19)
➢ Sufficient latrine and urinal accommodation of prescribed types shall be provided
and conveniently situated to make them accessible to workers at all times while they
are at
the factory.
➢ It should be adequately lighted, ventilated.
➢ Latrines and urinals must be kept in a clean and sanitary condition.
Spittoons (Sec.20)
➢ There should be sufficient number of spittoons in convenient place.
➢ It must be maintained in a clean and hygienic condition.
➢ No persons shall spit expect in the spittoons
INTRODUCTION:
LABOUR AND WELFARE:
➢ The term ‘Labour Welfare’ refers to the facilities provided to workers in and outside
the factory premises such as canteens, rest and recreation facilities, housing and all
other services that contribute to the wellbeing of workers. Welfare measures are
concerned with general wellbeing and efficiency of workers. In the early stages of
industrialization, welfare activities for factory workers did not receive adequate
attention.

43. The act of 1948 builds upon the act of 1934 after understanding the defects and
weaknesses of the earlier act. An important change was the widening the definition of a
'Factory' to include any industrial establishment employing 10 or more people that
uses power, or any industrial establishment that employs more than 20 people that
does not use any power. Other important changes were:
1. Increasing the minimum age of children eligible to work from 12 to 14.
2. Reducing the hours of work for children from 5 to 4 and a half.
3. Prohibiting children from working after 7 PM and before 6 AM.
4. Explicit and special focus on health, safety, and welfare of all sorts of workers.
WELFARE PROVISIONS (42-50)
WASHING FACILITIES(SEC-42)
(a) Firstly, provide and maintain adequate and suitable facilities for washing for all the
workers in the factory
(b) Secondly ,provide separate and adequately screened facilities separately for men and
women.
(c) Thirdly, make accessible all the facilities to all the worker.
Facilities for storing and drying clothes(SEC-43)
 This section contests some powers with the State Government. It states that the
State Government has the powers to direct the factories regarding the place of
storing the clothes of the worker.
 Moreover, they can also direct them regarding the manner of drying the clothes of the
workers. It applies to the situation when workers are not wearing their working
clothes.

44. Facilities for sitting(SEC-44)
There are various kinds of jobs in a factory. Some of them require the workers to stand for a longer
period of time. There is no doubt that human power to stand has limits. Looking at such case, this
section states:
(a) Firstly, the factory should provide suitable arrangements for sitting for the workers.This is
important because whenever the worker gets some free time, he/she may be able to take some rest
by sitting. This will also enhance their efficiency.
First-aid-appliance(SEC-45)
Injuries are somehow an inescapable part of life for the workers especially working in the factories.
Looking at the safety and welfare of the workers this section provides that:
 The factory should provide and maintain proper first-aid boxesat every workroom. Under this Act,
the number of boxes should not be less than one for every 100 or 50 workers
 In case the number of workers exceeds 500, then the factory should arrange an Ambulance
Room’ with the availability of all necessary equipment
Canteens(SEC-46)
(a) Every factory where the number of workers exceeds 250, then the State Government may
direct
the factory owners to provide and maintain a canteen for the workers.
(b) Moreover, the government may lay down certain conditions in the construction of canteen, like:
1. the standard in respect of construction, accommodation, furniture and other equipment of the
canteen
2. the foodstuffs to be served therein
3. the date by which such canteen shall be provided
4. the constitution of a managing committee for the canteen

45. Shelters, rest-rooms, and lunch-rooms(SEC-47)
This section states:
(a) If the number of workers in a factory crosses 250, then the factory owners
should construct andmaintain shelters, rest-rooms and lunch rooms for the workers.
It allows the workers to eat the food which they bring along with them.
(b)The shelters, rest-rooms and lunch rooms should be properly ventilated and
lighted.
Elements of Safety programme and Safety
Management
SAFETY PROVISIONS SEC(21-41)
Fencing machinery
According to Section 21 of the Factories Act 1948, every dangerous machinery in a
factory must be securely fenced to avoid accidents. The section provides for fencing
the following
machineries while they are in use
(i) every moving part of a prime mover and every flywheel connected to a prime
mover whether the prime mover or flywheel is in the engine house or not;
(ii) the headrace and tailrace of every water-wheel and water turbine.

46. Sec 22:Work On Or Near Machinery In Motion
➢ Examination shall be carried out only by specially trained male workers
➢ Should wear tight fitting clothes
➢ No woman or young person shall be allowed to clean, lubricate or adjust any part of prime mover.
Employment of young persons on dangerous machines (Sec.23): This section provides
that young person shall be required or allowed to work at any machine to which he has been fully
instructed as to the dangers arising in connection with the machine and the precautions to be
observed and-
➢ (a) has received sufficient training in work at the machine,
➢ (b) is under adequate supervision
Striking gear and devices for cutting off power (sec-24)
In every factory, suitable devices for cutting off power in emergencies from running machinery shall
be
provided and maintained in every workroom.
Self-acting machines (Sec. 25): No traversing part of a self-acting machine in any factory and
no material carried thereon
Prohibition of employment of women and children near cotton_x0002_openers
(Sec. 27): In any part of a factory where a cotton-opener is at work for pressing cotton, no woman or
child shall be employed. women and children may be employed on the side of the partition where the
feed-end is situated.
Hoists and lifts (Sec. 28): Every hoist and lift shall be of good mechanical construction, sound
material and adequate strength, properly maintained ,protected.
Lifting machines, chains, ropes and lifting tackles (Sec. 29):
every chain, rope or lifting tackle shall be of good construction, sound material and adequate strength
and free from defects. It should be properly maintained.

47. Revolving machinery (sec-30)
According to Section 30, In every factory in which the process of grinding is carried on there
shall be permanently affixed. The effective measure shall be taken in every factory to ensure
that the safe working peripheral speed of every revolving vessel, cage, basket, flywheel,
pulley, disc or similar appliance driven by power is not exceeded.
Pressure plant(sec-31)
Section 31 of the Act, If in any factory, any plant or machinery or any part thereof is operated
at a pressure above atmospheric pressure, effective measures shall be taken to ensure that
the safe working pressure of such plant or machinery or part is not exceeded.
Floors, stairs and means of Access(sec-32)
According to Section 32 Floors, stairs and means of Access must be of sound construction
and shall be free from obstructions, causing persons to slip.
Pits, sumps, opening in floors, etc(sec-33)
According to Section 33 of the Said Act, In every factory every fixed vessel, sump, tank, pit or
opening in the ground or in a floor which, by reason of its depth, situation, construction or
contents, is or may be a source of danger, shall be either securely covered or securely fenced.
Excessive weights(sec-34)
Section 34 of Factories says that no person shall be employed in any factory to lift, carry or
move any load so heavy as to be likely tocause him an injury.
Protection of eyes (Section 35) -
State Government may by rules require that effective screens or suitable goggles shall be
provided for the protection of persons employed on, or in the immediate vicinity of, the
process.

48. Precautions against dangerous fumes, gases etc(sec-36)
No person shall be required or allowed to enter any confined space, until all practicable measures have
been taken to remove any gas, fume, vapour or dust, which may be present so as to bring its level within the
permissible limits and to prevent any ingress of such gas, fume, vapour or dust and unless -
(a) a certificate in writing has been given by a competent person, based on a test carried out by himself that
space is reasonably free from dangerous gas, fume, vapour or dust: or
(b) such person is wearing suitable breathing apparatus .
Explosive or inflammable dust, gas, etc(sec37)
1) Where in any factory any manufacturing process produces dust, gas, fume or vapour of such character
and to such extent as to be likely to explode on ignition, all practicable measure shall be taken to prevent any
such explosion by
a) effective enclosure of the plant or machinery used in the process;
b) removal or prevention of the accumulation of such dust, gas, fume or vapour;
c) exclusion or effective enclosure of all possible sources of ignition
Section38: Precautions In Case Of Fire:
(a) Safe means of escape for all persons in the event of a fire
(b) Necessary equipment and facilities for extinguishing fire
➢ Workers are familiar with the means of escape
➢ Free passage–way giving access
➢ Workers should be trained
Section39: Power To Require Specifications Of Defective Parts Or Tests Of Stability
Safety officers (sec-40)
This section makes provision for the appointment of for safety officer in the factories, where 1000 or more
workers are employed.

49. Fundamental of accident prevention :
a) Incident – An incident is an undesirable occurrence that could, but usually does not, result in a
loss.
b) Accident – An accident is an unplanned, unforeseen and undesirable occurrence which interrupts
a normal activity and which results in either an injury, loss of life, damage to material, equipment or
facility or any combination of these.
c) Preventable Accident – An accident that occurred as a result of an act or failure
to act on the part of an employee or the management or both.
d) Unpreventable Accident – An accident which no act whatsoever on the part of
the employee could have prevented the injury or damages to vehicle, equipment
or property.
e) Unsafe Act – Any act on the part of a person which increased his or her chances
of having an accident.
f) Unsafe Condition – A condition within the working environment which increases
the worker’s chances of having an accident, or which may cause impairment of
health.
g) Hazard – Any arrangement, equipment, material, object, condition, method or
procedure capable of causing bodily harm or impairment of health or both.
Successful accident prevention requires a minimum of four fundamental activities:
a) A study of all working areas to detect and eliminate or control physical hazards which contribute to
accidents.
b) A study of all operating methods and practices.
c) Education, instruction, training and discipline to minimize human factors which
contribute to accidents.
d) Thorough investigations of accidents to determine contributing circumstances.

50. Reasons for Unsafe Acts
Unsafe acts are brought about usually by one of the following:
a) Lack of knowledge, skill, coordination or planning.
b) Improper attitude.
c) Physical or mental incapability.
d) Carelessness.
Control of Accident Causes
There are four main methods utilized in the control of accident causes. They are
(1)engineering; (2) education and training; (3) enforcement; (4) enthusiasm. These four
methods sometimes referred to as the four E’s of safety, area as outlined below.
1.Engineering. Environmental causes of accidents, or unsafe conditions, can be eliminated through the
application of engineering principles. When an operation is mechanically and physically safe, it is
unnecessary to be as concerned about the uncertain behavior (unsafe acts) of people. Machines
are less apt to fail than men. It may be necessary to make mechanical revisions or modifications to
eliminate existing unsafe conditions and, in some cases, to prevent unsafe acts. Design of machine guards,
automobile brakes, traffic signals, pressure relief valves and handrails are varied are example.
OSHA now prefers engineering practices to take precedence over the wearing of personal equipment.
For example, OSHA recommends the use of mechanical ventilation over the assignment of respirators to
deal with harmful vapors.
2. Education and Training. Just as safety engineering is the most effective way of preventing
environmental accident causes (unsafe conditions), safety education is the most effective tool in the
prevention of human causes (unsafe acts). Through adequate instruction, personnel gain useful
knowledge and develop safe attitudes.
Training is a particularly important accident prevention control; it gives each man a personal safety tool by
development in him habits of safe practice and operation.

51. Enforcement No organized accident prevention effort can be successful without effective
enforcement because accidents are frequently the direct result of violations of safety principles. This
is particularly true of vehicle accidents.
Heads of departments and supervisors are responsible for enforcing safety standards and
regulations. Failure to do so would, in some cases that leads to preventable accidents.
Enthusiasm. Can be effective to a good degree in prevention of accidents.
When we say one is enthusiastic about preventing accidents to himself or his co-workers, we mean
that he/she does all within his endeavor as a human being to prevent the creation of an unsafe
condition; corrects or reports an unsafe act or a hazard; uses the right tool for the job; uses the
personal protective equipment provided for his job and works safely unsupervised.
To be completely effective, accident prevention controls cannot be applied “hit or miss.” All
engineering, education, training, supervision and enforcement measures will be directed
toward the solution of specific problems based on collection of facts relating to unsafe acts or
unsafeconditions.
how to avoid unsafe condition
a)Remove all obstacles and impediments to the safe movement of personnel, vehicles or machines.
b) Repair damaged floors, broken steps, broken glass, cracked walls and ceilings.
c) Replace damaged floors, broken steps, broken glass, cracked walls and ceilings.
d) Replace worn or damaged tools.
e) Provide proper equipment for the hoisting and movement of heavy objects.
f) Install guards for moving parts of machinery, fans, etc.
g) Provide protective equipment such as goggles and hard hats
h) Replace worn electrical wiring and fixtures.

52. Safety Orientation of New Employees
To form good safety attitudes, the new employee must be impressed by everyone’s concern
with the prevention of accidents at the time he starts to work. He must be told that unsafe
workers will not be tolerated and that he will be required to obey safety rules and instructions,
wear protective equipment whenever required and attend safety meetings in order to continue
as an employee of the City.
The supervisor will review safety rules and procedures with the new employee pointing out
the possible hazards involved in doing the job. If possible, the new employee should be
assigned to work with a safety-minded employee during the first few weeks. The new
employee should be checked at frequent intervals, asked about any problems that may have
arisen, and reminded of safe practices.
Safety Training:
a) Basic Safety Course (BSC)
All City employees shall be required to complete a Basic Safety Course BSC). This training shall review the
established safety rules and procedure, fire prevention and protection, written hazard
communication program, emergency evacuation procedures, hazard recognition.
b) Supervisor Job Instruction
New and regular employees shall be trained on a continual basis through the supervisor’s job instruction
and when a new process or equipment is introduced.
c)Safety Meetings
Supervisors shall conduct regular departmental safety meetings. Time shall be set aside at safety meetings
to allow for employee discussion and recommendations. The Safety Officer shall attend these meetings as
often as possible.
All other departments shall hold their safety meetings at least once a month.
Supervisors shall keep records of attendance and submit a report of each meeting on City of Manassas
Safety Meeting Report form to the Safety Officer not later than the third work day after .

53. Physicochemical measurement of effluents ,BOD , Determination of
some contaminants
physicochemical parameters, namely pH, temperature, turbidity, BOD, COD, DO, TOC,
conductivity, TDS, TSS, total alkalinity, sulphate, nitrate, and phosphate and heavy metal
concentrations (iron, copper, lead, nickel, and zinc)
PH : the instruments used were in the limit of precised accuracy and caliberated. The chemicals
used were of AR grade. Due care was taken during sampling to avoid any possibility of
contamination. Temperature and pH were measured in situ. Known buffer solutions of pH 4, pH
7, and pH 10 were prepared and used to standardize the equipment, and the pH readings of
the water samples were immediately taken.
Total dissolved solid was determined by subtracting the values of the suspended solids from
the corresponding total solids of the samples. Total suspended solid was determined by using
Whatman filter paper rinsed in double distilled water and was dried in an oven at 105 C for
exactly one hour and cooled in desiccators. Its residue weight (W1) was determined using a
digital balance. The sample of 100 mL of water was filtered through the resin paper and then
evaporated at 105°C for one hour. This weight which represents W2 of the filter paper
containing the residue was noted, and TSS was calculated using (W2 − W1) × 100 mg/L.
Alkalinity values are determined by titration methods. 50 ml of the water samples was taken in
a clean 150 mL conical flask, and three drops of the phenolphthalein indicator were added. After
that, it was titrated with 0.05 M H2SO4 until colour disappeared. To the colourless solution,
three drops of the methyl orange indicator were added and titrated further until colour changed
from yellow to permanent reddish or orange red, and then titre values were recorded, and
alkalinity was calculated

54. BOD :Biochemical oxygen demand is a measure of the quantity of oxygen consumed by microorganisms
during the decomposition of organic matter.
BOD bottle was prepared and incubated at 20°C for 5 days in the dark. After five days, incubated BOD
bottle was poured with mixing 2 mL of orthophosphoric acid. This was shaken gently and titrated with
sodium thiosulphate to the end point where there was change in colour. The titre value represents dissolve
oxygen on day five. BOD was then calculated as the difference between dissolve oxygen on day one and
that on day five.
COD : Chemical oxygen demand (COD) is the oxygen requirement of a sample for oxidation of organic
and inorganic matter.
Determination of COD was done as per the method described in standard methods. 50 ml of the water
sample was taken in a reflux flask, and 10 mL of potassium dichromate solution with 1 g mercuric sulphate
was thoroughly mixed. Antibumping beads were added to control boiling of the solution. To this, 10 mL of
concentrated sulphuric acid containing silver sulphate was added through the open end of the condenser
carefully and mixed by swirling motion. The reflux apparatus was operated for around 1 hour and allowed
to cool. The flask was removed, and its content was diluted to 150 mL with distilled water. To the resulting
solution, three drops of the ferroin indicator were added. This sample was titrated with standard ferrous
ammonium sulphate to an end point where blue-green colour just changed to reddish-brown. Chemical
oxygen demand (COD) of the blank sample was then calculated.
Determination of total organic carbon (TOC
. The dried sediment samples were finely pulverized, and 0.2 grams each was weighed into 500 ml conical
flasks, and 10 mL of 0.5 M K2Cr2O7 was added and swirled gently. Concentrated H2SO4 (20 mL) was
added with care directly into the suspension. The mixture was swirled gently and allowed to stand for
about 40 minutes. 200 ml of distilled water was added followed by careful addition of 10 mL concentrated
H3PO4. The mixture was allowed to cool, and three drops of the ferroin indicator were added. The
contents were then titrated with 0.25 M FAS to the wine-red end point. (%) TOC of the water sample was
calculated as per the following formula : (%) TOC = (Vb − Vs) × M × 1.38 = R/W, where Vb = volume
of FAS for blank; Vs = volume of FAS for the sample; M = morality of FAS; and W = weight of the

55. Sulphate was determined by the gravimetric/turbidimetric method using BaCl2 as
precipitant.
Nitrate :Determination of nitrate was done by the phenoldisulphonic acid method.
Effluent treatment procedure :
ETP OR EFFLUENT TREATMENT PLANT IS USED TO TREAT THE INDUSTRIAL
WASTE WATER.
INFLUENT: UNTREATED INDUSTRIAL WASTE WATER.
EFFLUENT: TREATED INDUSTRIAL WASTE WATER.
SLUDGE: SOLID PART SEPARATED FROM WASTE WATER BY ETP

56. SCREENING IS THE FILTRATION PROCESS FOR THE SEPARATION OF COARSE
PARTICLES FROM INFLUENT. STAINLESS STEEL NET IS USED FOR SCREENING.
HARD PLASTIC BRUSHES ARE USED TO CLEAN THE NET, WHICH ARE DRIVEN
MECHANICALLY.
EQUALIZATION EQUALIZATION IS THE PROCESS TO MAKE THE WASTE WATER-
HOMOGENOUS & -COOL. EQUALIZATION TANK IS ALSO CALLED HOMOGENOUS
TANK. RETENTION TIME 8 HOURS.
PH CORRECTION IN THIS TANK PH OF THE INFLUENT IS CORRECTED TO MEET THE
STANDARD. ACID OR ALKALI IS ADDED TO THE EFFLUENT BY DOZZING TO INCREASE
OR DECREASE THE PH OF INFLUENT RESPECTIVELY. MULTI-METER TYPE PH METER
IS USED.
DISPERSE UNIT FUNCTION OF DISPERSE TANK IS TO MIX THE SLUDGE COMING
FROM RECYCLE TANK WITH WASTE WATER. IT HELPS TO PROPER AERATION.
AERATION FUNCTION OF AERATION IS OXIDATION BY BLOWING AIR. AEROBIC
BACTERIA IS USED TO STABILIZE AND REMOVE ORGANIC MATERIAL PRESENTS IN
WASTE. ABOUT 200 KG AEROBIC BACTERIA IS GIVEN TO THE PLAN FOR 5 YEARS.

57. SEDIMENTATION PACK IN THIS TANK SLUDGE IS SETTLED DOWN PARTIALLY
SEDIMENTATION PACK PROVIDES THE ADVANTAGE OF FAST SLUDGE SEPARATION
SEDIMENTATION TANK IN THIS TANK SLUDGE IS SETTLED DOWN FINALLY.
EFFLUENT IS DISCHARGED FROM PLANT THROUGH A FISH POND. SLUDGE IS
PASSED TO THE THICKENING UNIT.

58. SLUDGE THICKENING UNIT IN THIS UNIT SLUDGE IS DRIED AND DISCHARGED. A
PARTIAL AMOUNT OF SLUDGE IS RETURNED BACK TO THE AERATION TANK FROM
THICKENING UNIT THROUGH RECYCLE TANK CALLED RETURN SLUDGE TANK AND
DISPERSE TANK.
RETURN SLUDGE TANK FUNCTION OF RETURN TANK OR RECYCLE TANK IS TO MIX
WATER WITH SLUDGE THIS MIXTURE IS THEN PASSED TO AERATION TANK THROUGH
DISPERSE TANK.

59. Role of emergency service :
During an emergency situation, it is all too easy to become confused and disoriented. But
with a little bit of preparation, you can ensure that you can go through any emergencies in
the best possible way. Recently '112' was launched as a pan-India emergency helpline
number.
You can use this single emergency helpline number for various emergency services such as
police, fire and ambulance etc. It provides 24*7 emergency responses across the country.
An immediate assistance will be provided to the affected.
Apart from the emergency helpline number, there a list of emergency numbers in India that
you must be aware of:
Four most important emergency numbers:
NATIONAL EMERGENCY NUMBER-112
POLICE-100
FIRE-101
AMBULANCE-102
The other list of emergency numbers:
Disaster Management Services-108
Women Helpline-1091
Women Helpline - Domestic Abuse-181
Air Ambulance-9540161344
Aids Helpline-1097
Anti Poison New Delhi -1066 or 011-1066
Disaster Management N.D.M.A 011-
26701728-1078
EARTHQUAKE / FLOOD / DISASTER
N.D.R.F: 011-24363260
Deputy Commissioner Of Police - Missing
Child And Women: 1094
Railway Enquiry: 139
Senior Citizen Helpline: 1091/ 1291
LPG Leak Helpline: 1906

60. Reference :
1. https://www.srcc.edu › filesPDF Web results THE FACTORIES ACT 1948 - SRCC
2. https://manassasworks.com › ...PDF
3. Fundamentals of Accident Prevention - Manassas Works
4. https://www.ncbi.nlm.nih.gov/pmc/articles/PMC7455830/
5. https://www.slideshare.net/akashtk/introduction-of-effluent-treatment-plant
6. https://www.indiatoday.in/information/story/list-of-emergency-numbers-in
7. ndia-1464566-2019-02-26
8. https://www.ncbi.nlm.nih.gov/pmc/articles/PMC6546586/
9. https://www.ccohs.ca/oshanswers/hsprograms/hazard_risk.html
10.https://www.osha.gov/shpmguidelines/SHPM_guidelines.pdf
11.https://carrus.co.nz/wp-content/uploads/2015/05/D.-Hazard-Management-
Procedure.pdf
12.http://www.ipr.res.in/safety/documents/Fundamentals%20of%20safety%20and%
20accident%20prevention.pdf
13.https://www.oshatrain.org/courses/pages/703system.html