Topic 01 - Introduction to Safety in Industries.pptx

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IHS 522 – Safety in Industries
HSE – A Critical Business Activity
• An accident that could result due to unsafe acts and unsafe conditions adversely
affects the production, costs and productivity of any industrial setup
• Spoils reputation and demoralizes workers
• Many a times results int court inquiries and disputes
• Could damage the environment
• There should be a balance amongst the production, productivity and safety, giving
equal weight to each of these components
Goals /
Objectives
PRODUCTION
PRODUCTIVITY HSE

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Classification of Hazards
Hazards
Man – Made Natural Disasters
Floods Draughts Fires Earthquakes Volcanoes
Epidemics Wind storms
Landslides
Chemical, Mechanical &
Physical
Electrical
• General
• Ignition / Spark
• Static Electricity
• Physical hazards
involving liquids
Health hazards of Industrial
substances
• Physical (noise, heat, cold,
vibration, radiation, ionization)
• Chemical (exposure to various
types of chemicals, e.g., Hg, Pb)
Chemical reaction hazards
• Reaction rate – inorganic &
organic
• Self-heating of solids
Flammability, fires and
explosions involving air
• Parameters of flammability
• Flammable & explosive dusts
• Liquid / vapour fires & explosions
Hardware hazards
• Mechanical causes of metal failures
• General hazards of moving
machinery
Explosion hazards of process
materials
• Deflagration & detonation (industrial
chemicals with explosive potential)
• Industrial chemicals other than
explosions
Corrosion
hazard
Inundation

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Industrial Hazards
• Hazard means danger, risk; Hazardous means dangerous, risky
• Hazard is a condition with the potential of causing harm or damage to resources of any
kind: man, property, air, water, land, flora and/or fauna
• Natural products are not hazardous under a given set of conditions but when any material is
synthesized to produce a chemical substance having any one of these properties:
flammable, explosive, corrosive, toxic, or if it readily decomposes to oxygen at elevated
temperature
• Some specific examples of hazardous materials:
– Chlorine is toxic when inhaled
– Sulfuric acid is extremely corrosive to (eating into or gradually wearing away) skin
– Steam confined in a drum at 600 psig contains a significant amount of potential
energy
– Acrylic (synthetic) acid can polymerize (process of joining two or more like molecules),
releasing large amount of heat

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Industrial Hazards
• Hazards cannot be changed, and they are the basic properties of the materials and the
conditions of usage
• Inherently safe approach is to reduce the hazard by reducing the quantity of the hazardous
material or energy, or by eliminating the hazardous agent
• Hazard in the process industry is the escape of process material, which may be inherently
dangerous (toxic or flammable) and/or present a high pressure and high or low temperature
• Large and sudden escape may cause explosion, toxic clouds and pollution whose effects
extend beyond the premises of a factory or an industrial establishment
• Examples:
– Release of toxic methyl isocyanate gas in Bhopal (1984), India causing 2,000 deaths
and 200,000 injuries
– Chernobyl nuclear disaster (1986), release of radioactivity into the environment
although causing < 100 deaths, but environmental damaged resulted in $68 billion
• Differ from industry to industry and even from process to process within the same industry

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List of Hazards
• Acute toxicity
• Chronic toxicity
• Flammability
• Reactivity
• Instability
• Extreme conditions (temperature or pressure)
• Environmental hazards including
– Air pollution
– Water pollution
– Ground water contamination
– Waste disposal
• Normal emissions, spills, leaks, fires and explosions, should be considered

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Disaster
• A major accident or natural event or natural calamity involving loss of lives (human
and other creatures), property and resources
• Could be a natural or manmade disaster
• Definition differs from country to country
• Hazard ultimately causes risks to health
Physical Hazards
Noise, vibrations, heat, cold,
radiations, inhalation bad odor /
smell
Chemical Hazards
Exposure to various types of
chemicals & dusts
Biological Hazards
Handling bacteria, viruses,
plants, animals
Streses
Overstress, overtime ionizing,
difficult conditions of toxics,
improper egronomics

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Occurrence of Fire
• Ignition can only lead to fire or explosion if three necessary components occur
simultaneously, these are:
a) A flammable gas or vapour is present in sufficient quantity
Occurs due to leakage or accidental discharge from an enclosed vessel,
pump, compressor, value, flange or the like
b) Sufficient air is present
It can be assumed that there will always be sufficient air in the area. The
oxygen in the air is required for the combustion
c) A source of ignition occurs
A spark having sufficient energy, or a hot surface that will cause
spontaneous or autoignition e.g., a hot exhaust manifold and piping of a
diesel engine

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Fire Triangle
Approx 16% required
• Normal Air contains
21% Oxygen
• Some fuels contain
enough oxygen
within their makeup
to support burning
OXYGEN SOURCE
To Reach Ignition Temp
• Open Flame – SUN
• Hot Surfaces
• Sparks & Arcs
• Friction
• Electrical Energy
• Compression of Gas
HEAT SOURCES
FUELS
Natural Gas, Propane,
Butane, Hydrogen,
Acetylene, CO, others
GASES
Gasoline, Kerosene,
Alcohol, COD Liver Oil,
Varnish, Olive Oil, Lacquer
LIQUIDS
Coal, Wood, Paper, Cloth,
Wax, Grease, Leather,
Plastic, Sugar, Grain, Hay
SOLIDS

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Concepts – Mechanism of Fire
• Flash Point
– Lowest temperature at which it gives off sufficient vapor to form an ignitable
mixture with the air, which is capable of ignition under prescribed test
conditions
• Fire Point
– Lowest temperature at which vapor above a liquid will continue to burn once
ignited, the fire point temperature is higher than flash point
• Auto ignition temperature
– Fixed temperature above which adequate energy is available in the
environment to provide an ignition source. applicable to both liquids as well as
gases
• Flammable liquids must vaporize before they ignite

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Flash Point vs Fire Point vs Auto Ignition Temp

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Concepts – Mechanism of Fire
• Flammable gases (or vapors) and air ignite readily only when their composition lies
within a certain range – the flammability limits, known as ‘lower-flammable
(explosive) limit’ and ‘upper-flammable (explosive) limit’
• Lower-flammable (explosive) limit (LEL)
– Smallest concentration of flammable gas or vapor in air, which is capable of
ignition and subsequent flame propagation under prescribed test conditions
• Upper-flammable (explosive) limit (UEL)
– Greatest concentration of flammable gas or vapor in air, which is capable of
ignition and subsequent flame propagation under prescribed test conditions
• Flammable gases and vapors of flammable liquids are in many ways more
dangerous than the liquids themselves

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LEL & UEL

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Major Ignition Sources of Fires
• Electric sparks and arcs (from electrical circuits, motors, switches etc.) – 23%
• Smoking – 18 %
• Mechanical sparks (from friction and falling objects) – 15%
• Flame (including flaring, boilers) – 7%
• Hot surfaces (hot work, hot processing equipment, electrical equipment) – 7%
• Static electrical sparks & lightning – 2%
• Chemical reactions (e.g. auto-ignition of oil-soaked lagging on hot piping) – 1%
• High energy radiation, microwaves, RF, etc.

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Fire Classification
• Class A fires – combustible materials
– Fires caused by flammable solids, such as wood, paper, and fabric
• Class B fires – flammable liquids
– Fires caused by flammable liquids, like petrol, paint, or white spirits
• Class C fires – flammable gases:
– Fires caused by flammable gases, such as hydrogen or methane
• Class D fires – combustible metals
– Fires caused by metals and chemicals such as magnesium, or potassium
• Electrical fires – electrical equipment:
– Fires caused by electrical items, like heaters. Once the electrical item has been removed,
the fire changes class, which means you can use a different colour fire extinguisher if
necessary
• Class F fires – cooking oils
– Typically, these are chip pan fires

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Fire Extinguisher Labels
• Fire extinguisher colours changed in 1997 to meet British and European Standard
BS EN3
• Colour is displayed in a wide band at the top of the extinguisher

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Fire Extinguisher Colour Code Identification Chart

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Minimizing the Incidence of Fire
• Fire detection and protection equipment should be provided in accordance with laid out
norms and prevalent regulations
• A facility for general audible alarm should be provided in all areas of risk
• Plans and procedures should be put in place for Fire prevention, Building evacuation &
muster points, Fire fighting and Maintenance (including periodic testing) of fire
protection equipment
• All fire escape routes and exit doors, alarm points and fire fighting equipment should be
kept clear of obstructions at all times
• All personnel should be familiar with the fire emergency procedures, alarms and
equipment available, personal responsibilities and evacuation procedures in the event
of a fire alarm. Regular fire drills should be performed to ensure this

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Minimizing the Incidence of Fire
• All flammable liquids, such as photocopier toners, cleaning solvents etc should be
stored away from sources of heat and ignition or naked flame, in metal cabinets.
Only quantities in direct use should be brought into the workplace
• Empty containers and aerosols, which have contained flammable liquids, should be
disposed of forthwith in a secure lidded refuse container and in accordance with the
laid-out procedures and prevalent regulations
• ‘No Smoking’ signs should be strictly obeyed

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Explosions
• A phenomenon in which there is a sudden widespread expansion / increase of
gases in rapidly moving pressure or shock wave
• Expansion could be mechanical, or it could be result of a rapid chemical reaction
• A noisy outburst
• Damage is caused by the pressure or shock wave
• Basic difference between fires and explosions is the rate of release of energy
• Faster in the case of explosions compared with fires
• Fires can result from explosions, and vice versa is also true
(‫أرضية‬ ‫)هزة‬

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Classification of Explosions
Explosions
Mechanical Shock wave Detonation
Pressure
Vessel
Confined Unconfined
Deflagration Vapor Cloud
Physical
Eruption
Dust &
Methane
Underground
Air-Blast
Underground
mines, coal
dust, sulfide
Ruptures /
Overpressure
• Exothermic Runaway Reactions
• Physical overpressure of pressure vessels
• Brittle fractures
• Polymerizations
• Decompositions
• Undesired reactions catalyzed by materials of
construction or by ancillary materials such as
pipe dope (lubricant) and lubricants.
• Boiling Liquid Expanding Vapor Explosion
(BLEVE)
• Underground – Rock Bursts & Bumps

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Dow Index to Access Degree of Hazards
• Chemical, Petroleum and Natural Gas industries are prone to fire and explosion
hazards
• Dow Index by Mond Division of Imperial Chemical Industries (ICI) provides
separate indices for
 Fire (F) – relates to the amount of flammable material in the industrial unit
 Internal Explosion (E) – measure of the potential for explosion within the
industrial unit
 Aerial Explosion Potential (A) – relates both to the risk and magnitude of a
vapor cloud explosion originating from a release of flammable material
 Overall Hazard Rating (R) – used to compare different industrial units with
different types of hazards

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Dow Index to Access Degree of Hazards
Potential Hazard Category Fire (F) Internal Explosion (E) Aerial Explosion (A) Overall Hazard (R)
Mild to Light 0 – 2 0 – 1.5 0 – 10 0 – 20
Low 2 – 5 1.5 – 2.5 10 – 30 20 – 100
Moderate 5 – 10 1.5 – 4 30 – 100 100 – 500
High 10 – 30 4 – 6 100 – 400 500 – 2500
Very High 20 – 50 Exceeding 6 400 – 700 2500 – 12500
Extreme 100 – 250 Exceeding 700 12500 – 65000
Very Extreme Exceeding 250 Exceeding 65000

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Dow Fire and Explosion Index (FEI)
• V1.0 was first Issued in 1964 By Bill Braise (RIP)
• V7.0 was last issued in 1994 and is now marketed by the AIChE ($50/copy)
• FEI is widely used outside of Dow
• FEI is the leading hazard index methodology recognized by the chemical industry
• Dow FEI is a ranking system that gives a relative index to the risk of individual
process units due to potential fires and explosions

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What is the Primary Purpose of the Dow FEI?
• Serves as a guide for the selection of fire and explosion protection methods
• Assists in determining the spacing between adjacent process units within the Inside battery
limit (ISBL)
• A guide for insurance agencies to set insurance rates
• Ranks individual process units where special safety attention can be focused
• Process Units:
– Unloading facility
– Storage tank
– Reactor
– Distillation Column
– Quench Vessel
– Storage Vessel
– Loading facility

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When Should one Perform an FEI?
• Late in Phase III Engineering after:
– Piping and instrumentation diagrams (P&IDs) have been completed
– Equipment has been sized
– A trial equipment layout has been done
– A Discounted Cash Flow (DFC) estimate has been completed
• Who Usually Performs the FEI?
– Generally, a senior process engineer, who is acquainted with the details of
the project, is assigned the task
– Occasionally, different groups tackle the assignment and results are compared
for consensus building

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What Does the FEI Consider?
• Six general process hazards
• Twelve special process hazard
• Nine process control credit factor.
• Four material isolation credit factor
• Nine fire protection credit factors

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General Process Hazards
1. Exothermic chemical reactions
2. Endothermic processes
3. Material handling and transfer
4. Enclosed or indoor process units
5. Access
6. Drainage and spill control

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Endothermic vs Exothermic

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Special Process Hazards
1. Toxic materials
2. Sub-atmospheric pressure (< 500 mm Hg)
3. Operating in or near flammable range.
 Tank farm storage flammable liquid
 Process upset or purge failure
 Always in flammable range
4. Dust explosion
5. Relief Pressure
6. Low temperature

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Special Hazard Processes
7. Quantity of flammable/unstable material.
 Liquids or gases in process
 Liquids or gases in storage
 Combustible solids in storage
8. Corrosion and erosion
9. Leakage – joints and packing
10. Use of fired equipment
11. Hot oil heat exchanger system
12. Rotating equipment

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Process Control Credit Factors
1. Emergency power
2. Cooling
3. Explosion control
4. Emergency shutdown
5. Computer control
6. Inert gas.
7. Operating instruction procedures
8. Reactive chemical review
9. Process hazard analysis

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Material Isolation Credit Factors
1. Remote control valves
2. Dump or blow down control
3. Drainage
4. Interlocks

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Fire Protection Credit Factors
1. Leak detection
2. Structural steel
3. Fire water supply
4. Special systems
5. Sprinkler systems
6. Water curtains
7. Foam
8. Hand extinguishers
9. Cable protection

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Flow Chart to Determine the F&EI
Select Pertinent Process Unit
Determine Material Factor
Calculate F1
General Process Hazard Factor
Calculate F2
Special Process Hazard Factor
Determine Process Unit Hazard
Factor F3 = F1 x F2
Determine FE&I
FE&I = F3 x Material Factor
Determine area of Exposure
Determine Replacement value in
Exposure area
Determine Base MPPD
Determine Actual MPPD
Determine MPDO
Calculate Loss Control
Credit Factor = C1 x C2 x C3
Determine Damage Factor
Determine BI
MPPD: Maximum Probable Property Damage
MPDO: Maximum Probable Days Outage
BI: Business Interruption

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Dow F&EI and Degree of Hazard
Degree of Hazard Dow F&EI
Mild to light 1 – 60
Moderate 61 – 96
Intermediate 97 – 127
Heavy 128 – 158
Severe 159 & above

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Incidents Responsible for Onset Of Hazards & Accidents
• Spillage
 Overflow, backing up, blowback, air lock, and vapor-lock
 Failure of control or major service
 Surging, priming, foaming, puking, spitting
 Condensed products in vapor, change in normal discharge
 Malicious intent, vandalism
• Leakage
 Broken, damaged or badly fitted pipe, vessel, instrument, glass, gasket, gland,
seal, flange, joint or seam-weld
 Internal leaks, overpressure of pipe or vessel
 Deterioration of bursting disc (pin holing)

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• Unintended venting
 Evaporation through open line, drain, cover
 Relief valves leaking, bursting discs blown, lutes blown
 Valve struck, scrubber overloaded, ejector failure;
 Equipment failed/out of service (e.g., scrubbers, flares), excessive pressure,
wrong routing, loss of vacuum
 Vessel damaged, tilted, collapsed, vibrated, over-stirred
 Overloading of open channel / conveyor
• Failures at normal working pressure
 Inadequate design, materials, construction, support, operation, inspection or
maintenance
 Deterioration due to corrosion, erosion or fatigue
 Mechanical impact

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• Equipment failure due to excessive pressure
 Overfilling, over-pressurizing or drawing vacuum
 Overheating or under-cooling
 Internal release of chemical energy
 Exposure to fire or other sources of external heating (e.g., radiation)
• Losses in the chemical industry due to fires and explosions
 Most frequent and severe losses are due to fire and explosions
 Main causes of explosions are accidental and uncontrolled chemical reactions
 Most explosions occur in closed buildings and involve batch reactions
 Rupture of vessels, pipes and equipment contribute greatly to the magnitude of
fire and explosion losses
 Release of flammable gases and liquids results from most of the fires

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Case History: On Static Electricity Hazards
• Two plant operators were filling a tank car with vinyl acetate. One operator was on
the ground, and other was on top of car with the nozzle end of a loading hose. A
few seconds after the loading operation started; the contents of the tank exploded.
The operator on top of the tank was thrown to ground; he sustained a fractured
skull and multiple body burns and died from these injuries
• Accident investigation indicated that a static spark that had jumped from the steel
nozzle to the tank car caused the explosion. The nozzle was not bonded to the tank
car to prevent static accumulation. The use of a nonmetallic hose probably also
contributed

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Toxic Gases
• Asphyxiate gases
– Simple in nature, exclude oxygen from lungs, for example, CH4, and CO2
– First symptom is fast breathing and hunger for air. With time there may be nausea,
vomiting, lying flat on ground, loss of consciousness and finally convulsion, deep coma and
death
– CO reduces the O2 carrying capacity of blood
– Seriousness can be judged by the presence of carboxyhaemoglobin in the blood
b (carboxyhemoglobin content in the blood, %) = 4  a  t  e/100
a = concentration of CO in air, ppm
t = time of exposure in hours
e = factor 1 for resting, 2 for walking and 3 for working
– If value of b is:
below 20% – no symptoms 20 – 30% – headache
30–50% – dizziness, nausea, muscular weakness and danger of collapse
50% and above – Unconsciousness and death

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Toxic Gases
• Irritant gases
– Induce inflammation to tissues such as skin, conjunctiva of eyes, the
membranes of the respiratory tract when they come into contact with them
– If the gases are not soluble into the moist upper respiratory tract, they enter
into the lungs and cause exudation of fluid from the lungs, which may lead to
suffocation
– Nitric oxide, Nitrogen dioxide and Sulfur dioxide are the most common irritant
gases. Nitrogen dioxide can cause inflammation of lungs, which is great
concern to health

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Toxic Gases
• Poisonous gases
– Destroy tissues with which they come in contact
– Nitric oxide, Hydrogen sulfide and Sulfur dioxide are not only irritant but also
poisonous
– Bhopal disaster in 1984 in India has demonstrated the hazards associated
with liquefied gases
– Prominent liquefied toxic gases include: Hydrogen chloride (HCl), Hydrogen
sulfide (H2S), Chlorine (Cl2), Ammonia (NH3), Sulfur dioxide (SO2), Phosgene
(COCl2), Hydrogen fluoride (HF) and Hydrogen cyanide (HCN)
– In addition to these there are about dozen more, which are considered to be
toxic

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Toxic Gases
• How the gases enter body?
– Occupational poisons gain entry to the body via the lungs thru inhalation, skin
– Absorption of a poison depends upon its physical state, particle size and solubility
– Of those substances entering into the lungs, some may be exhaled, coughed up
and swallowed, be attacked by scavenger cells and remain in lung, or enter the
lymphatic system
– Soluble particles may be absorbed into the blood stream
• Remedial measures
– Prevention of formation of gases
– Prevention of exposure of persons
– Dilution of gases
– Removal of gases.

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Hazards While Using Machinery
• Every industry invariably uses machines, equipment, appliances, tools and tackle for carrying out various unit
operations, and is liable to have hazards due to the following:
 Hazards while operating machines and equipment; and working in a construction site
 Crushing
 Shearing
 Cutting or severing
 Entanglement
 Drawing-in or trapping
 Impact
 Stabbing or puncture
 Friction or abrasion
 High pressure fluid ejection
 Electrical shock
 Noise and vibrations
 Contact with extremes of temperature
 Falling from height

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Dos And Don’ts While Operating Plant, Machinery & Equipment
Remember
Prior to operating any machine, make sure that
you know how to stop it
Make sure that all guards are fitted properly, and
they are in working order
Materials if any to be used are clear of working /
moving parts of the equipment
The space around the equipment is free of any
obstruction
Inform the competent person including the
concerned supervisor in case of its failure or
breakdown
Make sure required PPEs are used
Never
Use/operate the equipment unless you are
authorized to do so and are fully conversant with
its operating procedure.
Attempt to clean a machine when it is in motion
Use a machine if it has been tagged with a
danger sign. The sign should be removed by the
authorized person who is satisfied that its
operation is safe.
Wear loose clothes, dangling chains, loose
rings, or keep long hairs, which could be caught
up in the moving parts.
Distract people who are operating the
equipment.

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Surface or Subsurface (Underground) Mine Hazards
• Working space is inherently tight, distorted, congested, isolated and inaccessible, of
poor quality, and deteriorating. These conditions endanger personnel, damage
mobile equipment, and affect all activities
• Adverse working conditions such as darkness, heat, humidity; gassy and watery
conditions that make the miner’s job difficult and risky
• Miners are also liable to occupational diseases such as asbestosis, silicosis and a
few others. In addition, the risks of fire, explosion, inundation and ground failure are
part and parcel of this industry

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Classification of Hazardous Materials
• In our day-to-day life, consumable hazardous substances can be in various forms; such as
liquids (paints, cleaners, solvents); dusts and fibers (from vacuum machines) fumes or
smoke, bacteria (such as those causing legionnaires’ diseases), vapors (such as petrol) or
gases
• Classification
– Class 1 – Explosives
– Class 2 – Gases
– Class 3 – Flammable Liquids
– Class 4 – Flammable Solids
– Class 5 – Oxidizing Substances
– Class 6 – Toxic Substances
– Class 7 – Radioactive Substances
– Class 8 – Corrosive Substances
– Class 9 – Miscellaneous Hazardous Materials

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Classification of Hazardous Materials

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Hazardous Materials – Divisions
UN Class Dangerous Goods Division(s) Classification
1 Explosives 1.1 - 1.6 Explosive
2 Gases
2.1 Flammable gas
2.2 Non-flammable, non-toxic gas
2.3 Toxic gas
3 Flammable liquid Flammable liquid
4 Flammable solids
4.1 Flammable solid
4.2 Spontaneously combustible substance
4.3 Substance which in contact with water emits flammable gas
5 Oxidizing substances
5.1 Oxidizing substance
5.2 Organic peroxide
6 Toxic substances
6.1 Toxic substance
6.2 Infectious substance
7 Radioactive material Radioactive material
8 Corrosive substances Corrosive substance
9 Miscellaneous dangerous goods Miscellaneous dangerous goods

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Class 1 – Explosives
• Explosives are materials or items which have the ability to rapidly conflagration or detonate
as a consequence of chemical reaction
• Division 1.1: Substances and articles which have a mass explosion hazard
• Division 1.2: Substances and articles which have a projection hazard but not a mass
explosion hazard
• Division 1.3: Substances and articles which have a fire hazard and either a minor blast
hazard or a minor projection hazard or both
• Division 1.4: Substances and articles which present no significant hazard; only a small
hazard in the event of ignition or initiation during transport with any effects largely confined
to the package
• Division 1.5: Very insensitive substances which have a mass explosion hazard
• Division 1.6: Extremely insensitive articles which do not have a mass explosion hazard
• Examples: Fireworks, Flares, Fuse, Primers, Igniters

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Class 2 – Gases
• Gases are defined by dangerous goods regulations as substances which have a
vapor pressure of 300 kPa or greater at 50°c or which are completely gaseous at
20°c at standard atmospheric pressure, and items containing these substances
• Includes compressed gases, liquefied gases, dissolved gases, refrigerated liquefied
gases, mixtures of one or more gases with one or more vapours of substances of
other classes, articles charged with a gas and aerosols
• Division 2.1: Flammable gases
• Division 2.2: Non-flammable, non-toxic gases
• Division 2.3: Toxic gases
• Commonly Transported Gases : Acetylene, Carbon Dioxide, Helium, Hydrogen
Gas, Oxygen Gas, Nitrogen Gas, Natural Gas, Oil Gas, Petroleum Gases

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Class 3 – Flammable Liquids
• Flammable liquids are defined by dangerous goods regulations as liquids, mixtures
of liquids or liquids containing solids in solution or suspension which give off a
flammable vapour (have a flash point) at temperatures of not more than 60-65°C,
liquids offered for transport at temperatures at or above their flash point or
substances transported at elevated temperatures in a liquid state and which give off
a flammable vapour at a temperature at or below the maximum transport
temperature
• Commonly Transported Flammable Liquids: Adhesives, Paints, Petrol, Diesel,
Kerosene

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Class 4 – Flammable Solids
• Flammable solids are materials which, under conditions encountered in transport, are
readily combustible or may cause or contribute to fire through friction, self-reactive
substances which are liable to undergo a strongly exothermic reaction or solid
desensitized explosives
• Also included are substances which are liable to spontaneous heating under normal
transport conditions, or to heating up in contact with air, and are consequently liable to
catch fire and substances which emit flammable gases or become spontaneously
flammable when in contact with water.
• Division 4.1: Flammable Solids
• Division 4.2: Substances liable to spontaneous combustion
• Division 4.3: Substances which, in contact with water, emit flammable gases
• Commonly Transported Flammable Solids: Carbon, Phosphorus, Sulphur

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Class 5: Oxidizing Substances; Organic Peroxides
• Substances which may cause or contribute to combustion, generally by yielding
oxygen as a result of a redox chemical reaction.
• Organic peroxides are substances which may be considered derivatives of
hydrogen peroxide where one or both hydrogen atoms of the chemical structure
have been replaced by organic radicals.
• Division 5.1: Oxidizing substances
• Division 5.1: Organic peroxides
• Commonly Transported Oxidizers; Organic Peroxides: Calcium Peroxide, Hydrogen
Peroxide, Magnesium Peroxide

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Class 6: Toxic Substances; Infectious Substances
• Substances that are liable either to cause death or serious injury or to harm human
health if swallowed, inhaled or by skin contact. Infectious substances are those
which are known or can be reasonably expected to contain pathogens
• Dangerous goods regulations define pathogens as microorganisms, such as
bacteria, viruses, rickettsiae, parasites and fungi, or other agents which can cause
disease in humans or animals.
• Division 6.1: Toxic substances
• Division 6.2: Infectious substances
• Commonly Transported Toxic Substances; Infectious Substances: Biomedical
Waste, Clinical Waste, Biological Cultures, Medical Cultures, Dyes, Acids,
Chloroform

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Class 7: Radioactive Substances
• Any material containing radionuclides where both the activity concentration and the
total activity exceeds certain pre-defined values
• A radionuclide is an atom with an unstable nucleus, and which consequently is
subject to radioactive decay
• Commonly Transported Radioactive Material: Radium, Thorium, Uranium

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Class 8: Corrosives Substances
• Substances which by chemical action degrade or disintegrate other materials upon
contact
• Corrosives cause severe damage when in contact with living tissue or, in the case
of leakage, damage or destroy surrounding materials.
• Commonly Transported Corrosives: Acids, Batteries, Dyes, Formaldehyde, Paints,
Sulphides, Polysulphides, Nitric Acid, Iodine

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Class 9: Miscellaneous Hazardous Materials
• Substances and articles which during transport present a danger or hazard not
covered by other classes.
• Includes, but is not limited to, environmentally hazardous substances, substances
that are transported at elevated temperatures, miscellaneous articles and
substances, genetically modified organisms and microorganisms and magnetized
materials and aviation regulated substances
• Commonly Transported Miscellaneous Dangerous Goods: Vehicles, Chemical Kits,
First Aid Kits, Benzaldehyde

60
Hazards Analysis Methods
• Every industry has hazards of various kinds, and there are a number of methods /
techniques that are applied to identify them
• Methods
a) Safety Review
b) Check List
c) Relative Ranking
d) Preliminary Hazard Analysis
e) What-If Analysis
f) What-if –Checklist
g) Failure Modes and Effects Analysis
h) Hazards & Operability Analysis
i) Fault Tree Analysis
j) Event Tree Analysis
k) Cause-Consequence
l) Human Reliability

61
Classification: Hazard Analysis Techniques / Methods
Broad Brush
Design & Routine
Operations
Special Situations
Analysis
• Safety Review
• Check List
• Relative Ranking
• Preliminary Hazard
Analysis
• What-If Analysis
• What-if Checklist
• Failure Modes and
Effects Analysis
• Hazards & Operability
Analysis
• Fault Tree Analysis
• Event Tree Analysis
• Cause – Consequence
Analysis
• Human Reliability

62
Application Of Hazards Analysis Methods During Various
Phases of an Industrial Setup
Different Phases of
Industrial Setup
Hazard Analysis Methods
Safety
Review
Check
List
Relative
Ranking
Preliminary
Hazard
Analysis
What-if
Analysis
What-if
Checklist
HAZOP
FMEA
Fault
Tree
Analysis
Event
Tree
Analysis
Cause-Consequence
Analysis
Human
Reliability
Analysis
R & D            
Conceptual Design            
Pilot Plant Operation            
Detailed Engineering            
Construction / Start-up            
Routine Operations            
Expansion or Modification          
Incident Investigation            
Decommissioning            
 - Commonly Used  - Rarely Used or inappropriate

63
Summary & Overview Of Selected HA Methods

Topic 01 - Introduction to Safety in Industries.pptx

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