1. INDUSTRIAL HAZARDS AND
PREVENTION SYSTEMS
P. Raja abhilash. M.Pharm. (Ph.D.)
Assistant professor
S.R. college of phramacy.

2. CONTENTS
 INTRODUCTION
 WHAT ARE INDUSTRIAL HAZARDS?
 GENERAL HAZARDS IN INDUSTRIES
 a) Fire accidents
 b) Mechanical
 c) Electrical
 d) Chemical and Pharmaceutical
 E) Dust explosion
 IMAGES FOR UNDERSTANDING BETTER INDUSTRIAL
SAFETY
 CONCLUSION
 REFERENCES.

3. INTRODUCTION
HAZARD is a situation that posses a level of threat to life,
health, property or environment
INDUSTRIAL HAZARD may be defined as any condition
produced by industries that may cause injury or death to
personnel or loss of product or property.
SAFETY in simple terms means freedom from the occurrence of
risk or injury or loss .
INDUSTRIAL SAFETY refers to the protection of workers from
the danger of industrial accidents .

4. WHAT ARE INDUSTRIAL
HAZARDS?
 Physical --noise,vibration, heat, cold,pressure,
radiation, fibres,…
 Chemical – flammable/explosive materials,
toxics, sensitising agents.
 Biological – dust , pathogens
 Psyhological – work place practices &
systems, payment systems

5. GENERAL HAZARDS IN
INDUSTRIES
 FIRE HAZARDS
 MECHANICAL HAZARDS
 ELECTRICAL HAZARDS
 CHEMICAL HAZARDS
 PHARMACEUTICAL HAZARDS
 RADIATION HAZARDS
 DUST EXPLOSION

6. FIRE HAZARDS
 Fire is an exothermic chemical reaction between oxygen and
fuel.
 Combustion
Slow combustion eg: cotton waste burning
Rapid combustion eg: petroleum product
Spontaneous combustion eg: paint, scrap
 The effect of fire on people take the form of skin burns .
 Fire can take several different forms including jet fires ,pool
fires and boiling liquid expanding vapour explosion.

7. SOURCES OF FIRE HAZARDS
 Hot surfaces
 Combustible and flammable liquids
 Heat utilization equipments (over heating)
 Chemical process equipments
 Lightening
 Gas cylinders
 Ovens and furnaces
 Reactor
 Welding and cutting
 Spark from metal to metal contact
 Carelessness

8. TYPES OF FIRE

9. Steps to be taken
 Don’t panic
 Raise the alarm
 Evacuate the premises
 Turn off the gas supply
 Attack the fire with extinguisher
 Or vacate the place
In case of fire safe methods to be followed
 Stair cases only to be used for evacuation
 Exit doors should be closed after getting out
 Go down the stair case to the ground
 Walk do not run
 Encounter heavy smoke crawl on the floor, do not talk, cover the
nose and mouth with a wet cloth

10. FIRE EXTINGUISHERS

11. FIRE EXTINGUISHERS TABLE

12. CONTROL OF FIRE ACCIDENTS
 Fire protection is an important part of good
house keeping.
 Prohibition of smoking in manufacturing area
 Oxygen present in atmosphere may be reduced
by dilution with gases as Nitrogen, Carbon
dioxide..

13.  Identification and control of ignition sources in
areas where flammable chemicals are
stored/handled/transferred.
 Elimination of ignition sources.
 Careful plant layout.
 Fire resistance brick walls or reinforced
concrete walls.

14.  Suitable exit facility to be provided.
 Adequate ventilation facility.
 Sprinkler with reliable water supply.
 Installation of sufficient fire alarms .

15. MECHANICAL HAZARDS
Occurs due to:
 Large number of equipments
 Crowded work place conditions
 Frequent interaction between worker and equipment
 Insecurely fixed machines
 Worn and teared parts
 Failure of SOP
 Dangerous Parts
 Negligence
 Improper maintenance of equipment
Most common in metal industries and construction sites.

16. Factors responsible are:
 PHYSICAL – Physical capability of worker
may not meet the job requirement.
 PHYSIOLOGICAL FACTORS:
a) Age
b) Sex
c) Time
d) Experience

17. Safety measures for Mechanical hazards
 All machinery must be fenced or mechanical
interlocking or photocell.
 Machine should be fitted with emergency shut down
system.

18.  Turn key system for cleaning and for repairing.
 Control system override should be monitored.
 Operator must have a safe distance from the machine.
 Strictly following SOP.
 Stop and lock button for machines.

19. PREVENTIVE MEASURES
 BUILDING PLANNING :
-- Floors must be non slippery type
-- Enough space to move easily
-- Easy access of workers to the safety
switches
 SAFE MATERIAL HANDLING :
--All material handling equipments should be
repaired and maintained properly.

20.  PERSONNEL PROTECTIVE DEVICES:
-- Protection of head by using hard hats and
helmets
-- Ears by using ear muffs and plugs
-- Face by using face masks

21. ELECTRICAL HAZARDS
 Electricity is the flow of electrons through a substance
which allows transfer of electrical energy from one
position to another.
How Shocks occur?
Current Level Probable Effect on Human body
1 mA Slight tingling sensation.
5 mA Slight shock felt; not painful but disturbing.
6-30 mA Painful shock, muscular control is lost.
50-150 mA Extreme pain, respiratory arrest, severe
muscular contraction and death is possible
1000-4300 mA Muscular contraction and nerve damage
occur. Death is most likely.
10,000 mA Cardiac arrest, severe burns and probable
death

22. The most frequent causes of electrical injury/death are:
1.Contact with power lines
2.Path to ground missing or discontinuous
3.Equipment not used in manner prescribed
4.Improper use of extension and flexible cords
5. Electric shocks and burns due to poor indication
facilities
6. wiring faults and improperly wired equipments
7. Sparking at loose connection

23. Safety Measures for electrical hazards
 Design a safer system
 Implement a safe electrical work program
 Observe work practice
 Use protective equipment
 Use warning labels
 Recheck the equipment everyday
 Heat producing electrical equipment
 Overhead electrical wire should have extra care
 Recheck the lines everyday
 Proper training to workers

24. PREVENTIVE MEASURES
 Proper maintenance of wiring and equipments.
 High voltage equipments should be properly
enclosed.
 Indication of danger sign at every high voltage
terminal.
 Safe work project
 Insulation, guarding , grounding,
electrical protective devices.

25.  Worker should avoid working with the
equipment in wet clothes and shoes.
 Water supply should be far away from
electrical circuits.

26. CHEMICAL HAZARDS
 Chemical hazards are:
- Toxic
- Corrosive
- Irritant
- Carcinogenic
- Flammable
- Mutagenic

27.  Chemical reactions may get out of control due
to:
-Wrong raw materials
-Raw materials with impurities
-Changed operating conditions
-Time delay
-Equipment failure

28. BHOPAL GAS TRAGEDY
 Bhopal gas tragedy, considered as one of the world’s worst
industrial chemical hazard
 It occurred on the night of Dec 2-3,1984 at union carbide
India limited pesticide plant in Bhopal
 water entered Tank 610 containing 42 tons of MIC. The
resulting exothermic reaction increased the temperature inside
the tank to over 200 °C (392 °F) and raised the pressure.
About 30 metric tons of methyl isocyanate (MIC) escaped
from the tank into the atmosphere in 45 to 60 minutes.
 A leak of methyl isocyanate gas causes 8000 deaths, 5,58,125
injuries.

30. Pictograms used in chemical hazards

31. Effects of chemicals on exposure
 Skin burn
 Ache
 Anthrax
 Ulcer in hand, nose etc
 Cancer
 Irritation on wind pipe

32.  Many chemicals can cause severe burns, if
they come in contact with living tissue.
 Living tissue may be destroyed by following
chemical reactions:
-Dehydration by strong dehydrating agents
-Digestion by strong acids and bases
-Oxidation by strong oxidising agents

33. SOME CLINICAL SYMPTOMS AND
HAZARD CAUSING CHEMICALS
ORGAN SYMPTOMS CHEMICALS
EYES Corneal and Sulphur
conjunctival dioxide,
disturbances hydrogen
sulphide
NERVOUS Drowsiness CNS
SYSTEM depressants
MOUTH and Green tongue Vanadium
THROAT Salivation Mercury

34. Additives Health effects
Azo dyes Bladder Cancer
Benzene Leukemia
Caustic Soda Blindness & respiratory damage
Zinc salts Skin & eye damage
Chlorine ions Lung and Skin damage
lead Lead poisoning

35. PREVENTIVE MEASURES
 Solvents used in extraction, purification of
synthetic drugs and chemical analysis should
be handled with care.
 Flammable and explosive chemicals should be
kept at proper distance.
 Tolerance level for toxic chemicals set by
federal regulation have to be followed.
 Suitable label to the chemicals for proper
handling.

36.  Personal protective cloth
 Application of cream before commencement
of work.
 Use of Goggles.
 Safety regulation and protecting measures of
good house keeping principles.

37. PHARMACEUTICAL HAZARDS
Some general health hazards in manufacture of
pharmaceuticals include:
 Dust and noise exposures
 Exposure to UV radiation
 Exposure to formaldehyde
 Repetitive motion disorders

38.  Formaldehyde – may cause lung cancer,
prostate cancer. Acute exposure may cause
pulmonary edema and pneumonia leading to
death. Also causes allergic dermatitis
 Repetitive motion disorder– motion associated
with packing and filling could lead to Carpal
tunnel syndrome or Tendonitis.

39.  Hazards from handling crude drugs and it’s
extracts eg: Ipecacunha.
 Solvents eg: Benzene
 Alkaloids eg: scopolamine, emetine
 Toxic intermediate
 Final product eg: Local anaesthetic
 Miscellaneous Hazards
 Radiant energy
 Bacteria and viruses

40. DUST EXPLOSION
 The term dust is used if the maximum particle size of
the solids in the mixture is 500 mm .
 Dust explosion is a rapid combustion of a dust cloud.
 Drying, milling and blending operations generate
atmospheric and fugitive dust emissions.
 During wet granulation, compounding and tablet
coating, hazardous air pollutants may be released to
the atmosphere or in the workplace as process or
fugitive emissions.

41. Control of dust explosion
 USE OF FILTERS

42. CYCLONE SEPERATORS

43. ELECTROSTATIC PRECIPITATORS

44. IMAGES FOR UNDERSTANDING
BETTER INDUSTRIAL SAFETY
In all places of
employment:
passage ways, store
rooms and service
rooms shall be kept
clean and orderly in a
sanitary condition.

45.  Every structure is
required to have load
bearing when using for
storage.

46.  Floor of every work
room shall be
maintained clean, dry
condition.

47.  Floor hole into which
persons can accidentally
walk shall be protected
by a cover that leaves
no opening more than 1
inch wide.

48.  Treads on all stairs
shall be reasonably
slip resistant.
 This picture illustrates
adequate slip
resistance in place.

49.  Employees must be able
to open an exit door
from inside at all times
without keys or special
knowledge even in the
dark.

50.  The door that
connects any room to
an exit route must
swing out in direction
of exit travel if the
room is designed for
more than 50 people
or if the room is a
high hazard area.

51. CONCLUSION
 Review of safety awareness and safety training
requirements of plant employees with respect
to hazards present in the plant.
 Review of constructor safety awareness and
recommend suitable improvement measures.
 Systematic training of employees is necessary.
 In addition, there should be a committee in
each department , responsible for safety in
their departments.

52. REFERENCES
1. Pharmaceutical production and
management by c.v.s subrahmanyam
pg: 393-412
2. Hazard analysis by HACCP in safety
management systems Q.A volume-2 pg:
200-211
3. Perry’s chemical engineering handbook
by Robert H.perry Don.W.Green,
seventh edition pg:26-49