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![FORM– A
[See rule 6(1)]
Application Form For recognition or renewal of recognition of Safety Auditor (to be filled in
by individuals)
(In Duplicate)
1. Name :
2. Father/Husband Name :
3. Date of Birth and Age :
4. Permanent Address:
5. Address for : Correspondence
Telephone No. :
Mobile No. :
Fax :
E-mail :
6. Educational Qualification : (Attach Certified copies)
Applicant’s
Latest
Photograph
signed
across.](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-43-2048.jpg)
![the recognition of the institution as Safety Auditor was revoked or cancelled in the past, its
details are as follows:–
FORM – B
[See rule 6(1)]
Form of Application for recognition or renewal of recognition to
an institution as Safety Auditor
Name and full address of
the Institution:
Institution status (specify
whether Government,
autonomous,
co-operative, corporate
or private) with
registration number:
a) Name of head of
Institution
b) Phone/Mobile No.
c) E-Mail address
d) Fax
Whether the Institution
has been declared as a
Safety Auditor by this
State or any other State?
If so, give details.
Attach bio-data of at least
three employed persons,
in the Annexure attached
to this application :
Any other relevant
information
Certificate No. (in case
of renewal)
.DECLARATION
I hereby declare that,-
(a) Recognition of the institution as Safety Auditor was not revoked or cancelled by
the State Government in the past;](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-46-2048.jpg)
![Chapter-XXIX Wages (R. 248, 249):Wages shall be paid before 7th day (workers<1000)
or 10th day (workers>1000) of the wage period concerned. In case of termination it shall be
paid before the expiry of the second working day from the date of termination. A notice of
wage period, date, time and place of payment shall be displayed in English, Hindi and the
local language.
Chapter-XXX Powers of Director General and Inspectors (R. 250 to 252) :Powers to
engage experts and agencies and powers of Inspectors including prohibition order are
prescribed.
The Building and other Construction Workers' Welfare Act 1996 and Rules 1998
provide for levy and collection of on the cost of construction to generate fund for Building
and other Construction Workers Welfare Board constituted under the main Act (Part 7.1).
THE BUILDING AND OTHER CONSTRUCTION WORKERS’ WELFARE CESS
ACT, 1996
ACT NO. 28 OF 1996
[19th August, 1996.]
An Act to provide for the levy and collection of a cess on the cost of construction incurred
by employers with a view to augmenting the resources of the Building and Other
Construction Workers’ Welfare Boards constituted under the Building and Other
Construction Workers (Regulation of Employment and Conditions of Service) Act,
1996.
BE it enacted by Parliament in the Forty-seventh Year of the Republic of India as
follows:—
1. Short title, extent and commencement.—(1) This Act may be called the Building
and Other Construction Workers’ Welfare Cess Act, 1996.
(2) It extends to the whole of India.
(3) It shall be deemed to have come into force on the 3rd day of November, 1995.
2. Definitions.—In this Act, unless the context otherwise requires,—
(a) “Board” means a Building and Other Construction Workers’ Welfare Board
constituted by a State Government under sub-section (1) of section 18 of the Building
and Other Construction Workers (Regulation of Employment and Conditions of
Service) Act, 1996 (27 of1996);
(b) “Fund” means the Building and Other Construction Workers’ Welfare Fund
constituted by a Board;
(c) “prescribed” means prescribed by rules made under this Act;
(d) words and expressions used herein but not defined and defined in the Building
and Other Construction Workers (Regulation of Employment and Conditions of
Service) Act, 1996 (27 of 1996) shall have the meanings respectively assigned to them
in that Act.
3. Levy and collection of cess.—(1) There shall be levied and collected a cess for the
purposes of the Building and Other Construction Workers (Regulation of Employment and
Conditions of Service) Act, 1996 (27 of 1996), at such rate not exceeding two per cent. but
not less than one per cent. of the cost of construction incurred by an employer, as the
Central Government may, by notification in the Official Gazette, from time to time specify.](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-65-2048.jpg)
![FORMII
[See rule 9(1)]
1. Name of Establishment Registration No. under Building and Other
………………………………………… Construction Workers’ (Regulation of
…………………………………… Employment and Condi-tions of Service) Act,
1996. Address
II. Date of commencement of work Estimated period of work:
………Month Year Date Month Year
Estimated cost of work (original) Advance Cess/ Deduction at source
………………………………………………… Date of Assessment order Amount of Cess assessed
III. Modification to the original
estimates Revised date of Reason
completion/ Date of stoppage
Actual cost estimates Actual cost
incurred
Whether work is being handed Yes/No.
over to any other person/agency for completion.
If yes, Name/ Address of such person/agency.
…………………………………………………………………….Signature of Employer
Name of Employer
Date
TO BE FILLED BYASSESSING OFFICER
Date of revision of assessment
Amount of cess after revision
Cess already received Cess to be recovered
Cess to be refunded, if any Reference to Board for refund;
Date /number
Signature
Designation
Maharashtra fire prevention and Life Saving acts 2007 and rules:
DRAFT RULES
1. Short Title and commencement –
(1) These rules may be called The Maharashtra Fire Prevention and Life Safety Measures
Rules, 2008.
(2) They extend to the whole State of Maharashtra.
(3) They shall come into force –](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-76-2048.jpg)
![Chapter - VII Account of the Central Board (R.17).
In addition to above mentioned Central Rules, State Rules are also available as under.
Gujarat Air (Prevention and Control of Pollution) Rules, 1983.
They were notified and came into force from II11-1983. They have 25 Rules, 2 Schedules
and Forms I to II.
Rule 2 gives 12 definitions.
A. Furnace means any structure or installation where any form or type of fuel is burnt
or otherwise a high temperature higher than ambient is maintained.
B. State Laboratory means that established u/s 17 of the Act.
Other provisions include terms, conditions and functions of the State Board, appointment,
fees and tours of consultant, air pollution control area, application for consent and its
inquiry, manner of taking samples of air, functions of state air laboratory, qualifications
for Govt. analyst and board analyst, appeals, budget, annual report and statement of
accounts etc.
Environment (Protection) Act, 1986:
This Act (29 of 1986) was enacted on 23-51986. It came into force, from 19-11-1986 in
the whole of India. It has 4 chapters and 26 sections.
The Statement of Objects and Reasons of the Act identifies the need for a general
legislation on environmental protection to enable co-ordination of activities of the various
regulatory agencies, creation of an authority which will assume a lead role for studying,
planning and implementing long-term requirements of environmental safety and give
direction to and co-ordinate a system of speedy and adequate response to emergency
situations threatening the environment.
Its preamble states that it is an Act to provide for the protection and improvement of
environment and for matters connected therewith
Chapter -I : Preliminary (S.I, 2) :
Some definitions are as under:
Environment includes water-air and land and the inter-relationship which exists among and
between , air and land and human beings, other living creatures, plants, micro-organism and
property [S.2(a)].
Environmental pollutant means any solid, liquid or gaseous substance present in such
concentration as to be injurious to environment, [S.2(b)].
Environmental pollution means the presence of any environmental pollutant in the
environment, [S.2(c)]
Handling in relation to any substance, means the manufacture, processing, treatment,
package, storage, transportation, use, collection, destruction, conversion, offering for sale,
transfer or the like of such substance [S.2 (d)].
Hazardous Substance means any substance or preparation which by reason of its chemical
or physiochemical properties or handling is liable to cause harm to human beings, other
living creatures, plant, microorganism, property or the environment. [S.2(e)].](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-94-2048.jpg)
![6) A pre-treatment is necessary to immobilise the mercury and reduce the volume of
waste to be disposed of for disposal in Treatment, Storage and Disposal Facility
7) ensure that no damage is caused to the environment during storage and transportation
of e-waste
8) Every manufacturer, producer, bulk consumer, collection centre, dealer, refurbished,
dismantler and recycler may store the e-waste for a period not exceeding one hundred
and eighty days and shall maintain a record of collection, sale, transfer and storage of
wastes and make these records available for inspection [RULE: 15- procedure for
storage of e-waste]
9) The transportation of e-waste shall be carried out as per the manifest system whereby
the transporter shall be required to carry a document (three copies) prepared by the
sender, giving the details as per Form-6. [RULE: 19- Transportation of e-waste]
10) Provided that the transportation of waste generated from manufacturing or recycling
destined for final disposal to a treatment, storage and disposal facility shall follow the
provisions under Hazardous Wastes (Management, Handling and Transboundary
Movement) Rules, 2008.
11) Storing of E-Waste in landfills - environmental & health hazard
Incineration - environmental & health hazard
Reusing and recycling-limited life span, hazardous in unorganised sector
12) Government assist by encouraging setting up of integrated Transport, Storage and
Disposal Facilities (TSDF) for hazardous waste management on Public Private
Partnership (PPP) mode
13) The Ministry of Environment, Forest and Climate Change has notified E-Waste
(Management) Rules, 2016. The rules - for the first time in India - introduced
Extended Producer Responsibility (EPR).
14) The EPR is an environment protection strategy that makes the producer responsible
for the entire life cycle of the product, especially for take back, recycle and final
disposal of the product.
15) DISPOSING E-WASTE
(a) Donate working older equipment to schools’ colleges or government entities
in need.
(b) If PCs are out of order then return it to the manufacturers. (HCL and Wipro in
India have best take back service).
(c) Send waste goods to authorised recycling facility for proper disposal.
BATTERIES (MANAGEMENT AND HANDLING) RULES, 2001
U/s 6, 8, & 25 of die Environment (protection) Act 1986, these rules were made and
brought into force from 16-5-2001.
They have 14 rules, I schedule and 9 forms.
They apply to every manufacturer, importer, reconditioner, assembler, dealer, recycler,
auctioneer, consumer and bulk consumer involved in manufacture, processing, sale,
purchase and use of batteries or components thereof.
There are 19 definitions u/r 3 some of which are as under -
"Battery" means lead acid battery which is a source of electrical energy and contains lead
metal;
"Consumer" means a person using lead acid batteries excluding bulk consumers;](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-103-2048.jpg)
![is prohibited. Testing and trial are permitted in a licensed factory. (R.5).
2 Application for authorisation of explosives is necessary. Particulars are prescribed for
submission. A sample shall be sent as per instruction from CC (R. 6).
3 Tests prescribed [R. 6 (6)]
1. Physical properties including consistency, reaction, tendency to absorb moisture,
segregation of the constituents, exudation, behaviour at low temperature,
specific gravity etc.
2. Chemical composition- percentage and quality of ingredients.
3. Stability - effect of environmental conditions which would produce spontaneous
ignition or variation in sensitiveness.
4. Ignition characteristics- ignition point, behaviour, liability to spontaneous
ignition.
5. Mechanical sensitiveness to friction and impact.
6. Air gap sensitivity and transmission of detonation..
7. Velocity of detonating.
8. Strength determination.
9. Gases evolved upon explosion.
10. Such other tests specified by the CCE.
11. Any other test required by CCE.
12. Delivery and Dispatch under licence and not exceeding the quantity (R.7).
13. Packing as per Schedule H and after approval of the sample (R. 8).
14. Marking of packages should mention the word "EXPLOSIVES" (not required
for fireworks and safety fuse), name of the authorised explosive, class number
and division, safety distance category, names of manufacturer, consignor and
consignee, net weight and letter 'V for permitted explosive (R.9)
15. Weight of explosive shall not include the weight of the packing box (10.)
16. Competent person should be in-charge of operations (R.11)
17. Precautions in handling- Floor should be checked, cleaned and swept before and
after use. The packages shall not be thrown, dropped, rolled or pulled but shall
be passed from hand to hand and carefully deposited. A slung package should be
prevented from fall (R. 12).
B. Handing between sunset and sunrise is restricted unless proper lighting and guarding is
provided. (R. 13).
C. Within 15 mt. of an explosive storage or at its place of handling or transport, smoking,
fires, lights and flammable substances or substances to cause fire or explosion such as
acids, petroleum, calcium carbide, compressed gases shall not be allowed (R. 14)
D. No person will carry matches, knives, fuses, iron or steel or wear shoes with iron nails
(R. 15).
E. Split explosive shall be safely destroyed (R. 16).
F. Employment of person below 18 years, intoxicated persons and persons of unsound
mind is prohibited (R. 17).
G. Precautions against danger from water (in compatible) or exposure to sun or heat are
necessary (R. 18).
H. Special precautions against accident (fire or explosion), thefts, entry of unauthorised
person near explosives are necessary. (R. 19).
5. Nitro-glycerine or Ethylene glycol dinitrate or explosives of Class-5, unauthorised,
deteriorated or damaged explosives shall not be transported without approval of CC,
except within the licensed factory solely for the purpose of manufacture of explosives
(R. 20).](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-119-2048.jpg)
![The related matter is available in the hard copy of the manual which can be had by placing an
order(by letter or through e- mail) to the following address
Dy. Chief Controller of Explosives
Testing Station
Amravati Road, Gondkhairy
NAGPUR 440 023
E- mail address: ccoe.ngp@nag.mah.nic.in
VARIOUS MODEL DRAWINGS WILL BE PROVIDED AT WEB-SITE
INSECTICIDES ACT, 1968:
This Act (46 of 1968) was enacted on 2-9 -1968. It came into force from 1-3-1971 (Sec.
4,7,8, & 36) and 1-8-1971 (remaining part). It extends to the whole of India. It has 38 sections
and a .schedule listing insecticides amended from time to time.
It is an Act to regulate the import, manufacture, sale, transport, distribution and use of
insecticides with a view to prevent risk to human beings or animals and matters connected
therewith.
Provisions are made for the Central Insecticides Board, its committees, procedure and
officers (S.4 to 8), Registration of insecticides, appeal and revision (S.9 toll), Licensing (S.12
to 15), Central Insecticides Laboratory (S.16), Prohibition of import and manufacture (S.17),
Sale, stock, distribute, transport, use etc. (S.18) Insecticide Analysis (S.19), Inspectors (S.20 to
23). Report of Insecticides Analyst (S.24), Confiscation of stock (S.25) Notice of poisoning
(S.26), Prohibition of sale etc. for reasons of public safety (S.27), Cancellation of registration
(S.28), Offences & punishment (S.29), Defences which may or may not be allowed (S.30),
Cognisance & trial (S.31), Special courts (S. 31A), Offences by companies (S.33), Power of
Central Govt. and State Govt. to make rules (S.36 & 37) and Exemption (S.38).
By various notifications from 1989 to 1996, many insecticides are banned or restricted
in India, e.g. DDT, chlorobenzilate, BBCP, PCNB, Toxaphene, Aldrin, Chlordane Heptachlor,
Titration, Nitrofen, Benzene Hexachloride etc.
Insecticides Rules 1971 :
These rules came into force on 30-10-1971. They have 9 chapters, 46 rules, 2 schedules
and 22 forms. Chapter-1 gives definitions.
Tests' means any insects, rodents, fungi, weeds and other forms of plant or animal life
not useful to human being s [R. 2 (h)]
'Laboratory' means the central insecticides laboratory. [(R. 2(e))].
Commercial Pest Control Operation means any application or dispersion of
insecticide(s) including fumigants in household or public or private premises or land and
includes pest control operations in the field including aerial applications for commercial](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-142-2048.jpg)
![Definition of employer is very wide and includes his managing agent; legal
representative of a deceased employer, contractor etc.
'Workmen' includes employees working in railway, ship, aircraft, motor vehicle,
abroad or as in Schedule-11 wherein some 48 categories are specified.
"Wages' excludes travelling allowance or concession, special expenses and
contribution towards any pension or P.P.
Partial disablement (temporary or permanent) and total disablement (temporary or
permanent) are defined as same in the ESI Act and the W.C. Act. See part 7 also.
Employer's Liability (Sec 3) : He is liable to pay compensation if accident arises out
of and in course of employment He is not liable for injury -
1. If disablement lasts less than 3 days
2. If the workman takes drink or drugs, or
3. Willfully disobeys any order or a rule of safety, or
4. Willfully removes or disregards any safety guard or device provided for his safety,
But he is liable even under such conditions if injury results in death or permanent total
disablement.
If a workman contracts any occupational disease (i) in Part-A of Schedule III or (ii)
in Part B of Schedule III if he is in continuous service of more than 6 months or (iii) in Part
C of Schedule III if he is in the service of one or more employers for such continuous period
as may be specified, it shall be deemed to be an injury by accident arisen out of and in
course of the employment and makes the employer(s) liable for compensation. The disease
should be directly attributable to his employment.
If a workman claims or agrees to take compensation under this Act, his suit for damages in a
Civil Court is not maintainable [Sec 3(5)].
Amount of Compensation (Sec. 4):
Type of Injury Amount
(
a
) Death
50% of monthly
wages X
Relevant factor
based on
age (from Schedule IV) or Rs. 80,000/-
whichever
i
s
m
o
r
e](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-162-2048.jpg)
![5. For finger damage
0.12 x 4000 x 189.56
480 x 189.56 = Rs. 90988.80
6. For lung damage
0.30 x 4000 x 189.56
1200 x 189.56 = Rs. 2,27,472
Total Rs. 90988.80 + 227472.00
= Rs. 3, 18,460.80
Comparing with permanent total disablement [Sec 4(1) (C), Explanation - 1]
19. 0.60 x 4000 x 189.56
20. 2400 x 189.56 = Rs. 4, 54,944 or Rs. 90000 whichever is more.
As amount Rs. 318460.80 does not exceed Rs. 454944, total compensation payable in
this case is Rs. 318460.80.
Example 6 :A worker worked in three sugar mills in a continuous period of 16 years and it
was detected that he was suffering from bagassosis due to sugarcane dust. This was found at
his age of 45 and monthly wages Rs. 7800. The lung damage (permanent partial
disablement) assessed by a doctor is 50%. Calculate the compensation payable by each, of
the three employers.
Compensation
4.0.50 x 4000 x 169.44
5.2000 x 169.44 = Rs. 338880
As per Section (2-A), each employer may pay Rs. 338880/3 = Rs. 112960 to the
worker, or in the proportion decided by the WC Commissioner depending on the facts of his
case. The employer in whose sugar mill suppose the dust concentration was higher or for
longer duration, may be directed by the Court to pay more proportion of the total amount.
Example 7: A worker while handling organo phosphorous compound, undergoes toxic
effect and remains absent for 3 months as per medical finding of this cause and advice. To
what compensation he is entitled for this temporary disablement? He is drawing Rs. 4500
per month.
As per Section 4 (1) (d), he is entitled to a half monthly payment of 25% of his
monthly wages i.e.. 0.25 x 4500 = Rs. 1125 from the 16th day from the date of disablement.
Here ceiling of Rs. 4000 per month is not applicable. It is applicable to death or
permanent total disablement only [Explanation II to Sec 4 (1)].](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-167-2048.jpg)
![Jolting - sand is manually put in the core boxes which are mounted on the machines. Jolting
of core box is done on machine table itself.
Hot and shell core Making - sand is supplied by a trolley bucket to the machine hopper by a
hoist. Sometime the sand is wet and sometime dry but mixed with resins. Box is
automatically heated up to& desired temperature.
Hand- some cores are made by hand i.e. putting the sand in core fixtures manually Small
parts of cores are at times assembled/joined
Handling of Core Boxes, Core Plates & Cores. Manual loading of cores in core baking ovens,
unloading after baking. Painting of some cores, drying of assembled cores in hot room with
portable gas burners. Assembly of a few cores on core assembly fixture. Cleaning of core
boxes. Cutting of reinforcement wires. Prepared cores are passed on to molding section.]
B) Machine Used:
Sand driver, Core Sand Mixers, Core Making Machines, Molding Machines for heavy cores,
Hettinger’s Hot & Shell Core making machine, Core Ovens
C) Hazards in Core Room:
1) Filling or collapsing of stacked sand bags, if not stacked properly or when wet sand bags
become dry.
2) Drying of sand in drier will give out smoke, it should be exhausted out through an outlet
or chimney. Chain drive of the driver to the enclosed.
3) All the pits and openings to be fenced (skip hoist, area below sand mixer platform).
Overhead platforms and steps to be provided side rails, toe guards (sand mixer platform
and approach to core making machines, core oven platforms), fixed ladders for reaching
heights.
4) Sand mixer platform and steps to be kept clear of sand accumulation.
5) Interlocking arrangements should be made for sand mixer hood or cover. Inspection
windows to be provided for sampling of sand. Samples to be taken by wooden spoons and
not by hand (this is a common unsafe practice causing injuries)
6) Sufficient space and arrangements for fencing around rollover type core making machines
to prevent accidental hit to persons working nearby while the machine is rolling over.
7) All V-Belt drives and chain drives to be guarded with fixed guards.
8) Possibility of fingers getting caught or pressed in between the core plate and squeeze
plate while making core on machine. Job Safety Training.
9) Back Fire hazard while lighting kerosene burner of sand drier and kerosene core baking
oven. Kerosene fired oven have not pilot arrangements. Piece of cloth or cotton waste
soaked in kerosene is tied to one end of a long stick and lighted. Kerosene and air are
slowly released and is lighted with the stick.
If Kerosene and air is not slowly released there will be a back fire.
Similarly, the lighting device should not be allowed to go off. Otherwise the kerosene and
air will get accumulated and later on while lighting there may be an explosion.
To overcome this a gas burner should be provided for lighting the ovens. Job Safety
Training to the operator's.
10) While loading and unloading cores on core baking oven hazard of cores falling down.
Employees will be exposed to heat, smoke & fumes, inform red rays and falling of hot](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-275-2048.jpg)
![7) VIEWING OF COMPUTER Proper body positioning for computer use.
Some important factors in preventing or reducing the symptoms of CVS have to do
with the computer and how it is used. This includes lighting conditions, chair comfort,
location of reference materials, position of the monitor, and the use of rest breaks.
i. Location of computer screen - Most people find it more comfortable to view
a computer when the eyes are looking downward. Optimally, the computer
screen should be 15 to 20 degrees below eye level (about 4 or 5 inches) as
measured from the center of the screen and 20 to 28 inches from the eyes.
ii. Seating position - Chairs should be comfortably padded and conform to the
body. Chair height should be adjusted so your feet rest flat on the floor. If your
chair has arms, they should be adjusted to provide arm support while you are
typing. Your wrists shouldn't rest on the keyboard when typing.
iii. Rest breaks - To prevent eyestrain, try to rest your eyes when using the
computer for long periods. Rest your eyes for 15 minutes after two hours of
continuous computer use. Also, for every 20 minutes of computer viewing,
look into the distance for 20 seconds to allow your eyes a chance to refocus.
iv. LIGHTING ANTIGLARE BLINKING ARE OTHER MEASURES TO
BE TAKEN.
II. CARPEL TUNNEL SYNDROME
1) Carpal tunnel syndrome (CTS) is a medical condition due to compression of the
median nerve as it travels through the wrist at the carpal tunnel. The main symptoms
are pain, numbness, and tingling, in the thumb, index finger, middle finger, and the
thumb side of the ring fingers.
2) Symptoms typically start gradually and during the night. Pain may extend up the arm.
Weak grip strength may occur and after a long period of time the muscles at the base
of the thumb may waste away.
3) The median nerve and several tendons run from your forearm to your hand through a
small space in your wrist called the carpal tunnel. The median nerve controls
movement and feeling in your thumb and first three fingers (not your little finger).
4) Suggested healthy habits such as avoiding repetitive stress, work modification
through use of ergonomic equipment (mouse pad, taking proper breaks, using
keyboard alternatives (digital pen, voice recognition, and dictation), and have been
proposed as methods to help prevent carpal tunnel syndrome.
5) Stretches and isometric exercises will aid in prevention for persons at risk. Stretching
before the activity and during breaks will aid in alleviating tension at the wrist. [61]
Place the hand firmly on a flat surface and gently press for a few seconds to stretch
the wrist and fingers. An example for an isometric exercise of the wrist is done by
clenching the first tightly, releasing and fanning out fingers.
6) The carpal tunnel is a space in the wrist surrounded by wrist bones and by a rigid
ligament that links the bones together.
7) Through this small tunnel pass the flexing tendons of the fingers and thumb as well as
the median nerve. These tendons attach muscles to bones in the hand and transfer the](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-306-2048.jpg)
![• level of perceived risk is a subjective risk judgment
Impact of risk perception
Why is it important to understand the mechanisms underlying risk perception?
▷ Strong impact on societal acceptance/tolerance of various hazardous activities
▷ Big influence on individuals’ “safety behavior’s” when exposed to a hazard
▷ Phenomenon called risk homeostasis: people tend to act so that the level of risk
to which they feel exposed is roughly constant
• Example: car drivers tend to keep the perceived level of risk at a constant level
• Impact of technological safety measures (abs, better lighting, smoother roads) is
limited because drivers compensate by increasing their speed
Poor perception of probabilities
▷ If you tell investors that, on average, they will lose all their money only every 30
years, they are more likely to invest than if you tell them they have a 3.3% chance
of losing a certain amount each year
▷ Most people rate themselves as being a better driver than the average driver
▷ The vast majority rate the probability for themselves to experience negative
events to be lower than that for the average citizen [McKenna 1993]
▷ Phenomena of unrealistic optimism and illusion of control:
• rare, striking events tend to be overestimated
• frequency of common events tend to be underestimated
Main factors affecting risk perception
These factors combine several characteristics of a risk that tend to be perceived in
the same manner by lay people into one “label”:
▷ “Dread risk”: perceived lack of control, catastrophic potential, inequitable
distribution of risks and benefits, involuntary
▷ “Unknown risk”: not observable, effects are delayed, little scientific knowledge
on the risk, unknown by those people exposed, new risk
▷ “People affected risk”: personally affected, general public affected and future
generations affected.
Impact of control](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-497-2048.jpg)
![▷ People tolerate substantially more risk when they engage in voluntary behavior
▷ Related to a sense of controllability: less risk is perceived in situations that are
under personal control
▷ Phenomenon of illusion of control
• the risk of winning the lottery is perceived to be higher if we pick the numbers
ourselves [Langer 1975]
• a person who sees themselves as being in control (driving the car vs being a
passenger) perceives the risk to be smaller [McKenna 1993]
Why different people have different perception on danger/risk
Unaware the fact about risk -
Ignorance about hazard.
Overconfidence
Previous experience.
Shortcut
Priority v/s Value
Showoff
Training
Education
Theory X – Theory Y
Management Theory
Dr. Douglas McGregor (1906-64):
• Social psychologist Douglas McGregor of MIT expounded two contrasting
theories in the 1960s
• Theories are about human motivation and management
• McGregor personally promoted Theory Y more than Theory X](https://image.slidesharecdn.com/adisstudynotes-230512151553-faa3f4c6/75/ADIS-Study-notes-pdf-498-2048.jpg)
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- 27. CHAPTER - 1 THEFACTORIES ACT 1948(AMENDED IN 1976 &1987) AND RULES: The Factories Act 1948: The above Act was subsequently amended in 1935, 1936, 1937, 1940, 1941, 1944, 1945, 1946 and 1947 before its major amendment in 1948. During the Interim Congress Regime, a five year plan was drawn up to ameliorate the labour conditions in India and also to revise the Factories Act of 1934 on the line of the UK Factories Act 1937 and latest ILO conventions in the matters of safety, health, welfare, working hours, industrial hygiene, medical examination of young persons and submission of plans of factory buildings. The 1942 Conference was important as being the first attempt at collaboration between Government, employers and workers in matters pertaining to Labour. Arising there from, a Plenary Tripartite Conference and a Standing Labour Committee had been set up to advice Government on Labour matters and this resulted in smoothening the way for introduction of legislative measures including the draft Bill. The Factories Bill was introduced in the Constituent Assembly on 30-1-1948 passed by it on 28-8-1948, received the assent of the Governor General of India on 23-9-1948 and came into force from 1-41949. Statement of Objects and Reasons: It was stated in this part that the Factories Act 1934 revealed a number of defects and weaknesses and the provisions for safety, health and welfare were found inadequate and unsatisfactory. The large mass of workers was not covered by the Act and in view of the large and growing industrial activities in the country; radical overhauling of the Factories law was essentially called for and cannot be delayed. It was also mentioned that "the present Act (of 1934) leaves important and complex points to the discretion of Inspectors placing heavy responsibility on them. In view of the specialized and hazardous nature of the processes employed in the factories, it is too much to expect Inspectors to possess an expert knowledge of all these matters. The detailed provisions contained in the Bill will go a long way in lightening their burden". The Labour Minister explained in the Legislature on 30-1-1948 an admirable summary of the New Law and pointed out the broad changes that were brought about. SECTION-2: a) ADUIT- means a person who has completed his 18th year of age. b) ADLESCENT- means a person who has completed his 15th year of age but has not completed his 18th year. c) CHILD -means a person who has not completed his 15th year of age. ca) Competent person – means a person or an institution recognized as such by the Director of Industrial Safety & Health (DISH) for the purpose of carrying out inspection /testing required to be done under the provision of this Act. cb) Hazardous process - Any process or activity carried out in a factory cause impairment to health of the person engaged in or connected to such process, result in a the pollution of general environment. LIST OF INDUSTRIES INVOLVING HAZARDOUS PRZARDOUS PROCESSES (THE FIRST SCHEDULE -THE FACTORIES ACT, 1948), 29 INDUSTRIES ARE LISTED IN THIS SCHEDULE. 1. Ferrous Metallurgical Industries 2. Non- Ferrous Metallurgical Industries 3. Foundries 4. Power Generating Industries 5. Fertilizer Industries 6. Cement Industries 7. Petroleum Industries 8. Petro – Chemical Industries 9. Chemical Industries 10. Highly flammable Liquids and gases
- 28. d) YOUNG PERSON– means a person who is either a child or an adolescent. k) MANUFACTURING PROCESS Means any process for- Making, altering, repairing ornamenting finishing, packing, oiling washing, cleaning, breakin up, demolishing. any article or substance. Pumping oil, water, sewage or any other substance. Generating, transforming, transmitting power. Printing, book binding. Constructing, reconstructing, repairing, refitting, finishing, or breaking up ships or vessels Preserving, or storing any article in cold storage. l) Worker – means a person a person employed directly or by/through any agency (including contractor) in any manufacturing process or connected with the manufacturing process. m) FACTORY Ten or more workers are working or were working on any day of the preceding 12 months, and in any part of which a manufacturing process is being carried out with the aid of power. Twenty or more workers are workers are working or were working on any day of the preceding 12 months, and in any part of which a manufacturing process is being carried out without the aid of power.(Health officer means municipal Health officer or District Health officer or officer appointed by state Govt. Factory Manager means the person responsible to the occupier for the occupier for the working of the factory for the purpose of this act.) SECTION 6- APPROVAL, LICENSING AND REQISTRATION OF FACTORIES 3—APPROVAL OF PLANS Permission for the site on which factory is to be situated – Application such permission shall be made in Form 1. 3A-CERTIFICATE STABILITY NO manufacturing process shall be carried out in a factory until a certificate of stability (Form 1-A) issued by a competent person. Once in each period of 5 years stability test is to be done and certificate of stability (Form 1-A) by a competent person is to be obtained. 5-APPLICATION FOR REQISTRATION AND GRAT OF LICENSE The occupier or factory manager shall submit to DISH an application in Form 2 for registration of the factory and application in Form 3 for grant of license. SECTON 7-A GENERAL DUTIES OF OCCUPIER (Occupier of factory means the person who has ultimate control over the affairs of the factory) Every occupier shall ensure, so far as is reasonably practicable, the health, safety and welfare of all workers while they are at work in the factory. THE INSPECTING STAFF SECTION 8- (RULE 17) INSPECTORS(DIRECTORS OF INDUSTRIAL SAFETY & HEALTH) The State Government may appoint such persons for the purposes of this act. State Government may appoint:- Chief Inspector (DISH) Additional Chief Inspector (ADSH) Joint Chief Inspector (JT DISH) Deputy Chief Inspector (DY. DISH) Inspectors (Assistant DISH)
- 29. SECTION 9 –POWER OF INSPECTORS – Make examination of factories Inquiry and investigation of accidents Suggest/recommends corrective measures SECTION10 – (RULE 18) CERTIFYING SURGEONS The State Government may appoint qualified medical practitioners to be Certifying Surgeons for the purpose of this act. State Government may appoint:- Dy Director (Medical) Any qualified medical practitioner (Area wise) to exercise powers of Dy Director (Medical) POWER OF CERTIFYING SURGEONS The examination and certification of young person The examination of person engaged in dangerous occupation/process Medical supervision/surveys Examination of young person (From 6) Visit the factories (carrying dangerous operations), examine the person employed and record the result in health register (form7 SECTION 11 (RULE 19) – CLEANLINESS White washing and colour washing – at least once in every period of 14 months. Where they are painted or varnished – repainted or revarnished once in every period of five years. SECTION 12 (RULE 22) – DISPOSAL OF WASTED AND EFFLUENTS In the factory where the drainage system is proposed to be connected to public sewerage system, prior permission shall be obtained from Local Authority. For the areas notified under Water (Prevention and Control of Pollution) Act – Approval to arrangement made for the treatment & disposal of trade wasted and effluents shall be obtained from MPCB. SECTION 13 (RULE 22A) – VENTILATION AND TEMPERATURE Adequate ventilation by circulating fresh air, such temp to give comfort and prevent injury to workers. Max. Wet-bulb temp. of air in work room at a height of 1.5m above the floor level – Max 3000 C (Wet-bulb temp. shall not exceed dry-bulb temp.) Air movement at least 30m/minute. The amount of fresh air supplied by mechanical means of ventilation in an hour shall be equivalent to at least 6 times the cubic capacity of work room and distributed evenly throughout the work room. SECTION 14 – DUST AND FUME Dust and fumes likely to be injurious to the workers – exhaust appliance shall be applied as near as possible to the point of origin of dusts and fumes or such point shall be enclosed (provide scrubber system to collect fumes). SECTION 16 – OVER-CROWDING In every work room of factory – 14.2m3 spaces for every worker is required. SECTION 17 (RULE 35/36) – LIGHTING Where natural lighting is not sufficient – additional lighting (uniform level, widely distributed, free from glare) shall be provided.
- 30. Stock-yard, entrance/exit roads,cat-walk, storage area Minimum intensity of illumination – 20 Lux Passage-way, stairways, basement – 50 Lux Boiler room, elevators, store rooms, toilet/wash rooms – 100Lux Where discrimination of detail (for such jobs) is not essential to where discrimination of extremely fine detail is involved – 50 to 1000 Lux Any source of artificial light is less than 5 meters above floor level or any light is producing glare shall be provided with suitable shade of opaque material or effective means to screen the light. SECTION 18 (RULE 39) DRINKING WATER The quantity of drinking water to be provided for the workers shall be at least 5 lit a day per worker. In every factory where in more than 250 workers are employed, the drinking water shall be cooled by ice or effective methods. Water centre shall be provided on canteen, lunch room, rest room and on each floor if the factory has more than one floor. One water centre for every 150 workers is to be provided. SECTION 21 (RULE 57) FENCING OF MACHINERY (GUARDS) Every moving part of prime mover Every flywheel connected to prime mover Headrace & tailrace of every water wheel & water turbine Any part of stock-bar which project beyond the head stock of lathe Every part of an electric generator, a motor or rotary converter Every part of transmission machinery Every dangerous part of any other machinery shall be securely fenced by safeguards of substantial construction Combined openers & scutchers, lap machines, hard waste breakers, cleaners, blenders, hopper moter and similar machines. The border covers and doors shall be fitted with effective interlocking arrangements. Carding Machine: - All Cylinder doors shall be secured by an automatic locking device which shall prevent the door being opened until the cylinder ceased to revolve and shall render it impossible to restart the machine, until the door is closed. Drawing Frame: - The gearing for driving the draft rollers shall be effectively guard by a cover which shall be so interlocked that it cannot be raised until the machine is stopped and the machine is stopped and the machine cannot be restarted until the cover is closed. Speed Frame: - Headstocks shall be fitted with automatic locking arrangement. Combers & similar machines: - The gearing shall be effectively guarded by a cover which shall be so interlocked that it cannot be raised until the machine is stopped and the machine cannot be restarted until the cover is closed. Self-acting Mules: - The drive shall be from countershaft which shall be provided with fast & loose pulley and efficient belt shifting devices. Shearing & Cropping Machines: - the dangerous moving outer blades shall be provided with an efficient interlock arrangement that prevent the complete cover or guard to be opened until the cutter blade has come to rest and would also make it impossible to restart the machine until the guard is closed. Singeing Machines: - Effective arrangement such as solenoid valve or other effective device shall be provided to cut off instantaneously supply of gas or electricity to machine in case of power failure. Cotton Ginning Machinery:-
- 31. The line shaftor second motion in cotton ginning factories when below floor level shall be completely enclosed by a continuous wall or un-climbable fencing. The bare portion of the line shaft between the bearing and also of the projection at the end of line shaft shall be provided with inverted “U” or sleeve type guards. Wood Working Machinery :- (Wood working Machinery means a circular saw, band saw, planning machine, chair mortising machine or vertical spindle molding machine operating on wood or cork. Circular Saw means working in a bench which is moved towards the wood for cutting operation. Band Saw means a band saw, the cutting portion of which runs vertical direction. Planning Machine means a machine for overhead planning or for thickening or for both operations). An efficient stopping and starting device shall be provided on every wood-working machine. Every Circular Saw Shall Be fenced as follows: Behind and in direct line with the saw there shall be an arriving knife, which shall have smooth surface, shall be strong, rigid and easily adjustable. The distance between the front edge of the knife and the teeth of the saw shall not exceed 10mms. For a saw having dia. Of <60cms, the knife shall extend upwards from the bench table to within 25mms, of the ton of the saw, for a saw having dia. Of 60cms or over, shall extend upwards from the bench table to a height of at least 22,5cms. The top of the saw shall be covered by a strong and easily adjustable guard, with a flange at the side of the saw farthest from the fence. The part of the saw below the bench table shall be protected by two plates of metal one on each side of the saw. Such plate shall not be more than 15 cm apart and shall extend from the axis of the saw outwards to a distance of not less than 5 cm. beyond the teeth of the saw. Push Sticks – A push stick shall be provided for use at every circular saw and at every vertical spindle molding machine. Vertical Spindle Molding Machine – The cutter of every vertical spindle moulding machine shall be guarded by the most efficient guard. Planning Machine – shall not be used for overhead planning unless it is fitted with a cylindrical cutter block. Every planning machine used for overhead planning shall be provided with a “bridge” guard capable of covering the full length and breadth of the cutting slot in the bench. The feed roller shall be provided with efficient guard. Chain Mortising Machine – The chain of every Chain Mortising Machine shall be provided with a guard which shall enclose the cutter. Rubber and plastic Mills – (Rubber and plastic Mills means machine with rollers used in breaking down, cracking washing. Grating, mixing, refining and warming of rubber, and plastics. A calendar means machine with rolls used for fractioning sheeting, coating and breading of rubber. compounds and plastic or plastic compounds) Rubber and plastic Mills shall be equipped with Hoppers so guarded that it is impossible to come into contact in any manner with the nip of rolls.Safety – trip rods shall extend across the entire. Length of the face of the face of the rolls and shall be located not more than 170cms above the floor or working level. Colander machines shall be equipped with Horizontal Safety – trip rods across both front and rear, which will when pushed or pulled operate instantly, to disconnect the power and apply the brakes or to reverse the roll. Injunction Molding Machine – An electrical interlock arrangement shall be provided so that the mould cannot be closed unless the front safety gate is fully closed and on opening the front safety gate, the moulds will stop automatically. Centrifugal Machines – (Centrifugal Machine includes centrifugal extractors, de-extractors, separators and driers).Centrifugal Machines shall be provided with efficient interlocking devices that will physically prevent the lids from being opened white the rotating drums or baskets are in motion under power and would also prevent the starting of the drums or baskets under power while the lids are open.
- 32. Centrifugal Machines –(Centrifugal Machine includes centrifugal extractors, de-extractors, separators and driers. )Centrifugal Machines shall not be operated at a speed in excess of the manufacture’s rating All Centrifugal Machines shall be provided with effective braking arrangement to bring cage, drum or basket to rest within short period of time after the power is cut off. The cages, drums or baskets shall be thoroughly examined by a competent person regularty to check their balance. Shears, Slitters and Guillotine Machines – (Shears, Slitters and Guillotine Machines means a machine. Whether driven by power or otherwise, equipped with a straight blade operating vertically against a resisting edge and used for shearing metals or non-metallic substances) A barrier metal guard shall be provided at the front of the knife, fastened to the machine frame and shall be so fixed as would prevent any part of the operator’s body to reach the descending blade from above, below or through the barrier guard or from the sides. At the back end of such machines, an inclined guard shall be provided over which the slit pieces would slide and be collected at a safe distance in a manner as would prevent a person at the back from reaching the descending blade. Slitting machines- (Slitter or Slitting Machine means a machine equipped with circular disc-type knives and used for trimming or cutting into metal or non -metallic substances or slitting them into narrow strips) Circular disc-type knives shall be provided with guards enclosing the knife edges. Index Cutters and Vertical Paper Slotters – (Index Cutters and Vertical Paper Slotters used for cutting strips from the ends of books). Shall be provided with fixed guards so arranged that the fingers of operators cannot come between the blades and blades and the tables. Corner Cutters- (Corner Cutters used in the manufacture of paper boxes) shall be equipped with suitable guards fastened to the machine in front of the knives and provided with slots or perforations to afford visibility of the operation. Band Knives -Band wheels or band knives and all portion of the blades shall be completely enclosed with hinged guards of sheet metal not less than 1mm in thickness. Aoitators and Mixing Machines – (Agitators and Mixing Machines means a tank or other container equipped with power driven mixing arms, blades or paddle wheels fixed to revolving shafts or other simple mechanical devices for blending, stirring liquids with other liquids or with solid substances or combinations of these). When the top of an open agitator tank, beater tank, or paddle tank is less than 1m above the adjacent floor or working level, adequate standard railing shall be installed on all open sides. Agitator & mixing machines shall be provided with an efficient interlock arrangement for the top lid, to prevent access to the agitating stirring or similar devices, while in motion and would prevent restart under power with the lid in open position. Openings at the top or sides of the containers vessels of the agitator and mixing machines provided for inspection & examinations shall be provided with standard grill guards as would prevent access of any part of operator’s body coming in contact with agitating, stirring while in motion. When discharge holes, openings are provided at the bottom or at the sides of containers vessels of the agitator and mixing machines, they shall be so guarded as would prevent access of any part of operator’s body coming in contact with agitating, stirring while in motion inside the vessel.
- 33. LEATHER, PLASTIC ANDRUBBER STRIPPER MACHINES- Strippers for trimming or punching tanned hides, plastic or rubber sheets in either making, footwear manufacturing shall be provided with suitable devices which require simultaneous action of both the hands of the operator or an automatic device which will remove both the hands of the operator from the danger zone at every descent of the blade, punch or stripper cutter. All couplings with projecting bolt heads and similar projections shall be completely encased or effectively guarded as to prevent danger. SAFE GUARDING THE POINT OF OPERATION DEVICS BARRIER GUARDS (BAR ACCESS TO THE POINT OF OPERATION) (CONTROL ACCESS TO THE POINT OF OPERATION) EMPLOYEE CONTROLLING MACHINE CONTROLLING EMPLOYEE CONTROLLING AND MACHINE CONTROLLING PULL BACK OR PULL OUT PRESENCE SENSING TWO HAND CONTROL RESTRAINT FIXED BARRIER GUARDS ENCLOSURE GUARDS ADJESTIBLE BARRIER GUARDS INTERLOCK BARRIER BARRIER GUARDS (Guards are made up of woven wire, expanded metal, perforated metal, sheet metal, wood or metal strips (crossed) wood or metal strips (not crossed), plywood/ plastic, standard railing) SECTION 22 (RULE 58/59) - WORKING ON OR NEAR MACHINERY IN MOTION Examination of any part of machinery or its operation shall be carried out by specially trained adult male worker wearing tight fitting clothing and register is to be maintained in form 10. Specially trained adult male worker shall not handle a belt at moving pulleys unless: The belt is not more than 15cms in width. The pulley is normally for the purpose of drive. There is reasonable clearance between the pulley and any fixed structure. Footholds and handholds are provided.
- 34. No woman oryoung person shall be allowed to clean, lubricate or adjust any part of prime mover or any transmission machinery while in motion. SECTION 28 (RULE62/63) HOIST AND LIFTS Every Hoist and lift shall be of good mechanical construction, sound material, and adequate strength and properly maintained. Thoroughly examined by a competent person atleast once in every period of six months and register is to be maintained. Every Hoist and Lift shall be protected by an enclosure fitted. With gates and so constructed as to prevent any person from being trapped between any part of it and any fixed structure or moving part. Maximum Safe Working Load (SWL) shall be marked on Every Hoist and Lift. The cage of every Hoist and Lift used for carrying persons shall be fitted with a gate on each side from which access is afforded to a landing. Every gate shall be fitted with inter-locking to secure that the gate cannot be opened except when the cage is at the landing and cage cannot be moved unless the gate is closed. There shall be at least two ropes or chains separately connected with the cage and balance weight and each roper pr chain shall be capable of carrying the whole weight of the cage together with its maximum load. Efficient device shall be provided capable of supporting the cage together with its maximum load in the event of breakage of the ropes, chains or attachments. Efficient automatic device shall be provided to prevent the cage from over-running. Register shall be maintained to record particulars of examinations as shown in Form 11. SECTION 29 (RULE 64) – LIFTING MACNINES, CHAINS, ROPES AND LIFTING TACKLES Lifting Machines – means a crane, crab, winch, pulley block, gin wheel, runway. Lifting Tackles – means any chain, sling, rope sling, hook, shackle, swivel, coupling, socket, clamp, tray, whether fixed or moving used in the raising or lowering of persons, loads by use of lifting machines. All parts of Lifting Machine and every Chain, Rope or Lifting Tackle shall be of good mechanical construction, sound material, and adequate strength and properly maintained. Thoroughly examined by a competent person at least once in every period of twelve months and register is to be maintained. No Lifting Machines, Chains, Ropes and Lifting Tackles shall be loaded beyond the SWL, Safe working Load shall be marked on it or displayed in prominent position. Ensure that the crane does not approach within 6m of the place where any person is working on or near wheel track of traveling crane. A register in Form 2 containing the particulars shall be maintained. SECTION 30 – REVOLVING MACHINERY In every factory in which the process of grinding is carried out there shall be permanently affixed or placed near each machine a notice indicating the maximum safe working peripheral speed of every grind stone or abrasive wheel, the speed of the shaft or spindle on which the wheel is mounted, and the diameter of the pulley upon which such shaft or spindle necessary to secure safe working peripheral speed. SECTION 31 (RULE 65) – PRESSURE PLANT Pressure Plant means the pressure vessel along with the piping and other fittings operated at a pressure greater than the atmospheric pressure. Pressure Vessel means any vessel subjected to or operated at a pressure greater than the atmospheric pressure.
- 35. SAFETY MEASURES FOREVERY PRESSURE PLANT OR PRESSURE VESSEL Property designed Good mechanical construction Sound material Sound material Adequate strength free from any defect and property maintained. {Section 32} Floors, stairs and means of access should be soundly constructed and properly maintained. {Section 33} Pits, sumps opening in floor etc., should be either securely covered or fenced. {Section 34} No workman shall be employed in any factory to lift, carry or move any load so heavy as to be likely to cause him injury. {Section 35} Necessary protective equipment should be provided to protect the eyes of the workman, where the working involves risk of injury to the eyes. {Section 36} Suitable precautionary arrangements should be taken against dangerous fumes, gases etc. {Section 37} Every practicable measures should be taken to prevent any explosion where the manufacturing process produces dust, gas, fume or vapour etc. {Section 38}Every practicable measures should be taken to prevent the outbreak of fire and its spread, both internally and externally. {Section 39} The Inspector of Factories can ask the Occupier or the Manager of the Factory to furnish drawings, specification etc., of any building, machinery or a plant, in case he feels that condition of such building, machinery or the plant may likely to cause danger to human life. {Section 40}The Inspector of Factories can suggest suitable measures of steps to take by the Occupier or Manager for implementation, when he feels the condition of any building, machinery or a plant may likely to cause danger to human life. Wherein 1000 or more workmen are employed in a factory, the Occupier should appoint a Safety Officer to look after the safety aspects of the factory. {Section 40-B}
- 36. The Factories (Amendment)Act 1954: The Government of India ratified the ILO Conventions No. 89 & 90 prohibiting employment of women and young person’s during night in factories. Therefore sections 66, 70 and 71 of the Factories Act 1948 were to be amended. Simultaneously opportunity was taken to amend other provisions also. Therefore the Factories (Amendment) Act, 1954 (25th of 1954) came into force with following major amendments: 1. Type composing for printing was included in the definition of manufacturing process. 2. Amendment of Section 4. 3. Prohibition of women and young persons from cleaning, lubricating and machinery in motion. 4. Encasement of machines. 5. Amendment of section 29 to prescribe clearly the safety requirements of lifting machines. 6. Allowing working 6 hours at a stretch without any interval when the shift is of 6 hours. 7. Exempting overtime work in case a shift worker does not turn up in time. 8. Amendment of sections 66, 70 & 71 in conformity with the ILO Convention No. 89 & 90 prohibiting employment of women and Chilean during night in factories. 9. Revision of Chapter-VIII relating to leave with wages to fix 240 days attendance, to raise the limit of carried forward leaves etc. 10. Recasting of section 93 to clarify the responsibility of the owner and occupier. Few minor changes were also incorporated. The Factories (Amendment) Act 1976: After 1948 and 1954, industrial growth was continued and need have Safety Officer was felt to advise management in the matters of industrial safety and health. Due to so many judgments on the definition of 'worker' and tendency to not include 'contract labour' therein in want of proof of 'Master Servant relationship' and feeling need of changes in many other sections including penal section, the Factories (Amendment) Act 1976 (94 of 1976) was enacted and brought into force from 26-10—1976. Its main amendments were: 1. Changes in the definitions of manufacturing process, worker, factory and occupier. Contract labour was included in 'worker'. 2. Approval of the plan and prior permission for the site. 3. Alterations in the provisions 'for inspector, certifying surgeons, cleanliness, disposal of waste and effluents, fencing of machinery, work on or near machinery in motion, striking gear and devices for cutting off power, pressure plant, floors, stairs and means of access, precautions against dangerous fumes, precautions in case of fire, specifications of defective parts, safety of building and machinery, first aid appliances, crèches, spread over, overtime wages, register of child workers, leave with wages, dangerous operation, notice of accidents, penalty for offences, determination of occupier in certain cases, limitation of prosecutions etc. In above alterations the posts of Additional, Joint and Deputy Chief Inspectors of Factories were added, more conditions for cleanliness, fire escape, first-aid etc. were imposed, women strength for crèche was reduced to 30, time limit of rules u/s 64 was extended to 5 years, more particulars of attendance in register and no permission to work without that was required by sections 62 (I-A) and 73 (I-A), carry forwarding of 'refused leave with wages', training and research institutes were included in section 86 for exemption purpose, the words 'manufacturing process or operation' were substituted in section 87 and requiring more welfare facilities including protective equipment and clothing under that section, time limit of one month for inquiry into fatal accident was fixed u/s 88(2), fine limit raised to Rs. 2000 from Rs. 500 u/s 92, and for enhanced penalty to Rs. 5000 from Rs. 1000 u/s 94 and provision of minimum fine in case of fatal accident and serious bodily injury (Rs. 1000 for death and Rs.
- 37. 500 for seriousbodily injury, these figures were doubled in case of enhanced penalty) was also made. 4. New additions were made by section 36A regarding use of portable electric light, section 40A for maintenance of building, 40B for Safety Officers, 62(1-A) and 73(1-A) for more particulars in muster roll, 88A for notice of dangerous occurrences and section 91A for safety and health surveys. In new section 40-A power to give order to carry out measures suggested by Inspector for maintenance of buildings was given and u/s 40B Safety Officers were required for factories employing workers 1000 or more, and the State Government was empowered to notify factories for this requirement and to prescribe rules for the duties, qualifications and conditions of service of Safety Officers. These rules were prescribed in 1983. For these S.0. Rules, 1983 The Factories (Amendment) Act 1987: The Bhopal accident created world-wide safety awareness and moved the governments to provide more stringent requirements for health and safety of workers and public. Therefore the Central and State Governments made necessary amendments in their Acts and Rules. A new Act 'the Environment (Protection) Act 1986' was enacted and the Factories (Amendment) Act 1987 was also enacted on 23-5-1987 providing a new chapter IV A on hazardous processes, many other requirements and severe penalties and imprisonment for breaches. In its Statement of Objects and Reasons it was stated that - "There has been substantial modernization and innovation in the industrial field. Several chemical industries have come up which deal with hazardous and toxic substances. This has brought problems of industrial safety and occupational health hazards. It is therefore, necessary to amend the Act to provide specially for the safeguards against use and handling of hazardous substances and laying down emergency standards and measures. The amendments also include procedures for sitting of hazardous industries for the safety of general public. Provision has been made for workers' participation in safety management, and making the punishment stricter." The Factories (Amendment) Bill, 1986 (Bill No. 141 of 1986) was introduced in Lok Sabah on 2-121986 and received the assent of the President on 235-1987 as the Factories (Amendment) Act 1987 (No. 20 of 1987), and published in the Gazette of India on 25-5-1987. By the Notification dated 29-10-1987, Ministry of Labour, Govt. of India, the Act came into force from 1-12-1987 except sections 7B, 41F and the 2nd Schedule which came into force from 1-6-1988. Its major provisions are : 1. Amendment of Section 2 adding the definitions of competent person, hazardous process and also clarifying the occupier for a firm, a company and government factories. 2. Insertions of section 7A and 7B for general duties of the occupier, manufacturers etc., section 87A giving power to prohibit employment on account of serious hazard, section 96A for penalty for breaches of section 41B, 41C and 41H, section 104A for proving limits of what is practicable etc., section 106A for jurisdiction of a court, section IIIA for right of workers, section II 8A for restriction on disclosure of information and insertion of new Schedules I & II for the list of hazardous industries and permissible levels of certain chemicals. 3. Insertion of a new Chapter IV-A regarding hazardous processes adding section 41 A for constitution of Site Appraisal Committee, section 41 B for compulsory disclosure of information including safety policy and on-site emergency plan and disaster control measures, section 41 C for medical examination, health, records & qualified supervisors, section 41D for Government's power to appoint inquiry committee, section 41E for emergency standards, section 41F for permissible limits of toxic exposures, section 41G for worker's participation in safety management and section 41H for right of workers to warn about imminent danger.
- 38. 4. Amendments ofsections 4, 9 (raising the powers of inspectors), 13, 16, 18, 19, 23, 25, 28, 29, 30, 31, 32, 36A, 64, 70, 71, 80, 87, 89, 90, 91A, 92, 94, 95, 96, 97, 98, 99, 115 and 119. The remarkable amendment is the heavy increase in penalties extending up to Rs. 2 lakhs and Rs. 5000 daily fine, imprisonment up to 10 years and minimum fine of Rs 5000 in case of serious injuries and Rs. 25000 in case of death. 5. Substitutions of section 36 and 38. 6. Omission of section 100 for nomination of occupier. Therefore, now, looking to the passing of above Act of 1987, the factory managers and occupiers must run their factories strictly according to the law to avoid dire consequences. SAFETY AUDIT RULE 2014 The Factories Act, 1948 No. FAC-2013/C.R.212/Lab-4 – In exercise of the powers conferred by section 112 and 115 read with section 41 of the Factories Act, 1948 (63 of 1948), in its application to the State of Maharashtra and clause (3) of section 23 of the General Clauses Act, 1897 (X of 1897) and of all other powers enabling it in that behalf, and in supersession of the Government Notification, Industries, Energy and Labour Department, No. FAC-2009/C.R.309/Lab-4, dated the 3rd January 2012; and to supplement the provisions of Chapter IV of the said Act as a measure for securing the safety of persons employed in certain class of factories, the Government of Maharashtra hereby proposes to make the following rules, the same having been previously published as required by sub-section (1) of section 115 of the said Act, as follows, namely:- 1. (1) These rules may be called the Maharashtra Factories (Safety Audit) Rules, 2013. (2) They shall apply to the factories,- (i) in which manufacturing processes, which involves use, storage, handling or processing of toxic or highly inflammable or explosive or hazardous chemicals or wherein such toxic or highly inflammable or explosive substances are likely to be generated or given out, are carried out, or (ii) in which the hazardous processes as listed in First Schedule appended to clause (b) of section 2 of the Factories Act, 1948 (LXIII of 1948) is carried out; or (iii) Employing more than 250workers. 2. (1) In these rules unless the context otherwise requires,- (i) “Act” means the Factories Act, 1948 (LXIII of 1948), as applicable to the State of Maharashtra; (ii) “Chief Inspector” means any person who is appointed by the State Government as a Chief Inspector, under sub- section (2) of section 8 of the Act; (iii) “Degree” means the degree of statutory university; (iv) “Diploma” means a diploma awarded by a statutory university or a recognized institution; (v) “Form” means a form appended to these rules; (vi) “the Government” or “the State Government” means the Government of Maharashtra; (vii) “safety audit” means a systematic, objective and document evaluation of the
- 39. occupational safety andhealth systems and procedures in a factory, (viii) “Safety Auditor” means a person recognized by a committee constituted by State Government as per rule 5 to carry out safety audit in accordance with these rules and include the safety auditors mentioned in sub- rule (3) of rule 5; (ix) “Schedule” means the Schedule appended to these rules; (x) “Section” means section of the Act. (xi) “hazardous chemical” means any chemical as defined in sub-rule (a) of Rule 2 of Maharashtra Factories (Control of Industrial Major Accident Hazards) Rules, 2003. (xii) “Institution” means a firm, association, body, corporate, society or a trust, whether registered in accordance with the law for the time being force or not, and dealing mainly with the object of ensuring safety and health of workers engaged in factories. (2) Words or expressions used but not defined herein, shall have their respective meanings as assigned to them in the Act or rules made there under. 3. The occupier of the class of factories mentioned in Sub rule (2) of rule 1 shall arrange to carry out the safety audit to supplement the provisions of Chapter IV of the said Act as a measure for securing the safety of persons employed therein, the following manner, namely:- (a) internally, once in a year by a team of Plant personnel; (b) externally, once in two years by the Safety Auditor: Provided that, in the year, when an external audit is carried out, it shall not be necessary to carry out an internal audit: Provided further that, in case of any changes, total or partial, in the manufacturing process, the occupier shall, within one month prior to such change, carry out the safety audit externally by the Safety Auditor. 4. The Safety Audit shall be carried out as per the standards laid down as IS 14489: 1998 in the Indian Standard Code of Practice on Occupational Safety and Health Audit or any such standards prevailing at the relevant time whichever is latest by the Safety Auditor or in case of an institution, by the person or employee possessing the qualification, experience and other requirements as set out in Schedule I as a Safety Auditor. 5. (1) The State Government may recognize any person possessing the qualifications, experience and other requirements as set out in the Schedule I hereto as a Safety Auditor for the purpose of carrying out Safety Audit as provided by these rules: (2) The State Government may recognize any institution, employing at least three persons possessing the qualifications, experience and other requirements as set out in the Schedule I as a Safety Auditor for the purpose of carrying out Safety Audit as provided by these rules. Provided that, where the institute to which such recognition has been granted ceases to employ at least three persons possessing the qualifications, experience and other requirements set out in the Schedule I, the recognition granted to such institute shall stand cancelled; Provided further that, State Government may for reasons to be recorded in writing, relax the requirements of qualification, if such institute is exceptionally specialized in the field of carrying out Safety Audit for not less than 5years. (3) Director General Factory Advise Services &Labour Institute (DGFASLI) and National Safety Council (NSC) or an Officer having working experience of not less than 15 years in the office of the DGFASLI or NSC or Directorate of Industrial Safety and Health, Maharashtra State (DISH) notebook the rank of Deputy Director shall be deemed to be Safety Auditor for carried out Safety Audit under these rules. (4) The State Government may from time to time fix the total number of such Safety Auditors to be appointed depending on the total quantum of work available in the State and also the manner in which applications are to be invited.
- 40. 6. (1) Anapplication for grant or renewal, of certificate of recognition as a Safety Auditor for carrying out safety audit shall be made to the Chief Inspector by an individual in Form A and by an institution in Form B. (2) (a) On receipt of an application duly made in accordance with these rules, the Chief Inspector shall register such application and recommend it to the Government for its approval, after having satisfied itself as regards the competence and facilities available at the disposal of the applicant or recommend to the Government for rejecting the application, after specifying the reasons therefore within 30days. (b) For giving an approval to the applicant as a Safety Auditor, the State Government may constitute a committee, if required, consisting of such members as it may deem fit, to advise it. The application shall be scrutinized by such committee and recommend it to the Government for its approval, after having satisfied itself as regards the competence and facilities available at the disposal of the applicant or recommend to the Government for rejecting the application, after specifying the reasons therefor within 30days. (c) On receipt of the recommendation of the Chief Inspector or such committee, if constituted under paragraph (b), the State Government may grant recognition to the applicant as Safety Auditor or reject the application, after specifying the reasons there for within 45days. (d) After the State Government grants approval to the applicant as the Safety Auditor, the Chief Inspector shall issue certificate of recognition in Form C, within 15 days subject to the following conditions and any other condition as may be specified by the State Government, namely:- (i) Safety Auditor shall maintain a log book of all safety audits undertaken by him indicating the name and address of the audited factory, name of the person who has carried out safety audit, contact persons, date of the audit and date of submission of the audit report to the Occupier. It shall be produced as and when required by officers of the Directorate of Industrial Safety and Health. (ii)Safety Auditor and the person authorized to carry out shall not conduct a Safety Audit of any factory where such auditor or person is employed, or an occupier, partner, director, or manager of that factory, or of any factory owned, operated, managed, or conducted by immediate family members, relatives or extended family members or wherein that auditor or such person has any direct or indirect interest whatsoever. An auditor or such person shall not carry out the safety audit of those factories to which that auditor or such person supplies any plant, machinery, raw material, safety equipments or other materials or equipment. (iii) Safety Auditor and the person authorized to carry out safety audit shall not disclose, even after he ceasing to be a recognized auditor or employee of the institution, any manufacturing or commercial secrets or working processes or other confidential information which may come to his knowledge in the course of their duties as an auditor. Any failure in this regard may make such auditor or person liable for criminal or civil proceedings, in accordance with the law for the time being in force. (3) The recognition granted under sub-rule (2) shall be valid for two years from the date of issue of Certificate of Recognition. (4) The application for renewal of recognition as a safety auditor shall be made at least three months before the expiry of the period of recognition and the procedure stated in sub-rule (2) shall apply mutatis mutandis for its renewal. (5) The applicant shall not be eligible for renewal of recognition as a Safety Auditor if,- (i) the State Government has revoked such recognition in the past on two occasions; or (ii) he has not carried out at least three safety audits of factories in past two years; or (6) The State Government may, after giving an opportunity to the Safety Auditor of being heard, revoke the certificate of recognition, if it has a reasons to believe that,- (i) the Safety Auditor has violated any of the conditions stipulated in the certificate of
- 41. recognition or renewalof recognition; or (ii) the Safety Auditor has carried out the safety audit in violation of the provisions of the Act or these rules or has acted in a manner inconsistent with the intent or the purpose of the Act or rules made there under or has omitted or failed to act as required under the Act and rules made there under; or (iii) for any other like reason; 7. The Occupier of the factory as well as the Safety Auditor shall inform in writing to the concerned office of the Directorate of Industrial Safety and Health, fifteen days in advance before commencement of the safety audit in a factory. 8. The Safety Auditor shall within one month from the date of completion of safety audit forward to the Occupier of the factory a Safety Audit Report in Performa prescribed under Schedule II on the letter head and his recommendations regarding improvement of the occupational safety and health in a factory. Provided that if during safety audit, auditor finds any hazard posing danger of causing an accident, he shall immediately communicate in writing to the occupier as well as to the inspector concerned. In such case the occupier in such case shall take immediate corrective action. 9. The Occupier shall, within thirty days of the receipt of the Safety Audit Report in Performa prescribed under Schedule II, forward the same to the concerned office of the Directorate of Industrial Safety and Health along with the action taken report in pursuant to the recommendations made in the Safety Audit Report. 10. On scrutiny of the Safety Audit Report, if it is found that the safety audit is not carried out in accordance with rule 4, the Chief Inspector may communicate the discrepancies to the occupier and Safety Auditor and shall direct the occupier to carry out re-audit only with respect to the discrepancies pointed out by him. Re-audit shall be completed within thirty days from the date of such direction. The provisions of rules 4, 8 and 9 shall apply to such mutatis mutandis apply to such re-audit. 11. (1) Subject to the provisions of sub-rule (2), the State Government may, by order in writing, exempt any factory or category of factories from all or any of the provisions of these rules, subject to such conditions as it may specify in such order. (2) No order under sub-rule (1) shall be issued unless, in the opinion of the State Government, the requirements of these rules, having regard to the frequency or the nature of manufacturing process carried out in that factory, which involves use, storage, handling or processing of hazardous chemicals or which involves generation of such substances, are impracticable or otherwise not necessary for the safety, health and protection of workers. (3) Notwithstanding anything contained in sub-rule (1) and (2), the State Government may, in its discretion, by order, revoke the exemption granted under sub-rule (1), at any time. SCHEDULE I (See rule 5) The applicant, for being recognized as Safety Auditor, shall possess the following qualifications and experience, etc.:- 1. Academic Qualification and Experience.- The applicant shall hold,- (i) degree in branch of Chemical, Mechanical, Electrical or Production Engineering and having five years’ experience in manufacturing, maintenance, design, project or safety department in
- 42. the supervisory orabove capacity in factories; or (ii) diploma in branch of Chemical, Mechanical, Electrical or Production branch Engineering and having seven years’ experience in manufacturing, maintenance, design, project or safety department in the supervisory or above capacity in factories; or (iii) degree of Bachelor of Science with Physics and/or Chemistry and having ten years’ experience in, manufacturing or safety Department of any factory in the supervisory or above capacity in factories, and one year full time Diploma in Industrial Safety recognized by the Board of Technical Education or All India Council of Technical Education or recognized University; or (iv) degree or diploma in any branch of Engineering and having fifteen years of experience in Factory Inspectorate or Directorate of Industrial Safety and Health or fifteen years of experience in the Director General Factory Advisory Services and Labour Institute or Regional Labour Institute or National Safety Council in the capacity of Assistant Director or above. 2. The applicant shall not be directly or indirectly interested in the factory or in any process or business carried on therein or in any patent or machine connected therewith, in respect of which the safety audit is to be conducted. 3. If the age of applicant is more than 62 years, he shall submit a certificate of physical fitness for carrying out safety audit of factories issued by civil surgeon or certifying surgeon along with the application for recognition or renewal of recognition. SCHEDULE II (See rule 8 & 9) Performa for Safety Audit Report 1. Name and address of the factory, 2. Name of the Occupier, 3. Date of Audit, 4. List of raw material with maximum storage quantity, 5. List of finished products with maximum storage quantity, 6. Manufacturing process flowchart, 7. P I Diagram of all plants (Chemical Factories), 8. Name of the Safety Auditor and Certificate No. and name of the person who has carried out safety audit, 9. Whether enclosed Safety Audit Report as per IS 14489, or any such standards prevailing at the relevant time, whichever is latest: Date: Signature of Safety Auditor/ Person or employee of an Institution authorized to carry out safety audit I (Occupier) undertake to submit the action taken report on recommendations of Safety Audit on or before ……………… Date: Signature of the Occupier.
- 43. FORM– A [See rule6(1)] Application Form For recognition or renewal of recognition of Safety Auditor (to be filled in by individuals) (In Duplicate) 1. Name : 2. Father/Husband Name : 3. Date of Birth and Age : 4. Permanent Address: 5. Address for : Correspondence Telephone No. : Mobile No. : Fax : E-mail : 6. Educational Qualification : (Attach Certified copies) Applicant’s Latest Photograph signed across.
- 44. Sr .N o. Degr ee/D iplo ma College/Institution/U niversity Year of completion 7. TechnicalQualification in Safety (Attach certified copies) Sr.No. Degree/Dipl oma College/Instituti on/University Year of completi on 8. Work Experience (Attach certified copies) Sr. No. Employ ment Date Name and address of Employer Desi gnati on Na tur e of wo rk From To 9. For renewal of recognition.- Certificate No. and date: 10. DECLARATION I hereby declared that, a) my recognition as a Safety Auditor was not revoked or cancelled by the State Government in the past; b) my recognition as a Safety Auditor was revoked or cancelled in the past, and its details are as follows:- Date of revocation or cancellation and its order number, if any Period Fro m To
- 45. Note.-If the recognitionwas cancelled or revoked twice in the past the Safety Auditor is not eligible for recognition. c) I have carried out three or more than three, Safety Audits in the past two years, the list showing the name, address of the factory and date of audits are attached herewith. d) I, ------------------------------------------ hereby declare that the information furnished above are correct to the best of my knowledge. I undertake to: (i) maintain the facilities in good working order, and (ii) Ful fill and abide by the conditions, if any, stipulated in the certificate of recognition. Signature of the Applicant: Full Name: Date : Place :
- 46. the recognition ofthe institution as Safety Auditor was revoked or cancelled in the past, its details are as follows:– FORM – B [See rule 6(1)] Form of Application for recognition or renewal of recognition to an institution as Safety Auditor Name and full address of the Institution: Institution status (specify whether Government, autonomous, co-operative, corporate or private) with registration number: a) Name of head of Institution b) Phone/Mobile No. c) E-Mail address d) Fax Whether the Institution has been declared as a Safety Auditor by this State or any other State? If so, give details. Attach bio-data of at least three employed persons, in the Annexure attached to this application : Any other relevant information Certificate No. (in case of renewal) .DECLARATION I hereby declare that,- (a) Recognition of the institution as Safety Auditor was not revoked or cancelled by the State Government in the past;
- 47. Date of revocationor cancellation and its order number, if any Period Form To Note.-If the recognition was cancelled or revoked twice in the past the institution is not eligible for recognition. (c) The institution has carried out three or more than three, Safety Audits in the past two years, the list showing the name, address of the factory and date of audits are attached here with.I, hereby declare that the persons whose bio-data it attached to the application are employees of the institution whose copies of appointment letters are attached herewith. (e) I, --------------------------------------- hereby declare that the information furnished above for -------------------------------------- (name of the institution) is correct to the best of my knowledge. I undertake to,- (i) notify to the Chief Inspector immediately, in case the employed person on the basis of which this recognition was procured leaves the employment, (ii) Maintain the facilities in good working order, (iii) Fulfil and abide by all the conditions stipulated in the certificate of recognition. Signature of the Head of the Institution: ------------------------------- Designation: ---------------------------------- Place: --------------------------- Date: ----------------------------
- 48. THE CASE LAW Beforestudying any law and citations on it (ie case law) it is important to know the meaning of following legal words. - 1. Law, common law and natural justice. 2. Legislation, legislative process, enactment, statute, statutory, mandatory, notification and ordinance. 3. Bill and statement of objects and reasons. 4. Act, preamble and code. 5. Sections, rules, regulations, schedules & forms. 6. Proviso, exception, exemption, explanation, not withstanding that and save as otherwise provided. 7. Penal section, fine, imprisonment, responsibility, occupier and manager. All offences under the Factories Act and Rules fall under the category of absolute criminal liability, which requires no menses or guilty intention to be proved (AIR 1966 Mad 448 and 1964 Vol.2 LLJ, 456). Out of many decided cases a few citations on safety and health matters are mentioned below to highlight the case law. 1. Citations under the Factories Act : 5.3 Object of the Act is for the benefit and welfare of the labour class only. AIR 1956 Born. 219. 5.4 Interpretation of the Act should be liberal and beneficial AIR 1956 Born. 33, AIR 1966 Guj. 96, AIR 1965, SC 639. 5.5 Limitation of prosecution u/s 106 - Knowledge of offence - Date of receipt of accident report by the Inspector is not the date of knowledge of dangerous occurrence. It is the actual date of his personal knowledge. AIR 1973 SC 309. 5.6 Where the word 'managei, is used specifically, generally he should be taken as accused though the occupier can be selected instead of manager u/s 52, SC ruling 1965 Vol. I LLJ 419. 5.7 Power presses : 1965 Vol. 2 LLJ 472 where section 21- was discussed, 1966 Vol. 2 LLJ 10, 1972 LIC 949, 1966 Vol. I LLJ 280. 1. Transmission Machinery : Height above 15 feet was considered safe by position for which no fencing necessary. 1965 Vol. 2 LLJ 200. In another case height of 9 feet was considered safe for which no-under guard was necessary 1966 Vol. I LLJ 304. 2. Drill machine : Defence that the factory inspector had not pointed out or suggested for guard, it was not provided, cannot be accepted. It was an absolute duty to provide the guard. 1966 Vol. 1 LLJ 705. 3. Calendar machine : Nip guard was necessary, 1966 Vol. 2 LLJ 867. Spur-gear wheel in oil mill : Defence that the guard was provided but some one else removed it, was not accepted. The words "while the machinery is in motion its dangerous parts shall be securely fenced." were sufficient to constitute the offence u/s 21(l)(iv)(c). State of Gujarat v/ s Jethalal Ghelabhai. SC ruling, 1964, Vol. I LLJ 389. 1 It is the duty of the employer who is running a factory to make every sort of protections for the safety of the employees. AIR 1966 Mad 380. 2 It cannot be said that if something goes wrong with the machinery while it is in
- 49. motion and apart of it slips down, there is no obligation on the employer to protect aworkman from injury arising under such circumstances. The basic idea is that the safeguard must be in position so that the rotating or moving part of the machinery is incapable or causing any injury. 1966 Vol. I LLJ 304. 3 It is an absolute obligation under the Factories Act to securely fence dangerous parts of machinery. The statute does not say that they should be fenced only if it is commercially practicable or mechanically possible. AIR 1966 MP 324, (1966) 2LLJ 867. 4 The obligation that a dangerous machine shall be securely fenced by safeguards of substantial construction is absolute, and should be complied with regard to all parts of the machinery. (1965) 2 LLJ 472. 5 Manager/Occupier cannot escape conviction for failure in securely fencing every dangerous part of machinery unless he has satisfied all requirements of section 22 (1) of the Act. (1965) I LLJ 528. 6 Mere fact that the die was not provided with any guard by its manufacture, no effective safety guards could be provided to the die without impairing the working of the machine, cannot affect the employer's responsibility under the law to securely fence the die by safety guards of substantial construction. (196465) 26 FJR 162. 7 Section 21(1) (iv) (c) of the Act requires not only that the dangerous part of a machine shall be securely fenced by safeguards, but also that the safeguards are kept in position when the machine is working. AIR 1964 SC 779, (1964) I LLJ 389. 8 The obligation of the occupier to securely fence the dangerous parts of the machinery is absolute whether those parts may be in motion or use or not. (1962) I LLJ 607. 9 Transmission machinery must be securely fenced unless the same, by reason of its position or construction is safe to every person employed in the factory as it would be if it were securely fenced. AIR 1960 Born. 1. 10 In order to claim the benefit of proviso to section 21 (1) (iv) of the .Act for getting the occasion excluded, it is a necessary condition that on such occasion the necessary adjustment operation to the moving part of the machinery must be done by a worker specified in section 22 of the Act in the manner provided therein. (1965) I LLJ 528. 11 Where instead of complying with the statutory requirements contained in section 24 of the Act and providing the equipment indicated therein, it had been the practice in the concerned factory to effect the movement of the belt with some rod, or crude contrivance which was unsafe, the employer was guilty of negligence under the said section. (1964-65) 26 FJR 153. 12 An owner or occupier of a factory cannot plead in his favour ignorance of the law as contained in the provisions of section 28(1) (e) of the Act. He was bound to provide interlocking arrangement required., (1964) 1"LLJ 689. 1. Only two diagonally opposite chains are necessary and sufficient for working of the tackle. If fourth chain of tackle is allowed to remain in a state of disrepair, the manager of the factory does not contravene the provisions of section 29 (1) (a) (ii) of the Act. (1969) Lab I.C. 783. 4. Failure to cover a pit inside the factory having inherent danger amounts to violation of section 33 of the Act (1967) 2 LLJ 616. 5. No manufacturing process shall be carried on in any building until a certificate of stability of the building has been obtained. Failure to do this is an offence. AIR 1957
- 50. Allh. 343. 6. Thedefence undersection 101 of the Act will not be available to an owner of a factory unless he has proved that he had used due diligence to enforce the execution of the Act. AIR 1964 SC 779. 7. Any person found working in the factory can be taken as employed in the factory until it is proved contrary. 1964 (1) LLJ 575. 8. Failure to comply with the provision of sec. 14 is a 'continuing offence'. Prior knowledge of the offence by the Inspector is not a bar in filing a complaint subsequently (1952-53) 4 FJR 231. Failure to construct a dustproof husk chamber as required under section 14 is a continuing offence. AIR 1962 MP 311. Omission to securely fence fermenting vats is a continuing offence. AIR 1964 Guj. 125, (1964) 5 GLR 29. Omission to provide a canteen is a continuing offence. AIR 1957 All ere (DB). Carrying on a manufacturing process in a building in the absence of a certificate of suitability of the. building as required by the rules is also a continuing offence. AIR 1955 Born.161 (DB.) 9. The plea of ignorance of law is not available to the accused under section 28(1) of the Act. 1964 (1) LLJ. 689. 10. Fencing and safeguard should not be such as can be disturbed and removed by a workman. 1972 Mah LJ. 279, 41 FJR 165. 11. A machinery or part thereof is dangerous if in the ordinary course of its working, danger may reasonably be anticipated from it when working without protection, taking into account the various factors incidental to its working, including the carelessness of the workman, AIR 1969 MP 110. 12. S.2 (m), 2 (k)(i) and 2(1) - Factory", meaning of - Sun cured tobacco leaves subjected to processes of moistening, stripping and packing in a company's premises with a view to their use and transport to company's main factory for manufacturing cigarettes- More than 20 persons under supervision of management working in premises - Held that the manufacturing process was carried on in premises and the persons employed Were workers and premises a factory. Lab IC 1970 S C 56A. 13. S. 2 (k)- "Manufacturing process" - Process of cleaning Water and storing and supplying it by pumping is a manufacturing process. Lab IC 1972 970F Raj. 14. Ss. 33 &2 (m) - Contravention of Section 33 in regard to a pit which is in the environments of the factory - Necessary proof. Lab IC 1972 772 Born. 15. S. 2 (k) (i) - "Manufacturing process" - Rice mill - Use of huller and sheller for converting paddy into rice and polishing it* is a manufacturing process Lab IC 1976, 1387 (Kant). 16. S. 92 - Karnataka Factories Rules. 1969 Allegation that first aid box was not maintained according to Rules - Prosecution must prove what was wanting in contents of box Lab IC 1976,538D (Kant). 17. S. 21 (1) (iv) (c) read with Bombay Factory Rules (1950), Sch. I, Chap. IV, R. 54 (2) and (3) - Compliance with safety measures is mandatory- Whether employer had foreseen casualty is totally irrelevent Lab IC 1978, 1220 Born. 18. S. 2 (m) and S. 103 - Ten workers found inside an automobile workshop during working hours - Plea that two of them were workers in a rice mill not acceptable Lab
- 51. IC 1979, 159AMad NOC. S. 2(m), 92 and Rule 4, GFR-'Factory'- meaning of - Construction work - Temporary work done with aid of power at certain places do not amount to 'factory' within meaning of Section 2(m) - Prevailing nature of work to be taken into account- Contract between company and contractor regarding work and labour manufacture of certain materials on same premises - Temporary use for manufacturing such articles with aid of power will not include premises in the term factory. FLR 1980(41)75, Gujarat. 7 S. 2(g), 2(k), 2(m) - Manufacturing process Meaning of-lroning of stitched clothes with the aid of power by tailoring firms, held, is an integral part of manufacturing process LLN 1985 Vol-ll 101. 8 S. 21(l)(iv)(c) & 92- Injury to worker due to alleged failure to securely fence dangerous part of machinery- Evidence of Factory Inspector silent on vital point- In the circumstances order of conviction of appellant- manager set aside LLN 1986 Vol 1 332. 9 S. 2(k) - Petrol pump service station carrying on business of sale of petrol, diesel, lubricants etc. and servicing of vehicles is a manufacturing process LLN 1987 Vol 1 912. 10 S 2(k)- Dairy farm- filling of milk pots for distribution- Also electric pump used for lifting water in farm- Held, manufacturing process 1987 Vol II 704. 11 S.2(l) - Effect of addition of words "including a contractor". The effect of including the said words in the definition of "worker" is that even a worker engaged through a contractor and working in a factory falls within the definition of worker for the purposes of Factories Act. This was done evidently with a view to ensure that the benefits of the several regulatory and welfare measures provided by the Act extends to such contract labour also. Govt. of A.P. vs. Bhadrachalam Paper Boards Ltd., 1990 (60) FLR 517 (A.P. - D.B.). 1. Workers-Staff engaged in the clerical work in the factory premises- Whether 'workers' within the meaning of section 2(1) of the Act? Yes. State (By Inspector of Factories, Guddalore) vs. A.K. GangllU, 1993 LLR 701 = 1993(67) FLR 627 = 1993 II CLR 57 = 1993 I LLN 791 (Mad. HC). 2. Conviction and sentence of respondent on his pleading of offence under section 92 providing minimum sentence of fine not less than 25000Trial court imposed fine of Rs. 200 onlyWhether order is illegal and perverse? Yes. State of Glljarat vs. B.S. "niakkar, Manager, Diguijay Cement Co. Ltd., 1993 LLR 843 = 1993 (67) FLR 1134 (Guj.HC). See also 1991 (1) 32 (1) GLR71 and 1992 II GLR 229 for State of Gujarat v/s Dr. CK Patel 1. The period of limitation for prosecution in contravening provisions of the Factory Act will be computed from the date of inspection and disclosure of offence. State of Gujarat vs MIT & MIR Pvt. Ltd. Surat, ,1994 LLR 116 (Guj. HC) 6. Appointment of certain number of safety officers in a factory having chemical plant and blast furnace is a statutory obligation on the part of the employer.
- 52. Tata Iron andSteel Co. Ltd. vs Inspector of Factories, Jamshedpur Circle No.I, Jamshedpur and .Others, 1995 LLR 684=1995 II LLN 474 (Pat.HC). 2. Employees of administrative accounts section of a factory will be eligible for overtime. Chief General Manager, Telecom Factory, Bombay & Ors.vs. All India Telecom Engg. Employees Union & Ors., 1996 LLR 333 (Born.HC). 3. In the event of conflict between the provisions of standing orders and Factories Act, the latter will prevail. Maharashtra General Kampar Union vs. Bharat Petroleum Corp. Ltd. &Ors., 1996 LLR 900 (Born. HC). 1. 2. Failure to provide safety electrical devices (earthing, rubber gloves, shoes etc.) resulting into death of a casual worker will make the employer liable for prosecution and fine. The High Court converted the order of acquittal into a fine of Rs. 50000 (in default, impris.onment for 3 months) each to the manager and occupier, accused, and directed to pay Rs. 50000 to the legal representatives of the deceased worker u/s 357(4) of the Cr. P. C. State of Karnataka vs. M. Siddappaq &Amr., 1997 LLR 411 (Karn. HC). 3. Factories Act, 1948 - S.2 (n) - Occupier in case of a company. Occupier in case of a company must be one of the Directors. As such relief claiming appointment of a person other than a Director as an occupier cannot be granted. Tata Oil Mills Co. Ltd. vs. State of U.P., 1997 (2) LLN 681 (All- D.B.). 1. Factories Act, 1948-S.92 read with Rule 61(1)(c)(i) – Punishment for breach of safety measures. Respondent runs a factory and the Factory Inspector found that the plant was not fitted with necessary safely valve in contravention of the aforesaid statutory provisions. On a complaint. Metropolitan Magistrate fined him Rs. 500/- on his pleading guilty. Hence this appeal for enhancement of sentence. Held: Factory owner guilty of contravention of safety measures has to be dealt with severally and seriously even on his pleading guilty to the charge. The workmen exposed to such unsafe working conditions in such factories can be said to be their exploitation by owner of such factories. The sentence of fine of Rs.500/- is enhanced to Rs. 5000/-. State of Gujarat vs. Sandeep Bhandari 1997 I CLR 1048 (Guj. H.C.). 1. Factories Act, 1948- S.92- Karnataka Factories Rules, 1969- Rule 86- Statutory duty not compiled with. This is an appeal against an order of acquittal of respondent accused for an offence under S.92 of the Act for contravention of Rule 86. Facts are that worker in the factory of the respondent received electrical shock and died on the spot. It is held that there was sufficient and clinching evidence on record to show that the accused did not provide for rubber gloves and rubber shoes to deceased worker and further that electric installations were not properly maintained by the accused, there was no justification on the part of Magistrate to hold accused not guilty.
- 53. State of Karnatakav. M. siddappa 1997 I CLR 705 (Kam.H.C.). 54 How it should be interpreted. The Act is meant to provide protection to the workers from being exploited by greedy business establishments and it also provides for the improvement of working conditions within the factory premises. Hence a beneficial construction should be given and the provisions of the Act should be so constructed/interpreted so as to achieve its objects i.e., welfare of the workers and their protection from exploitation and unhygienic working conditions in the factory premises. It is also a cardinal principle of interpretation to give effect to the plain, fair and ordinary meaning to the words if such interpretation is not opposed to the intention of the legislature. Ravi Shankar Sharma vs. State of Rajasthan 1993 L.LC.987 (Raj.H.C.). 55 S.2(m) - & 2(k)(i) - Stone crashing unit is a factory. As per the definition of "manufacturing process" as .given in the Act, there can be no doubt that breaking of boulders into chips would be a manufacturing process. For this purpose coming into existence of a new product is not necessary. If that be so, the premises where ten or more persons are working and the operation is carried on with the aid of power has to be regarded as a factory. M/s. Larsen & Toubro Ltd. vs. State of Orissa 1992 LIC 1513 (On. - D.B.). 56 S.21(l)(i)(iv)(c) and S.92 - Enhancement of sentence. This criminal appeal is filed for enhancement of sentence of fine of Rs.2000/for an offence punishable under S.92 qf the Factories Act, 1948. It is unfortunate and shocking that the Magistrate failed to note the minimum sentence of fine of Rs.5000/- for the offence. He was even not conscious of the object underlying the beneficial piece of legislation viz. Factories Act, 1948. Such gross defiance of law, prima facie, is serious dereliction of duty and unbecoming on the part of any learned Magistrate. The sentence of fine is enhanced to Rs.5000/-. Action is directed against the Magistrate. State of Gujarat vs. Ishwarbhai Harkflabhai Patel 1994 II CLR 721(Giij.H.C.). 1. S.36 - (as it stood before its amendment by Act 20 of 1987) - Interpretation of sub- section (5) of S.36 - There is no absolute duty cast on employer to prevent entry - Burden is on prosecution to prove that employer had not taken all reasonable steps for preventing entry and not on employer to prove that he had taken all reasonable steps. If necessary instructions are issued by employer and worker acts in contravention of those instructions, employer cannot be held responsible for violation of S.36(5). State of Gujarat vs. Dilipkumar Dahyabhai Patel & Anr.1995 II CLR 497 (Guj H.C.). 6.1 S.40-B and W.B. Factories, (Safety Officers) Rules, 1978 - Rule 3(b) - Appointment - Compliance of two pre-conditions The petitioner, who was appointed as safety officer, challenges, termination of his service to be against the provisions of the Rules. High Court has not accepted the challenge observing as follows : Appointment of safety officers, is mandatory on existence of two conditions : (i) wherein 1000 or more workers are ordinarily employed and the State Government
- 54. issues notification requiringthe occupier to appoint safety officer or officers and (ii) wherein the State Government is of opinion wherein manufacturing process is carried which involves risk etc. and issuance of notification in above manner. Issuance of notification is a indispensable condition for employment of safety officers in terms of S.40-B of the Factories Act. In the instant case no such notification was issued. Thus the mandatory requirement of S.40-B cannot be said to have been fulfilled to make employment of the petitioner as Safety Officer within the meaning of clause 3(b) of the Rules of 1978. The termination was thus not violative of the Rules. Debesh Kumar Bhattacharya vs. Rishra Steel Ltd. & Ors.1994 II CLR 944 (CaL H.C.).59 S.41-A - Safety precautions in handling chemicals. The Union of employees filed writ petition to direct Chief Inspector of Factories to enforce safety precautions in the factory. Inspector of Factories had given certain directions to the management of the factory and thereafter he again visited the factory and submitted report. High Court considered the same and accepted the report and dismissed writ petition. The Union filed this appeal against said order. In appeal it is observed that new complaints regarding atmosphere pollution and provision of insurance cover to employees cannot be entertained as they are not the grievances in the main writ petition. Addision Paints and Chemicals Ltd. vs. Chief Inspector of Factories 1993 II L.L.N. 728 (Mad.D.B.). 2. Ss82 and 106 - Magistrate dismissing complaint made by Inspector under S.92 on preliminary contention that it was filed beyond period of limitation of three months as prescribed under S.106. In fact complaint was filed within three months of the date on which commission of offence came to knowledge of Inspector - Matter remanded - Practice of disposing of cases on grounds such as (i)complainant absent, (ii) no witnesses examined, or (iii) accused pleading guilty, deprecated. State ofGujarat vs. Mit and Mir Private Ltd., Swat 1994-1 CLR 149 (Guj.H.C.). 6.3 S.92 - Karnataka Factor Rules, 1969 - Rules 84 and 88 - Negligent shunting of carriages Occupier not responsible. Accident took place in Railway Workshop due to negligent shunting of carriages. Occupier is prosecuted for contravention of Rules 84 and 88. He filed this petition praying for quashing of proceedings against him. Held : Rule 84 prohibits any process of work which is likely to cause risk of bodily injury to be carried on in the factory. It is not complainant's case that the work of shunting which was done within the factory premises was likely to cause risk of bodily injury. Rule 84 is therefore not affected. If due to negligence in carrying out a work which is permissible, an accident takes place, the occupier cannot be held responsible for contravention of Rule 84. So far as Rule 88 is concerned, if bodily injury is caused to a worker not on account of any inherent defect in the construction, situation, operation or maintenance of the means of transport, but on account of negligence of another employee, then it cannot be said that there -is any contravention of Rule 88. Proceeding of prosecution against petitioner occupier is quashed. Ramchandra vs. A.R. Vijendra 1994 II CLR 946 (Kar.H.C.).
- 55. 62 S.92 -Proviso - Minimum sentence is prescribed. The accused pleaded guilty for having committed offence under S.29(l)(a) and S.29(l)(b) of the Act and was awarded fine of RS.IOO/-. Proviso to S.92 provides that the fine shall not be less than RS.IOOO/-. Merely because the accused pleaded guilty is no reason to award punishment lesser than the minimum. State of Gujarat vs. Mahavir Prasad Jain 1992 I CLR 863 (Guj. H.C.). 63 Ss.92, 52, 2(m)(ii) and 6 - Opportunity of hearing to find if establishment is a factory. Prosecution is lodged against the petitioner as failed to comply with the provisions of the Act and Rules. In a challenge against the same, it is urged that before filing the complaint opportunity for hearing should have been given to the petitioner. Rejecting the submission, it is observed that there is no provision under the Act that before launching prosecution, there should be first determination of the fact whether the establishment is a factory or not. This is a question of fact which can be gone into only during the course of hearing. Prabhu dayal Gupta vs. State of Bihar 1993 (66) F.L.R. 398 (Pat.H.C.). 64 S.92 and Gujarat Factories Rules - Rule IIO-A Not providing identity cards is serious breach. Offence of not providing identity cards to workers under S.92 read with Rule IIO-A is not trivial or technical but is grave and serious. For such an offence fine of Rs.20/- is not only unduly lenient and manifestly unjust but is quite ridiculous and travesty of justice. In the circumstances, sentence is enhanced to fine of Rs.l020/- State of Gujarat vs. Lallubimi T1iakorb1im Desai 1994 I CLR 610 (Guj. H.C:). S.94 - Plea of guilty not proper. 1. Accused repeated the offence under S.92 of the Act within span of two years. Under S.94 for such repeated offence, the punishment of fine is not less than Rs.10000/-. Accused pleaded guilty but in the said plea, the element of defence and justification for wrong doing were incorporated. Such a plea cannot be acted upon. Proceeding remanded. State of Gujarat vs. Dineshchandra Hirabhai Patel 1993 II CLR 607 (Guj.H.C.). 66 S..94 - Plea of guilty. The accused gave a plea of guilty in writing wherein he cleverly put some more facts either by way explaining away or justifying the alleged wrong committed by him. Such a plea cannot be said to be plea of guilty at all. Proceeding remanded. State of Gujarat vs. Harishbhai Veljibhai Tilakkar 1994 II L.L.N. 342 (Guj.H.C.). 67 S.94 - Repeated offences - Judicial Magistrate F.C. has no jurisdiction. S.94 provides a higher punishment viz. 3 years imprisonment and fine which shall not be less than RS. 10000/- when the offence is repeated. The Judicial Magistrate F.C. cannot impose such sentence and as such he has no jurisdiction to try the said offence. Chief Judicial magistrate is required to try the same. State of Gujarat vs. Harishbhai Veljibhai TJlakkar 1994 II L.L.N. 342 (Guj.H.C.). 3. High court or Supreme court will not quash FIR lodged by the Factory inspector. S.M. Datta v. State of Gujarat & Anr., 2001 LLR 1076 (SC).
- 56. 4. An occupierof a factory owned by Government need not be Director of the company. Container Corporation of India Ltd. V. Lt. Governor, Delhi & Ors., 2002 LLR 1068: 2002 LIC 2649: 2002-111 LLJ 447 (Del. HC). 1 Section wise Citations : Table 27.4 is useful to find out section wise citations. Only a few citations are given and many more can be added: Table 27.4 :Section wise Citations Section of Subject in Brief Citation. the Factories Act. 2 (m) Substations and zonal stations are not factories. 1972 Lab. I.C. 1438 (SC) 2 (n) Difference between occupier and owner. 1968 ( 1 ) L L J 12 21 1 Shifting or repairs of machinery are not normal AIR 1960 Bom operation in the working go machinery. Therefore the 1 section does not apply. 2 Removable guards are not secured guards, Employer AIR 1 2 6 4 S C is guilty. 779 3 Grinding Wheel, dangerous part 1955 (1) ALL ER 870 4 Dangerous parts. 1966 ( 1 ) L L J 705. 5 Risk must be reasonably foreseeable. 1965 ( 2 ) L L J 200 6 Failure of inspector to point out guard is no defence. 1966 ( 1 ) L L J 705 29 Chains: Number necessary for launder. 1969, L.I.C.783 49 Meaning of ‘ordinarily’ Section 49 can apply to sugar 6 DRL All 297. factories. 62 Failure to maintain register is one offence. If name of any one 1952 ( 2 ) L L J worker is not therein then, it is failure to maintain register. 80 101 Any one means any one and not more of the partners/ 1960 ( 1 ) L L J directors. 42, 105 CIF can file complaint as an inspector. AIR 1960 ALL 373, 1 9 ( 1
- 57. 6 0 ) LLJ 288 106 1Period of limitation 1961 ( 2 ) L L J 717. 2 Report of accident 1947 L I C 2 7 4 (SC) CHAPTER - 2 2.1 LAWS ON CONSTRUCTION SAFETY : Building and other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996; This Act (No. 27 of 1996) came into force from 1-3-1996. It extends to the whole of India,. The Act has II chapters and 64 sections. Preamble: It states that this Act is to regulate the employment and conditions of service of building and other construction workers and to provide for their safety, health and welfare measures and for other matters connected therewith or incidental thereto. Amenability: The Act applies to every establishment (an individual, firm, association, company, contractor. Government etc.) which employs or had employed on any day of past one year ten or more building workers in any building or other construction work. It does not apply to an individual who constructs his own residence costing less than Rs. 10 lakhs. Definitions : Section 2 defines appropriate government (means Central or State Govt), Board, building or other construction work, building worker, Chief Inspector, Director- General, employer (Govt authority, contractor), establishment, fund, wages etc. Scope : The' Act has chapters on advisory and expert committees, registration of establishments and building workers as beneficiaries, welfare boards, working hours, welfare and other conditions, safety and health measures, inspecting staff, special provisions, penalties (max. Rs. 2000 or 3 months or both) and procedure and miscellaneous. Welfare: Powers are given to the States to constitute a Welfare Board and the Central/State Government can make rules for prescribing working hours, intervals, rest day, double wages if worked on rest day, overtime wages at twice the ordinary wages, records & registers, latrines & urinals for more than 50 workers, temporary living accommodation (free of charge) which shall be removed or demolished after the work is over, first aid and canteen facilities for employing more 'than 250 workers. The Act prohibits to employ person who is deaf or has a defective vision or a tendency to giddiness to avoid accident, The Act provides for drinking water points situated 6 mt. away from any washing place, urinal or latrine, and crèche rooms for more than 50 female workers for their children under the age of six years. Safety and Health Measures (Chapter 7, Sec. 3841): They are as under : 1. For 500 or more workers. Safety Committee is necessary. 2. For 500 or more workers qualified Safety Officer is necessary. 3. Notice of accident is required for disablement of more than 48 hours. If 5 or more persons die, inquiry within one month is required. 4. Central/State Government has power to make rules pertaining to
- 58. a) Scaffolding atvarious stages, means of support and safe means of access. b) Precautions while demolition, shoring etc. c) Competent person to control hazards of explosion or flying material. d) Competent persons to drive or operate transport equipment such as locomotives, trucks, wagons, cranes, trailers, etc. e) Hoists, lifts, lifting gear, their testing, heat treatment and precautions while rising or lowering loads etc. and requirement of competent persons. f) Sufficient .and suitable lighting. g) Adequate ventilation at work place, confined space and prevention of dust, fumes, gases, vapours etc. h) Precautions while stacking, unstacking, stowing, unstowing and handling of materials or goods. i) Safeguarding of- machinery. j) Safe handling and use of pneumatic tools, equipment, etc. k) Fire precautions. l) Maximum weight to be lifted or moved. m) Safety of workers while transporting them by water and their rescue from drowning. n) Safety of workers from live electric wires, overhead wires and electrical machinery, apparatus and tools. o) Safety nets, safety sheets and safety belts as per need. p) Standards of compliance with regard to scaffolding, ladders, stairs, lifting appliances, ropes, chains, & accessories, earth moving equipment and floating operational equipment. q) Precautions while pile driving, concrete work, work with hot asphalt, tar etc. insulation work, demolition, excavation, underground construction and handling materials. r) Safety policy. s) Information of Bureau of Indian Standards under the Bureau of Indian Standards Act, 1986, (63 of 1986). Regarding use of any articles or process covered under that Act. t) Medical facilities for building workers. u) Any matter concerning the safety and health of building/construction workers. 5 The Central Government may frame model rules in respect .of matters stated above which shall be followed by the State while making their rules. Inspection Staff (Chapter-8, S.42,43) : The Central Govt. may appoint the Director- General of Inspection and the State Govt. may appoint the Chief Inspector of Inspection of Building and Construction and both the Governments may appoint necessary Inspectors for local limits. All such Inspectors are public servants u/ s 21 of the IPC. Any document or information shall be produced to the Inspector u/s 175 & 176 of the IPC, and Sec. 94 of the Cr. P. C. is also applicable for the power of search & seizure. Wide powers are prescribed u/s 43 for the Inspectors. Special Provisions (Chapter-9, S.44 to 46) : An employer is responsible to provide constant and adequate supervision to prevent accidents and to comply safety provisions under this Act (S.44), to pay wages and compensation to building workers (S.45) and to give notice of commencement of building or other construction work at least 30 days before to the Inspector concerned (S.46). Next Chapter-10 (S.47 to 51) provides for penalties and procedure and Chapter-11 (S.56 to 64) for delegation of powers, returns, protection of action taken in good faith and power' of Central Government to give directions, to remove difficulties and to make rules.
- 59. The Building andother Construction Workers" Welfares Act, 1996 (No. 28 of 1996), received the assent of the President on 19-8-1996 and came into force from 3-11-1995. An employer is required to pay more than 1% but less than 2% of the cost of construction for the purposes of the Act No. 27 of 1996. The local authority or the State Government can collect the in advance while giving approval of a building or construction and shall pay to the Board after deducting the cost of collection not exceeding 1% of the amount collected. Late payment interest is 2% per month on the unpaid amount and a penalty not exceeding the amount of is also chargeable after giving opportunity to be heard. Building and other Construction Workers (Regulation of Employment and Conditions of Service) Central Rules, 1998: U/s. 62 and Sec. 40 of the Act (previous Part 7.1), the Central Government made these rules. They came into force from 19-11-1998. They apply to the work under the jurisdiction of the central Government. They have 5 parts, 30 chapters, 252 rules, 12 schedules and 26 forms. Section-2 gives 74 definitions most of which are technical terms. Thus these rules are very exhaustive and contain many technical details. Part wise subject division is as under: Part I Preliminary Chap I II R. I to 9. Part II Central Advisory Committee Registration of Establishments Chap III to V R. 10 to 33. Part III Safety & Health Chap VI to XXV R. 34 to 233. Part IV Hours of work. Welfare Payment of Wages Registers & Records etc. Chap XXVI to XXIX R. 234 to 249. Part V Chap XXX Miscellaneous provisions. R. 250 to 252. Thus out of 252 rules, 200 are pertaining to Safety & Health and mostly require engineering knowledge. Chapter wise subject matter is as under : Chapter-1 Preliminary (R. I to 4) :Short title, application, commencement, definitions, interpretation of words not defined and savings. Chapter-11 Responsibilities and Duties of Employers, Architects, Project engineers & Designers, Building workers etc. (R. 5 to 9): Rule 5 pertaining to duties of employer and Rule 8 regarding duties of workers are important They have to comply with the provisions of these rules, maintain lifting appliance, transport equipment and all safety devices conforming to safety standards, testing etc., discover and report defects if any, not to remove or interfere with fencing, gangway, gear, ladder, life saving appliances etc., to use only safe means of access and to keep latrines, urinals, washing facilities and canteen in clean and hygienic condition. Chapter-111 Central Advisory Committee (R. 10 to 22): Constitution of the Committee, terms of office, membership, staff, meetings, quorum etc. are prescribed.
- 60. Chapter-IV Registration ofEstablishment (R. 23 to 27): Application for registration in triplicate in Form1, with fees (by DD) to the Registering Officer, grant of certificate of registration (Form-11), Register of Registration (Form-111), and conditions of registration. Fees as under: Building workers up to 100 - Rs. 100 101 to 500 - Rs. 500 501 and more - Rs. 1000 Chapter-V Appeals, Copies of Orders, Payment of Fees, etc. (R. 28 to 33): Appeal and hearing procedure is prescribed. All fees are to be paid by a crossed DD. Chapter-VI Safety & Health, General Provisions (R. 34 to 54): Noise level within limits (Sch. VI), fire protection, emergency action plan for site employing more than 500 workers, fencing of machinery, manual lifting within limits (adult man 55 kg, adult woman or adolescent male 30 kg and adolescent female 20 kg), Health & Safety policy for employing 50 or more workers. Carbon monoxide below 50 ppm and removal of hazardous dust, gas, fumes and oxygen deficiency from any confined space, overhead protection for a building under construction of 15 mt or more in height, the width of protection should be more than 2 mt and height less than 5 mt above the base of the building, protection against slipping, tripping, cutting, drowning and falling hazards, safety net and other adequate equipment to prevent fall, PPE for protection of eye, head and safety from corrosive chemicals, control of electrical hazards, vehicular traffic, stability of structures, illumination of passageways, stacking of materials, disposal of debris, numbering and marking of floors and use of safety helmets and shoes conforming to IS. Chapter-VII Lifting Appliances and Gear (R. 55 to 81):All lifting appliances including their parts and working gear, whether fixed or movable should be of sound construction, sound material, adequate strength and maintained in good repair and working condition (R. 55). Provisions for test and examination by a competent person at every 5 years in the manner specified in Sch.I, automatic safe load indicators, safe installation, winches, buckets, safe working load, loading safely and within SWL, operator's cabin, operating instructions, hoists, fencing, rigging of derricks, securing of derrick foot, yearly examination of lifting gears, ropes, heat treatment, register of testing (Form V to X and XXVI), vacuum and magnetic lifting gear, knotting of chains & wire ropes, carrying of persons, attachment of loads, tower cranes and qualification of operator are also prescribed. Chapter-VIII Runways and Ramps (R. 82 to 85): Runways or ramps to be used by building workers should have width more than 43 cm, plank thickness 2.5 cm or more, open sides above 3 mt should have guard rail of I mt height and sufficient strength. Runway or ramp to be used by transport equipment should have a width more than 37 mt with timber curbs of 20 cm x 20 cm in width and placed parallel to and secured to the sides of such runway or ramp. Slop of ramps less than I in 4, continuous rise less than 3.7 mt and no more rise without broken by horizontal landing of length 1.2 mt or more. Runway or ramp to be used for wheel-barrows, hand carts or hand trucks should have width more than a metre with plank thickness more than 5 cm. Chapter-IX Work on or adjacent to Water (R. 86, 87): Water transport vessel with responsible person, life buoys on deck, prevention from drowning by fencing and suitable rescue equipment etc. are prescribed. Chapter-X Transport and Earth moving equipment (R. 88 to 95) : They should be of sound construction and sufficiently strong for the purpose, of sufficient size, duly certified, inspected weekly and safe carrying capacity marked. Power trucks and tractors with effective brakes, head lights, tail lamps, tie chains etc.
- 61. Power shovels andexcavators, bulldozers, scrappers, mobile asphalt layers and finishers, pavers and road rollers should have silencers, tail lights, power and hand brakes, reversing alarm and search light for forward and backward movement. Pavers should have guards to prevent workers walking under their skip. While moving downhill the engine should be in gear. Open light is not permitted to see level of asphalt. Load bearing capacity of the ground should be examined before using a road roller. Chapter-XI Concrete Work (R. 96 to 107) : In addition to general provisions regarding use of concrete, specific safety and health provisions are prescribed for preparation and pouring, erection of concrete structures, buckets, pipes & pumps, mixing and " pouring of concrete, panels & slabs, stressed and tensioned elements, vibrators, inspection & supervision, beams, floors and roofs, stripping and re-shoring. Chapter-XII Demolition (R. 108 to 118) :Provisions are made for preparation before demolition, protection of adjacent structures, demolition of walls, partitions etc., method of operation, access to floor, demolition of structural steel, storage of material, floor openings, inspection, warning signs, barricades and mechanical methods of demolition (i.e. by swinging weight, clamshell bucket, power shovel, bulldozer etc.). Chapter-XIII Evacuation and Tunneling Works (R. 119 to 168): Subjects prescribed are notification of intention to carry out such work, project engineer, responsible person, warning signs and notices, register of employment, illumination, stability of structure; pilling, shoring & bracing, safe access, trenches, depth of trenches, positioning and use of machinery, breathing apparatus, safety measures for tunneling operation, pneumatic tools, shafts, lift for shaft, means of communication, signals, clearances, shelters, use of internal combustion engine, inflammable oils, coupling and hoses, hose installation, fire resistant hoses, flameproof equipment, storing of oil and fuel underground, use of gases underground, water for fire fighting, flooding, steel curtains, rest shelters, permissible limit of exposure of chemicals (Sch. XII), ventilation, air supply intake point, emergency generators, air mains, bulk head and air-locks, diaphragms, portable electric hand tools (up to 24 volts), circuit breaker, transformer, live wires, welding sets, quality and quantity of air (more than 0.3 m3/ min/person), working temperature (less than 29"C), man-locks and working in compressed air environment, safety instruction and medical lock. Chapter-XIV Steep Roof (R. 169 to 171):Safety measures are prescribed for work on steep roofs, construction and installation of roofing brackets and crawling boards. Chapter-XV Ladders & Step-ladders (R. 172 to 174):Provisions are made for their construction and safe use, rungs and materials. Chapter-XVI Catch platform and Hoarding, Chutes, Safety belts & Nets (R. 175 to 180) : Provisions are made for catch platforms (minimum width 2 mt, inclined height 1.5 mt and open end with fencing of 1 mt height), hoarding for protection of workers, chutes and its use, safety belts, • nets, their use and storage. Chapter-XVII Structural Frame & Frame work (R. 181 to 185) :Provisions are made for trained workers for erection of structural-frame and framework, formwork, false work, shoring and deshoring, erection and dismantling of steel and prefabricated structure. Chapter-XVIII Stacking & Unstacking (R. 186, 187) : This should be in a safe way, on firm foundation, not against weak partition or wall, safe means of access for a height above 1.5 mt, under supervision, 10 cement (lime etc.) bags in a pile and adequate support for more height, storing of cement or lime in dry place, bricks, tiles or blocks on firm ground, steel according to its shape, size and length and at the lowest level, pipe should not fall by rolling, angle of repose (See Table-21 of Chapter32) of loose materials to be maintained and dust mask for handling of dust laden material.
- 62. Chapter-XIX Scaffold (R.188 to 205) : Provisions are made for scaffold construction (bamboo or metal), supervision by a responsible person, maintenance, standards, ledger, putlogs, working platform, board, plank and decking, repair of damaged scaffold, opening, guardrails, scaffold used by building workers of different employers, protection against electric power line, screening net and wire nets, tower scaffold, gear for suspension of scaffold, trestle scaffold and cantilever scaffold, scaffold supported by building, use of winches and climbers for suspended scaffold and safety devices for suspended scaffold. Chapter-XX Cofferdams and Caissons (R. 206,207): These should be of good construction, sound material, of adequate strength and inspected by a responsible person. Safe means of access, work under supervision and work in compressed air as per standard laid down procedure. Pressure plant and equipment should be examined by a competent person and maintained in good repairs and working condition. Safety valve, pressure gauge (dial range within 1.5 to 2 times the maximum working pressure) and stop or isolation valve are also necessary. Chapter-XXI Safety Organization (R: 208 to 211): Safety Committee is necessary where 500 or more building workers work. Equal number of members from employer and employees Meeting monthly. Senior person having overall control over the affairs of the construction site should be the chairman. Main function prescribed. Agenda and minutes should be circulated and shown to the Inspector on demand. Safety Officer is necessary where 500 or more building workers work. Their number, qualification, condition of service (including status and scale), duties and facilities are prescribed in Sch. VIII. Requirement of Safety officers is as under : Up to 1000 building workers - 1 Safety Officer Up to 2000 - 2 Safety Officer Up to 5000 - 3 Safety Officer Up to 10000 - 4 Safety Officer For every additional 5000 workers, one more safety officer is required. Qualification required is B.E., B. Tech or B. Arch with 2 years experience or Diploma holder with 5 years experience and a degree or diploma in industrial safety with an elective subject of construction safety. Other experience is also prescribed. Their duties are reproduced below from Sch. VIII. I. To advise the building workers in planning and organizing measures necessary for effective control of personal injuries; II. To advise on safety aspects in a building or other construction work and to carry out detailed safety studies of selected activities; III. To check and evaluate the effectiveness of action taken or proposed to be taken to prevent personal injuries; IV. To advise purchasing and ensuring quality of personal protective equipment confirming to national standards; V. To carry out safety inspections of building or other construction work in order to observe the physical conditions of work, the work practices and procedures followed by building workers and to render advice on measures to be adopted for removing unsafe physical conditions and preventing unsafe actions by building workers;
- 63. VI. To investigateall fatal and other selected accidents; VII. To investigate the cases of occupational diseases contracted and reportable dangerous occurrences; VIII. To advise on the maintenance of such records as are necessary with regard to accidents, dangerous occurrence and occupational diseases; IX. To promote the working of safety committees and to act as an advisor to such committees; X. To organize, in association with concerned departments, campaigns, competitions, contents and other activities which will develop and maintain the interest of building workers in establishing and maintaining safe conditions of work and procedures; XI. To design and conduct, either independently or in collaboration with other agencies, suitable training and educational programmes for prevention of accidents to building workers; XII. To frame safe rules and safe working practices in consultation with senior officials of the establishment; XIII. Supervise and guide safety precautions to be taken in building and other construction work of the establishment. Fatal accident shall be reported - within 4 hours and non-fatal - causing disability of more than 48 hours - accident shall be reported within 72 hours to the Regional Labour Commissioner (Central), Board, Director General and the near relative of the deceased. It should be in the Form No. XIV. Procedure for enquiry into cases of accident or dangerous occurrence is also prescribed u/r 211, Chapter-XXII Explosives (R. 212, 213): All explosives at construction site should be used, stored or handled as per MSDS and provisions of the Explosives Act and Rules. Prohibition of smoking and sources of ignition, safe distance and use of Non sparking tools while opening packing, prior warning and danger signals before use, avoiding injury and use under supervision are all necessary. Chapter-XXIII Piling (R. 214 to 222): Provisions are made for good design, construction, operation, inspection and maintenance of pile driving equipment, considering ergonomic principles, electrical safety, air or steam hammer, stability of adjacent structure, protection of operator, instruction and supervision, entry of unauthorized person, working platform on piling frames and pile testing. Chapter-XXIV Medical Facilities (R. 223 to 232): Provisions are made for pre and periodical medical examination of workers as per Sch-VII, by the doctors and hospitals approved by the Central Government, certificate of medical examination in Form No. XI, record in Form No. XII, duties of construction medical officers, occupational health centre for hazardous processes mentioned in Sch. IX with services and facilities laid down in Sch. X and qualification of a Construction Medical Officer in Sch. XI, ambulance room equipped with the articles specified in Sch. IV with necessary staff and records, ambulance van specified in Sch. V, stretchers, occupational health services, notice of poisoning or occupational diseases specified in Sch. II and notice in Form No. XIII, first-aid boxes with articles specified in Sch. Ill and emergency care services or treatment with essential life saving aids and appliances as mentioned in R. 232. Chapter-XXV Information to Bureau of Indian Standards (R. 233): Details regarding performance, deviation or shortcomings of the building materials, articles or processes
- 64. against IS prescribedshall be furnished to the Bureau of Indian Standards. In case of no IS prescribed, suggestions for improvement shall be given to the Bureau to consider and form necessary standards. Chapter-XXVI Hours of work. Rest intervals and Weekly off etc. (R. 234 to 237) : Provisions are made for 9 hours a day or 48 hours a week, rest interval of at least half an hour before more than 5 hours work, spread-over 12 hours on any day, double wages for overtime work or working on rest day, weekly rest day with its previous intimation notice, substituted holiday on one of the five days immediately before or after such rest day and to be given before ten days continuous working. Chapter-XXVII Notices, Registers, Records and Collection of Statistics (R. 238 to 242) : Notices of rates of wages, hours of work, wage period, date of payment of wages, names and addresses of the concerned Inspectors and date of payment of unpaid wages in English, Hindi and local language with a copy to the concerned Inspector are required. Notice of commencement and completion of work in Form No. IV before 30 days and notice of change in this notice within 2 days of the change are also necessary. Following registers are required: Register Form No. Register of workers XV Muster roll XVI Register of wages XVII Wage –cum-muster roll where a wage period is 15 days or less XVIII Register of deductions for damage or loss XIX Register of fines XX Register of advances XXI Register of overtime XXII Wage book (for a wage period one week or more) XXIII Service certificate XXIV Registers under Payment of Wages Act, Maternity Benefit Act and Contract Labour Act shall be deemed to be the respective registers. A combined or alternative form in lieu of above Forms shall require -prior approval of the Central Government. All registers/records should be maintained up-to-date, kept at the workplace, preserved for 3 years and produced on demand before the authority. An annual return in Form Number XXV shall be sent before 15th February to the registering authority with a copy to the Inspector concerned. Chapter-XXVIII Welfare (R. 243 to 247): Separate latrines or urinals (as required u/s 33 of the Act) for male and female workers, canteen for more than 250 workers at a distance 15.2 mt away from any latrine, urinal or source of dust, smoke or obnoxious fumes. Tea and snacks shall be served at a workplace 200 mt from the canteen.
- 65. Chapter-XXIX Wages (R.248, 249):Wages shall be paid before 7th day (workers<1000) or 10th day (workers>1000) of the wage period concerned. In case of termination it shall be paid before the expiry of the second working day from the date of termination. A notice of wage period, date, time and place of payment shall be displayed in English, Hindi and the local language. Chapter-XXX Powers of Director General and Inspectors (R. 250 to 252) :Powers to engage experts and agencies and powers of Inspectors including prohibition order are prescribed. The Building and other Construction Workers' Welfare Act 1996 and Rules 1998 provide for levy and collection of on the cost of construction to generate fund for Building and other Construction Workers Welfare Board constituted under the main Act (Part 7.1). THE BUILDING AND OTHER CONSTRUCTION WORKERS’ WELFARE CESS ACT, 1996 ACT NO. 28 OF 1996 [19th August, 1996.] An Act to provide for the levy and collection of a cess on the cost of construction incurred by employers with a view to augmenting the resources of the Building and Other Construction Workers’ Welfare Boards constituted under the Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996. BE it enacted by Parliament in the Forty-seventh Year of the Republic of India as follows:— 1. Short title, extent and commencement.—(1) This Act may be called the Building and Other Construction Workers’ Welfare Cess Act, 1996. (2) It extends to the whole of India. (3) It shall be deemed to have come into force on the 3rd day of November, 1995. 2. Definitions.—In this Act, unless the context otherwise requires,— (a) “Board” means a Building and Other Construction Workers’ Welfare Board constituted by a State Government under sub-section (1) of section 18 of the Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (27 of1996); (b) “Fund” means the Building and Other Construction Workers’ Welfare Fund constituted by a Board; (c) “prescribed” means prescribed by rules made under this Act; (d) words and expressions used herein but not defined and defined in the Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (27 of 1996) shall have the meanings respectively assigned to them in that Act. 3. Levy and collection of cess.—(1) There shall be levied and collected a cess for the purposes of the Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (27 of 1996), at such rate not exceeding two per cent. but not less than one per cent. of the cost of construction incurred by an employer, as the Central Government may, by notification in the Official Gazette, from time to time specify.
- 66. (2) The cesslevied under sub-section (1) shall be collected from every employer in such manner and at such time, including deduction at source in relation to a building or other construction work of a Government or of a public sector undertaking or advance collection through a local authority where an approval of such building or other construction work by such local authority is required, as may be prescribed. (3) The proceeds of the cess collected under sub-section (2) shall be paid by the local authority or the State Government collecting the cess to the Board after deducting the cost of collection of such cess not exceeding one per cent. Of the amount collected. (4) Notwithstanding anything contained in sub-section (1) or sub-section (2), the cess liveable under this Act including payment of such cess in advance may, subject to final assessment to be made, be collected at a uniform rate or rates as may be prescribed on the basis of the quantum of the building or other construction work involved. 4. Furnishing of returns.—(1) Every employer shall furnish such return to such officer or authority, in such manner and at such time as may be prescribed. (2) If any person carrying on the building or other construction work, liable to pay the cess under section 3, fails to furnish any return under sub-section (1), the officer or the authority shall give a notice requiring such person to furnish such return before such date as may be specified in the notice. 5. Assessment of cess.—(1) The officer or authority to whom or to which the return has been furnished under section 4 shall, after making or causing to be made such inquiry as he or it thinks fit and after satisfying himself or itself that the particulars stated in the return are correct, by order, assess the amount of cess payable by the employer. (2) If the return has not been furnished to the officer or authority under sub-section (2) of section 4, he or it shall, after making or causing to be made such inquiry as he or it thinks fit, by order, assess the amount of cess payable by the employer. (3) An order of assessment made under sub-section (1) or sub-section (2) shall specify the date within which the cess shall be paid by the employer. 6. Power to exempt.—notwithstanding anything contained in this Act, the Central Government may, by notification in the Official Gazette, exempt any employer or class of employers in a State from the payment of cess payable under this Act where such cess is already levied and payable under any corresponding law in force in that State. 7. Power of entry.—Any officer or authority of the State Government specially empowered in this behalf by that Government may— (a) with such assistance, if any, as he or it may think fit, enter at any reasonable time any place where he or it considers it necessary to enter for carrying out the purposes of this Act including verification of the correctness of any particulars furnished by any employer under section4; (b) do within such place anything necessary for the proper discharge of his or its duties under this Act; and (c) Exercise such other powers as may be prescribed. 8. Interest payable on delay in payment of cess.—If any employer fails to pay any amount of cess payable under section 3 within the time specified in the order of assessment, such employer shall be liable to pay interest on the amount to be paid at the rate of two per cent. for every month or part of a month comprised in the period from the date on which such payment is due till such amount is actually paid.
- 67. 9. Penalty fornon-payment of cess within the specified time.—If any amount of cess payable by any employer under section 3 is not paid within the date specified in the order of assessment made under section 5, it shall be deemed to be in arrears and the authority prescribed in this behalf may, after making such inquiry as it deems fit, impose on such employer a penalty not exceeding the amount of cess: Provided that, before imposing any such penalty, such employer shall be given a reasonable opportunity of being heard and if after such hearing the said authority is satisfied that the default was for any good and sufficient reason, no penalty shall be imposed under this section. 10. Recovery of amount due under the Act.—any amount due under this Act (including any interest or penalty) from an employer may be recovered in the same manner as an arrear of land revenue. 11.Appeals.—(1) Any employer aggrieved by an order of assessment made under section 5 or by an order imposing penalty made under section 9 may, within such time as may be prescribed, appeal to such appellate authority in such form and in such manner as may be prescribed. (2) Every appeal preferred under sub-section (1) shall be accompanied by such fees as may be prescribed. (3) After the receipt of any appeal under sub-section (1), the appellate authority shall, after giving the appellant an opportunity of being heard in the matter, dispose of the appeal as expeditiously as possible. (4) Every order passed in appeal under this section shall be final and shall not be called in question in any court of law. 12. Penalty.—(1) Whoever, being under an obligation to furnish a return under this Act, furnishes any return knowing, or having reason to believe, the same to be false shall be punishable with imprisonment which may extend to six months, or with fine which may extend to one thousand rupees, or with both. (2) Whoever, being liable to pay cess under this Act, wilfully or intentionally evades or attempts to evade the payment of such cess shall be punishable with imprisonment which may extend to six months, or with fine, or with both. (3) No court shall take cognizance of an offence punishable under this section save on a complaint made by or under the authority of the Central Government. 13. Offences by companies.—(1) Where an offence under this Act has been committed by a company, every person who, at the time the offence was committed, was in charge of, and was responsible to, the company for the conduct of the business of the company, as well as the company, shall be deemed to be guilty of the offence and shall be liable to be proceeded against and punished accordingly: Provided that nothing contained in this sub-section shall render any such person liable to any punishment if he proves that the offence was committed without his knowledge or that he had exercised all due diligence to prevent the commission of such offence. (2) Notwithstanding anything contained in sub-section (1), where an offence under this Act has been committed with the consent or connivance of, or is attributable to any neglect on the part of, any director, manager, secretary or other officer of the company, such director, manager, secretary or other officer shall also be deemed to be guilty of that offence and shall be liable to be proceeded against and punished accordingly.
- 68. Explanation.—For the purposesof this section,— (a) “company” means anybody corporate and includes a firm or other associationof individuals; and (b) “director”, in relation to a firm, means a partner in the firm. 14.Power to make rules.—(1) The Central Government may, by notification in the Official Gazette, make rules for carrying out the provisions of this Act. (2) Without prejudice to the generality of the foregoing power, such rules may provide for all or any of the following matters, namely:— (a) the manner in which and the time within which the cess shall be collected under sub-section (2) of section3; (b) the rate or rates of advance cess liveable under sub-section (4) of section3; (c) the particulars of the returns to be furnished, the officer or authority to whom or to which such returns shall be furnished and the manner and time of furnishing such returns under sub-section (1) of section4; (d) the powers which may be exercised by the officer or authority under section7; (e) the authority which may impose penalty under section9; (f) the authority to which an appeal may be filed under sub-section (1) of section 11 and the time within which and the form and manner in which such appeal may be filed; (g) the fees which shall accompany an appeal under sub-section (2) of section 11;and (h) Any other matter which has to be, or may be, prescribed. (3) Every rule made under this Act shall be laid, as soon as may be after it is made, before each House of Parliament, while it is in session for a total period of thirty days which may be comprised in one session or in two or more successive sessions, and if, before the expiry of the session immediately following the session or the successive sessions aforesaid, both Houses agree in making any modification in the rule or both Houses agree that the rule should not be made, the rule shall thereafter have effect only in such modified form or be of no effect, as the case may be; so, however, that any such modification or annulment shall be without prejudice to the validity of anything previously done under that rule. 15. Repeal and saving.—(1) The Building and Other Construction Workers’ Welfare Cess Third Ordinance, 1996 (Ord. 26 of 1996), is herebyrepealed. (2) Notwithstanding such repeal, anything done or any action taken under the said Ordinance shall be deemed to have been done or taken under the corresponding provisions of this Act.
- 69. THE BUILDING ANDOTHER CONSTRUCTION WORKERS’ WELFARE CESS RULES, 1998 In exercise of the powers conferred by sub-section (1) of section 14 of the Building and Other Construction Workers’ Welfare Cess Act, 1996 (Act 8 of 1996), the Central Government hereby makes the following rules, namely:— 1 Short title and commencement.—(1) These rules may be called the Building and Other Construction Workers’ Welfare Cess Rules, 1998. (2) They shall come into force on the date of their publication in the Official Gazette. 2 Definitions.—In these rules, unless the context otherwise requires,— (a) “Act” means the Building and Other Construction Workers’ Welfare Cess Act, 1996 (Act 28 of 1996); (b) “Main Act” means the Building and Other Construction Workers (Regulation of Employment and Conditions of Service) Act, 1996 (Act 27 of 1996); (c) “Form” means the form annexed to these rules; (d) all other words and expressions used in these rules but not defined and defined in the Act or in the main Act shall have the meanings respectively assigned to them in those Acts; (e) “specified” means specified by a State Government by an order published in the Official Gazette; (f) “Cess Collector” means an officer appointed by the State Government for collection of cess under the Act; (g) “Assessing Officer” means a gazetted officer of a State Government or an officer of a local authority holding an equivalent post to a gazetted officer of the State Government appointed by such State Government for assessment of Cess under the Act; (h) “Appellate Authority” means an officer, senior in rank to the Assessing Officer, appointed by the State Government for the purposes of section 11 of the Act. 3. Levy of cess.—For the purpose of levy of cess under sub-section (1) of section 3 of the Act, cost of construction shall include all expenditure incurred by an employer in connection with the building or other construction work but shall not include— —cost of land; —any compensation paid or payable to a worker or his kin under the Workmen’s Compensation Act, 1923 4. Time and manner of collection.—(1) The cess levied under sub-section (1) of section 3 of the Act shall be paid by an employer, within thirty days of completion of the construction project or within thirty days of the date on which assessment of cess payable is finalised, whichever is earlier, to the cess collector. (2) Notwithstanding the provisions of sub-rule (1), where the duration of the project or construction work exceeds one year, cess shall be paid within thirty days of completion of one year from the date of commencement of work and every year thereafter at the notified rates on the cost of construction incurred during the relevant period.
- 70. (3) Notwithstanding theprovisions of sub-rule (1) and sub-rule (2), where the levy of cess pertains to building and other construction work of a Government or of a Public Sector Undertaking, such Government or the Public Sector Undertaking shall deduct or cause to be deducted the cess payable at the notified rates from the bills paid for such works. (4) Notwithstanding the provisions of sub-rule (1) and sub-rule (2), where the approval of a construction work by a local authority is required, every application for such approval shall be accompanied by a crossed demand draft in favour of the Board and payable at the station at which the Board is located for an amount of cess payable at the notified rates on the estimated cost of construction: Provided that if the duration of the project is likely to exceed one year, the demand draft may be for the amount of cess payable on cost of construction estimated to be incurred during one year from the date of commencement and further payments of cess due shall be made as per the provisions of sub-rule (2). (5) An employer may pay in advance an amount of cess calculated on the basis of the estimated cost of construction along with the notice of commencement of work under section 46 of the Main Act by a crossed demand draft in favour of the Board and payable at the station at which the Board is located: Provided that if the duration of the project is likely to exceed one year, the demand draft may be for the amount of cess payable on cost of construction estimated to be incurred during one year from the date of such commencement and further payment of cess due shall be made as per the provisions of sub-rule (2). (6) Advance cess paid under sub-rules (3), (4) and (5), shall be adjusted in the final assessment made by the Assessing Officer. 5. Transfer of the proceeds of the cess to the Board.—(1) The proceeds of the cess collected under rule 4 shall be transferred by such Government office, Public Sector Undertakings, local authority, or cess collector, to the Board alongwith the form of challan prescribed (and in the head of account of the Board) under the accountings procedures of the State, by whatever name they are known. (2) Such government office of Public Sector Undertaking may deduct from the cess collected, or claim from the Board, as the case may be, actual collection expenses not exceeding one per cent, of the total amount collected. (3) The amount collected shall be transferred to the Board within thirty days of its collection. 6. Information to be furnished by the employer.—(1) Every employer, within thirty days of commencement of his work of payment of cess, as the case may be, furnish to the Assessing Officer, information in Form I. (2) Any change or modification in the information furnished under sub-rule (1) shall be communicated to the Assessing Officer immediately but not later than thirty days from the date of affecting the modification or change. 7. Assessment.—(1) The Assessing Officer, on receipt of information in Form I from an employer shall make a scrutiny of such information furnished and, if he is satisfied about the correctness of the particulars so furnished, he shall make an order of assessment within a period not exceeding six months from the date of
- 71. receipt of suchinformation in Form I, indicating the amount of cess payable by the employer and endorse a copy thereof to the employer, to the Board and to the cess collector and despatch such order within five days of the date on which such order is made. (2) The order shall inter-alia specify the amount of cess due, cess already paid by the employer or deducted at source and the balance amount payable and the date, consistent with the provision of rule 4, by which the cess shall be paid to the cess collector. (3) If on scrutiny of information furnished, the Assessing Officer is of the opinion that employer has under-calculated or miscalculated the cost of construction or has calculated less amount of cess payable, he shall issue notice to the employer for assessment of the cess. (4) On receipt of such notice the employer shall furnish to the Assessing Officer a reply together with copies of documentary or other evidence in support of his claim, within fifteen days of the receipt of the notice: Provided that the Assessing Officer may, in the course of assessment, afford an opportunity to the assessed to be heard in person, if he so requests to substantiate his claim. (5) If the employer fails to furnish the reply within the period specified under sub-rule (4), or where an employer fails to furnish information in Form I, the Assessing Officer shall proceed to make the assessment on the basis of available records, and other information incidental thereto. (6) The Assessing Officer may, at anytime while the work is in progress, authorise such officer to make such enquiry at the work site or from documentary evidence or in any other manner as he may think fit for the purpose of estimating the cost of construction as accurately as possible. 8. Return of overpaid cess.—(1) Where the Assessing Officer has passed an order of assessment and the employer decides to withdraw from or foreclose the works or modifies the plan of construction thereby reducing the cost of construction undertaken or has been forced by other circumstances to call off the completion of the work undertaken, he may seek revision of the assessment order by making an information in Form II to the Assessing Officer giving details of such reduction or stoppage of work. (2) Revision of order of assessment shall be made by the Assessing Officer, in the same manner as the original order, within thirty days of receipt of such information in Form II. (3) Following the revision of assessment as per sub- rule (2), the Assessing Officer shall, wherever necessary, endorse a copy of the revised assessment to the Board or cess collector, as the case may be, for making the refund of excess cess as ordered in the revised assessment. (4) The Board shall, within thirty days of receipt of the endorsement from the Assessing Officer under sub-rule (3), refund the amount specified in the order to the employer through a demand draft payable at the station where the establishment is located. (5) Where the Appellate Authority has modified the order of assessment reducing the amount of cess, refund shall be made within such time as may be specified in that order. 9. Exemption.—(1) Any employer or class of employers in a State seeking exemption under section 6 of the Act may make an application to the Director
- 72. General of LabourWelfare, Ministry of Labour, Government of India, stating the details of works undertaken, name of the Act or corresponding law in force in that State under which he is liable to pay cess for the welfare of the construction workers and amount of cess actually paid along with the date of such payment and proof thereof. A copy of such application shall be endorsed to each of the Assessing Officer and the board concerned. (2) On receipt of such application the Central Government may, if it feels necessary, seek a report from the State Government concerned. (3) On examining the grounds, facts and merits of such application the Central Government may, by notification in the Official Gazette, issue an order exempting the employer or class of employers, as the case may be, from payment of cess payable under the Act where such cess is already levied and payable under such corresponding law. (4) Assessment proceedings shall be stopped by the Assessing Officer for a period of thirty days commencing from the date of the receipt of a copy of the application under sub-rule (1) to him, or till the order of the Central Government under sub-rule (3) is conveyed to an employer or class of employers who made the application under sub-rule (1), whichever is earlier. 10. Powers of Assessing Officer and other officers.—(1) An Assessing Officer, or an officer authorised under sub-rule (6) of rule 7, if empowered by the State Government under section 7 of the Act, may,— (a) enter any establishment where building and other construction work is going on; (b) make an inventory of materials, machinery or other articles lying at the work place; (c) enquire about the number of workers engaged in various activities; (d) require the production of any prescribed register or any other documents relevant to the assessment of cost of construction or number of workers employed; (e) seize or take copies of any such records; (f) make general assessment of the stage of the construction work having been completed; (g) direct the employer or any other person in charge of the place that no material or machinery shall be removed or disturbed for so long as is necessary for the purpose of any examination; (h) take measurement, notes or photographs; (i) exercise such other powers considered absolutely necessary for reasonable assessment of cost of construction. 11. Date of payment.—Date of payment of cess shall be the date on which the amount is deposited with the cess collector under sub-rule (1) of rule 4, or the date of deduction at source under sub-rule (3) of rule 4, or the date on which the draft has been deposited with the local authority under sub-rule (4) of rule 4, as the case may be. 12. Penalty for non-payment.—(1) An Assessing Officer, if it appears to him that an employer has not paid the cess within the date as specified in the assessment order or has paid less cess, including the cess deducted at source or paid in advance, shall issue a notice to such employer that it shall be deemed to be in
- 73. arrears and suchAssessing Officer may, after such inquiry as it deems fit, impose on such employer, a penalty not exceeding such amount of cess: Provided that before imposing any such penalty, such employer shall be given a reasonable opportunity of being heard and if after such hearing the Assessing Officer is satisfied that the default was for any good and sufficient reason, no penalty shall be imposed on such employer. 13. Recovery of overdue amount.—For the purpose of recovery of sums due on account of unpaid cess, interest for overdue payment or, penalty under these rules, the assessing officer shall prepare a certificate signed by him, specifying the amount due and send it to the collector of the district concerned who shall proceed to recover from the said employer the amount specified thereunder as if it were an arrear of land revenue. 14. Appeal.—(1) An employer aggrieved by an order of the assessment made under rule 7 or by an order imposing penalty made under rule 12 may appeal against such order, within three months of the receipt of such order, to the Appellate Authority. (2) The appeal shall be accompanied with— (a) the order appealed against; (b) a certificate from the cess collector to the effect that the amount of cess or penalty or both, as the case may be, relating to such appeal has been deposited; (c) a fee equivalent to one per cent, of the amount in dispute or penalty or both, as the case may be, under such appeal; (d) a statement of points in dispute; (e) documentary evidence relied upon. (3) On receipt of the appeal the Appellate Authority may call from the Assessing Officer a statement on the basis of his assessment order appealed against, as such Appellate Authority may consider necessary for the disposal of such appeal. (4) The Appellate Authority shall give the appellant an opportunity of being heard in the matter and dispose of the appeal as expeditiously as possible. (5) On being satisfied on the quantum of cess the Appellate Authority shall confirm the order of the Assessing Officer or if in his opinion the assessment was wrong; or on the higher side shall modify the order of assessment or if in his opinion the assessment is on the lower side or if the basis of assessment is wrong, it shall remand back the assessment order to the Assessing Officer alongwith his observations to rectify the wrong. (6) An order remanded back under sub-rule (5) shall be disposed of by the Assessing Officer within one month in view of the observation made by the Appellate Authority: Provided that if the amount of cess is proposed to be enhanced the assessee shall be given an opportunity of being heard. (7) No appeal shall lie against the order of the Appellate Authority under this rule.
- 74. (8) If theAppellate Authority is of the opinion that the quantum of penalty imposed is on the higher side or not correctly made it shall suitably modify or set aside the order of the Assessing Officer, as the case may be. (9) The appeal under this rule shall be disposed of by making a speaking order and a copy of such order shall be sent to each of ‘the appellant, the Assessing Officer and the Board within five days of the date on which such order is made. (10) An order in appeal reducing the amount of cess shall also ask the Board to refund the excess cess. (11) An order in appeal reducing, enhancing or confirming the orders of penalty, as the case may be, shall also specify the date by which the amount of penalty should be paid/refunded. 15. Filing of complaints.—(1) The Assessing Officer, or any inspector under the main Act, or a Trade Union, having come to know of violation of an obligation to furnish return, furnishing of false information, intentionally or wilfully evading or attempting to evade the payment of cess may make a complaint to the Board. The Board on receiving such complaint shall examine the complaint and if it so decide may refer such complaint to the Central Government for taking legal action against the offender. (2) The Central Government on receiving such reference may make such inquiry as may be considered necessary and authorise an inspector of appropriate jurisdiction to file a complaint in the court of law furnish return, furnishing of false information, intentionally or wilfully evading or attempting to evade the payment of cess may make a complaint to the Board. The Board on receiving such complaint shall examine the complaint and if it so decide may refer such complaint to the Central Government for taking legal action against the offender. (2) The Central Government on receiving such reference may make such inquiry as may be considered necessary and authorise an inspector of appropriate jurisdiction to file a complaint in the court of law.
- 75. FORM I (See rule7) 1. Name of Establishment Registration No. under Building and Other Construction Construction Workers’ (Regulation of Employment Employment and Conditions of Service) Act, Act 1996. Registering Authority 2. Address 3. Name of Work 4. No. of workers employed 5. Date of commencement of work Estimated period of work: Month Month Year Date Month Year 6. Estimated cost of construction Details of payment of cess …Stages Cost Amount Challan No. Advance—A …………………..and date Deduction at Source—D ……………………………………………………………………………...Final—F 1st Year 2nd Year 3rd Year 4th Year Total: Signature of Employer ………………………………………………………………………………Name of Employer Date ................. TO BE FILLED BYASSESSING OFFICER 7. Date of completion 8. Final Cost 9. Date of assessment 10. Amount assessed 11. Date of Appeal, if any, 12. Date of order in Appeal 13. Amount as per Order in Appeal 14. Date of transfer of cess to the Board 15. Amount transferred Challan No. and date Signature Designation
- 76. FORMII [See rule 9(1)] 1.Name of Establishment Registration No. under Building and Other ………………………………………… Construction Workers’ (Regulation of …………………………………… Employment and Condi-tions of Service) Act, 1996. Address II. Date of commencement of work Estimated period of work: ………Month Year Date Month Year Estimated cost of work (original) Advance Cess/ Deduction at source ………………………………………………… Date of Assessment order Amount of Cess assessed III. Modification to the original estimates Revised date of Reason completion/ Date of stoppage Actual cost estimates Actual cost incurred Whether work is being handed Yes/No. over to any other person/agency for completion. If yes, Name/ Address of such person/agency. …………………………………………………………………….Signature of Employer Name of Employer Date TO BE FILLED BYASSESSING OFFICER Date of revision of assessment Amount of cess after revision Cess already received Cess to be recovered Cess to be refunded, if any Reference to Board for refund; Date /number Signature Designation Maharashtra fire prevention and Life Saving acts 2007 and rules: DRAFT RULES 1. Short Title and commencement – (1) These rules may be called The Maharashtra Fire Prevention and Life Safety Measures Rules, 2008. (2) They extend to the whole State of Maharashtra. (3) They shall come into force –
- 77. (a) in theareas of the local authorities and the planning authorities, on such date as the State Government may, by notification in the Official Gazette, appoint; (b) in other areas or part of the areas, on such date as the State Government may, by the same or like notification appoint; and different dates may be appointed for different provisions thereof and for different areas or part of the areas; and (c) any reference in these rules to the commencement of the rules shall, in relation to a provision or an area, be constructed as a reference to the coming into force of these rules or any provision thereof in that area. 2. Definitions.- In these rules, unless the context otherwise requires, - (a) “Act” means The Maharashtra Fire Prevention and Life Safety Measures Act, 2006; (b) “form” means the form appended to these rules; (c) “regular fire service” means a service rendered, for the administration, prevention or protection of fire, with the State Government, local authority or planning authority; (d) “section” means the section of the Act; (e) the words and expressions used in these rules but not defined shall have the same meaning as assigned to them in the Act. 3. Appointment and qualifications of nominated officer.- (1) The nominated officer to be appointed under clause (9) of section 2 of the Act shall be from amongst the fire officers mentioned in clauses (a) and (b) of sub-section (3) of section 21, in each of the respective Municipal Corporation, Municipal Council, Nagar Panchayat, Industrial Township or Planning Authority; and where the cadre of such fire officers is not yet be established, the nominated officer shall be appointed by the Director, Maharashtra Fire services from amongst fire officers or fire personnel in the Municipal Corporation, Municipal Council, Nagar Panchayat, Industrial Township or Planning Authority, possessing the following qualifications, namely :- (a) for “ A” and “B” class Municipal Corporations, the nominated officer shall be a fire officer who, - i) possesses an Advance Diploma in Fire Engineering from the National Fire Service College, Nagpur, Ministry of Home Affairs, Government of India or the State Fire Academy, Government of Maharashtra; and at least two years’ experience of regular fire service for inspection and testing of fire prevention and protection work ; or (ii) has passed the Graduate ship Examination( Fire ) of Institute of Fire Engineers, India or the Institution of Fire Engineers of United Kingdom and at least two years’ experience of regular fire service; and of fire prevention and protection work. (b) for “C” and “D” class Municipal Corporations, the nominated officer shall be a fire officer who, - (i) possesses Diploma in Fire Engineering from the aforesaid National Fire Service College, Nagpur or the State Fire Academy, Government of Maharashtra; and at least two years’ experience of regular fire service and of fire prevention and protection work ; or (ii) has passed the Graduate ship Examination (Fire) of Institute of Fire Engineers India or the Institution of Fire Engineers of United Kingdom; and at least two years’ experience of regular fire service for inspection and testing of fire prevention and protection work. (c) for Municipal Councils, Nagar Panchayats or Industrial Townships, the nominated officer shall be a fire officer who, - possesses a Diploma in Fire Engineering from the aforesaid National Fire Service College, Nagpur or the State Fire Academy, Government of Maharashtra; and at least two years’ experience of regular fire service ; (d) for Special Planning Authorities and Special Economic Zones (SEZs), Private Townships and Hill Station Projects, the nominated officer shall be a fire officer who.- (j) possesses an Advance Diploma in Fire Engineering from the National Fire Service College, Nagpur, Ministry of Home Affairs, Government of India or the State Fire
- 78. Academy, Government ofMaharashtra; and at least two years’ experience of regular fire service for inspection and testing of fire prevention and protection work ; or (ii) has passed the Membership Examination of Institute of Fire Engineers India or the Institution of Fire Engineers of United Kingdom; and at least two years’ experience of regular fire service and of fire prevention and protection work. (2) In any area or areas not covered by sub-rule (1), the nominated officer shall be appointed by the Director from amongst fire officers from the office of the Director or from any adjoining local authority or planning authority, who possesses qualifications specified in clauses (a) or (b) of sub-rule (1), having regard to the potential of the fire hazard in the buildings or the project concerned. (3) Notwithstanding anything contained in clauses (a), (b), (c) or (d) of sub rule (1), where any special, high-rise, or mega project is coming up within or without the areas covered by the said clauses of sub-rule (1), the scrutiny and the inspection of the building will be carried out by the Chief Fire Officer or qualified nominated officer, if any, from the nearby Municipal Corporation or by any Fire Officer as the Director may, by any general or special order in that behalf, specify. (4) Notwithstanding anything contained in sub-rules (1), (2) and (3), a fire officer shall be required to have acquired a certificate of fire prevention course of the State Fire Academy, Government of Maharashtra, before his appointment as a nominated officer. 4. Certificates to be issued by Licensed Agency.- (1) A certificate regarding the compliance of the fire prevention and life safety measures in a building or a part thereof as required by or under the provisions of the Act, to be issued by a Licensed Agency, shall be in “Form – A”. (2) A certificate which is to be issued by a Licensed Agency twice a year in the months of January and July regarding the maintenance of fire prevention and life safety measures in a building or premises being in good repair and efficient condition as specified in sub-section (1) of section 3 of the Act, shall be in “Form-B” 5. Notice directing the removal of objects or goods likely to cause the risk of fire.- (1) The notice to be given under sub-section (2) of section 4 to the owner or occupier of a building or premises, directing the removal of objects or goods likely to cause the risk of fire, to a place of safety shall be in “Form C”. (2) On failure of the owner or occupier to comply with the notice issued under sub-rule (1), he shall be given a further notice under sub-section (2) of section 4 to submit his say as to why the objects or goods should not be seized, detained or removed. Such notice shall be in the “Form-D”. 6. Memorandum of seizure, etc. and panchanama.- Where any objects or goodsinvolving risk of fire are required to be seized, detained or removed under subsection (2) of section 4, the memorandum of seizure etc. to be prepared in that behalf shall be in the “Form E” ; and the panchanama to be made in that behalf shall be in the “Form-F” 7. Notice to be given for entry and inspection. - (1) The notice for entering and inspection required to be given under sub-section (1) of section 5 for ascertaining the adequacy or contravention of fire prevention and life safety measures in any place or building or part thereof, shall be in “Form-G”. (2) The notice required to be given under sub-section (4) of section 5 to a woman, who, according to the custom does not appear in public, shall be in the “Form-H”. 8. Report of inspection by nominated officer: - Where the inspection is carried out by the nominated officer under section 5, he shall give the report of such inspection in the “Form-I” . 9. Notice to be given to the owner or occupier of a building or part thereof to undertake certain measures.- (1)Where on completion of the inspection of the place or building or part thereof, any deviation from, or contravention of, the requirements with regard to the fire
- 79. prevention and lifesafety measures or any inadequacy or non-compliance of such measures provided or to be provided therein with reference to the height of the building or the nature of the activities carried on in such place or building or part thereof, is noticed, the owner or occupier of such place or building or part thereof shall be given a notice thereof under section 6 of the Act in “Form J”, directing him to undertake the requisite measures within 7 days. (2) The time to be specified in the notice given to the owner or the occupier under sub-rule (1) shall be specified having regard to the nature of the measures to be taken but such time shall not exceed 120 days. 10. Procedure to be followed for sealing of a place or building or part thereof.- The Director or Chief Fire Officer shall follow the following procedure in respect of the sealing of any place or building or part thereof, required to be sealed under sub-section (3) of section 8, namely:- (a) he shall require persons, in possession or occupation of the place or building or part thereof to be sealed, to remove themselves from there forthwith; (b) in case of non-compliance of the said order, he shall direct any police officer having jurisdiction in the area to remove such persons from such place or building or part thereof; (c) after the removal of persons in possession or in occupation from such place or building or part thereof, he shall cause such place or building or part thereof to be sealed by such police officer forthwith in the manner which he deems fit; (d) the seal used to seal as aforesaid shall remain in the custody of the Director or, as the case may be, the Chief Fire Officer; (e) (i) if the place or building or part thereof required to be sealed on receipt of the report of the nominated officer, is found to be locked or inaccessible, he may cause the lock to be broken by the police officer and enter the premises and after taking all necessary steps required to be taken under the Act, or under these rules, relock and cause it to be sealed as afore said; (ii) where a place or building or part thereof is sealed under sub clause (i), an inventory of the material found in such place or building or part thereof shall be prepared in the presence of two independent witnesses and a copy thereof shall be delivered to the owner or occupier, if present at the site. The forms “E” and “F” shall, respectively, be used mutatis mutandis for such inventory and the panchanama to be prepared in that regard. (f) The Director or, the Chief Fire Officer or as the case may be an Officer nominated shall report in writing to the Police Station concerned if the seal so fixed on any place or building or part thereof is found to be broken or tampered. 11. Orders to Authorities responsible for supply of electricity or water to disconnect supply or to a Police Officer to remove persons from, a place or building or part thereof which is in imminent danger.- (1) An order under clause (a) of sub-section (2) of section 8, directing the authority responsible for supply of electricity, or as the case may be, water, to a place or building or a part thereof, which is dangerous to any person or property, to disconnect the supply of electricity, or as the case may be, water, shall be in “Form – K”. (2) An order under clause (b) of sub-section (2) of section 8, directing any Police Officer having jurisdiction in the area, to remove persons from any place or building or part thereof which is dangerous to any person or property shall be in “Form-L”. 12. Eligibility to act as Licensed Agency.- No person shall be eligible to apply for grant of licence to act as a Licensed Agency ; and shall be granted a license to act as Licensed Agency, unless he .- (1) (a) possesses - (i) at least any of the qualifications mentioned in clause (b) of sub-rule (1) of this rule; or (ii) a degree or diploma in Mechanical, Electrical, Electronics or
- 80. Civil Engineering orComputer applications; and (iii) experience in executing fire prevention and fire protection system as laid down in National Building Code 2005 or code published by National Fire Protection Association (NFPA, USA) 2008, as amended from time to time, or (b) has in his employment, for the purpose of execution and supervision of the work relating to fire protection and life safety measures in a building or a project, an officer or supervisory officer holding any of the qualifications mentioned in clause (a), so however that, a degree or diploma in fire engineering or any other qualifications in relation to fire protection, prevention and safety measures shall be an essential qualification. (2) holds a solvency certificate for an amount as may be specified by the Director, with prior approval of the Government. (3) has, during the period of 3 years immediately preceding the year of making the application, executed the work in relation to fire prevention and fire protection system; or holds a certificate of fire protection specialist awarded by the State Fire Academy, Government of Maharashtra. (4) has adequate machinery, tools and other requisite equipment in relation to fire prevention and fire protection systems ; and (5) has not been black- listed by any Government Department or Organization or any other state. 13. Application to be made for Licensed Agency, manner of making it and fees in respect thereof.- (1) Every application for licence to act as Licensed Agency for the purposes of the Act under section 9 shall be in “Form-M”. (2) Such application may be presented in person or sent by registered post or through courier agency or online. (3) Every such application shall be accompanied by.- (a) the following fees :- Clas s of local or plan ning auth ority Mini mum solve ncy certif icate for (rup ees in lakh) Presc ribed limit for exec ution of the work s as per estim ated cost (rupe es in lakh) Cost of annual works minimum executed in the last three years rupees in lakh Regist ration free in rupee s Fire fighti ng syste m install ation such as hydra nt sprin klers pump ing etc. Dete ction & fire separ ation syste m Passiv e prote ction such as cable prote ction, fire doors etc. 1 2 3 4 5 6 7 A 150. 00 Unli mite d 500.0 0 200.0 0 200.0 0 25000
- 81. (b) documents asmay be specified by the Director; and which shall include the following, namely:- (1) solvency certificate for an appropriate amount as specified under sub-rule (2) of rule 12. (2) attested copy of deed of partnership and power of attorney or articles of memorandum of association or affidavit on stamp paper in case the individual is the sole proprietor of the firm; (3) last three years’ certificates from the concerned department regarding satisfactory completion of works; (4) orders of works in hand in current year (up to the prescribed amount for that class); (5) certificate from the chartered accountant or registered income tax practitioner in the prescribed form in case of private works; (6) if the application for registration is made for the first time for a specific class, one has to execute at least one work up to the maximum amount in the class, which falls one class below the specific class, applied for; (7) certificate regarding appointment of at least one officer possessing any of the qualifications specified in clause (b) of sub-rule (1) of rule 12; (8) attested passport size photographs of partners or directors or individual proprietor and also of the officer or officers referred to in item (8); (9) attested copy of VAT registration certificate; (10) affidavit on appropriate stamp paper, stating that his or her firm is not black listed in the Government or any semi Government organization; and (11) list of technical staff with their qualifications. 14. Licence to act as Licensed Agency.- The Licence to act as a Licensed Agency shall be granted in “Form-N” and shall be subject to the following conditions, namely :- 1. The licence shall be (a) non transferable (b) valid for one year from the date of issue, unless suspended or cancelled earlier, (c) renewable, if so desired , before expiry of the licence; 2. Changes, if any, in respect of the :- (a) Partners, Directors or Members, (b) address of the office of the licensed Agency shall be forthwith reported to the Authority issuing the licence. 3. The Licensed Agency shall always keep the work , being executed, or executed by it, open for inspection by the Director, Chief Fire Officer or any fire officer authorized by the Director or Chief Fire Officer. 15. Renewal of Licence.- An application for renewal of a licence granted under section 9, read with rule 14, shall also be made in “Form-M” and shall be accompanied by a fee specified under clause (a) of sub rule (3) of rule 13 and also documents as mentioned in clause (b) of sub-rule (3) of rule 13. 16. Additions to Licence held by Licensed Agency.- (1) Any person holding a licence to act as a Licensed Agency for any class or description as granted or renewed under section 9, read with rule 14, and who is also eligible to act as a Licensed Agency for any other class or B 10.0 0 1000. 00 300.0 0 100.0 0 100.0 0 15000 C 05.0 0 600.0 0 200.0 0 50.00 50.00 5000 D 02.5 0 300.0 0 100.0 0 25.00 25.00 2500
- 82. description, may applyin “Form M” for the addition of such other class or description to the licence. (2) The provisions of rule 13 shall apply to an application made under subrule (1) as if the said application were for grant of a licence under section 9, read with rule 14, for the class or description which the applicant desires to be added to his licence. 17. Notice to show cause why licence be not suspended or cancelled.- Where any person to whom the Licence has been granted contravenes any provisions of the Act or of the rules or fails to comply with the conditions of the licence or is unfit by reason of incompetency, misconduct or any other grave reason, a notice to show cause as to why the licence granted to him to act as Licensed Agency should not be suspended or cancelled, to be given to such person, shall be in “Form-O”. 18. Application for assessment of fire service fees.- (1) An Application under sub-section (1) of section 14 for assessment of fire service fees payable by a person, who intends to construct a building or who has commenced construction of a building in the manner provided in the sub-section (1), shall make an application to the authority in “Form P”. (2) Such application shall be made at the time of making an application to the Authority for permission to construct a building and in any case, before the Authority grants such permission; and a person who has commenced construction of a building without making an application for such permission of the Authority, shall make an application for assessment of fees payable in respect of such building within 30 days from the date of commencement of the Act. (3) Such application may be presented in person or sent by registered post or through courier agency or online. 19. Notice of hearing.- The authority shall give a notice in “Form-Q” to the person, who has made an application under sub-section (1) of section 14 or a person who has constructed a building without permission, in respect of assessment of fire service fees livable in case of a building intended to be constructed by the applicant or the construction made without permission; and having regard to the matters to be considered as specified in sub-section (2) of section 14 and also to the following guidelines, assess the fees, so livable and payable by such person :- Guidelines.- 1. In the case of - (1) Residential Buildings: (a) Lodging or Rooming Houses, (b) One or Two family private dwellings, dormitory, apartment houses, (c) Hotels, (d) starred Hotels. (2) Educational Buildings: (3) Institutional Buildings: (a) Hospitals, Sanatoriums, Nursing Homes (b) Custodial, penal and plantal (4) Assembly Buildings: (5) Business Buildings: (6) Mercantile Buildings: (a) F-1 and F-2 buildings, (b) Underground Shopping Complexes – (i) If the building consists of different wings or has an annex, being contiguous and forming part of the building, the total area of the main building, wings thereof and annex shall together be calculated as that of one building. (ii) If any additions are made to the existing buildings, the entire area of the building shall be calculated and the fire service fee leviable and payable in respect thereof shall be for the entire such area less the fire service fee, if any, paid earlier. (iii) If the interior of a building is changed by internal alterations including construction of loft or mezzanine floor which are carried out there in, without any addition in the gross built-up, then fire service fee shall be levied thereon. 2. In the case of – (1) Industrial Buildings (a) – Low Hazard, (b) Moderate Hazard , (c) High Hazard (2) Storage Buildings: (3) Hazardous Buildings;, (i) Where a building is having mixed occupancy, fire service fee shall be levied having regard to the nature of each of the occupancies;
- 83. (ii) If abuilding is compartmentalized, then the compartment which is newly built or if any additions or alterations are made to an existing compartment, the fire service fee shall be levied on such new or added compartment, irrespective of the fact that such compartment is contiguous or forming a part of the same building; (iii) If the interior of a building is changed by internal alterations including construction of loft or mezzanine floor which are carried out therein, without any addition in the gross built- up area, then fire service fee shall be levied thereon. 20. Notice of assessment of fire service fee and collection thereof.- (1) After the assessment of fees made under rule 19, a notice in “Form R” of such assessment shall be served upon the applicant or the person concerned. (2) The provisions of rule 19 and sub-rule (1) of this rule shall apply mutatis mutandis to assessment of fire service fees in respect of a building, the construction of which has been completed on or after the date of coming into force of the Act. (3) Save as otherwise provided in the Act or under these rules, the procedure followed by the authority in respect of collection of the taxes or fees levied by it under any relevant law or instrument applicable to it, shall apply also to collection of fire service fees assessed under these rules. 21. The Director of Fire Services appointed under section 18.- Without prejudice to the rules, if any, regulating recruitment to the post of Director, Maharashtra Fire Services, Group-A for the time being in force, the Director of Fire Services to be appointed under section 18 shall always be a person possessing academic qualifications and practical experiences in fire services. 22. Duties and responsibilities of fire officers and staff.- (1) Subject to the provisions of sub-rule (2), the duties and responsibilities of fire officers and staff shall be as specified in the Fire Service Manual. (2) The Director, with the approval of the Government, may, by general or special order, add to, or delete from, or modify the duties and responsibilities of the fire officers or fire staff; and there upon the Fire Service Manual shall stand amended accordingly. 23. Order of requisition of firefighting equipment.- Order of requisition of firefighting equipment or property of any Authority or any institutions or individual to be issued under sub-section (1) of section 26 shall be in “Form-S”. 24. Report on damage caused to premises during fire fighting operations and assessment and payment of compensation.- (1) The Director or the Chief Fire Officer or any other fire officer who is in-charge of fire fighting operations on the spot, shall make a report in “Form- T” to the respective Local Authority or as the case may be, the planning Authority, on the damage, if any, caused to premises by fire officers or fire personnel during fire fighting and rescue operations as referred to in sub-section (2) of section 27. (2) On receipt of report under sub-rule (1), the damage caused to any premises or any other property shall be assessed by an officer of the respective Local Authority or case may be planning Authority, as the Authority may nominated in that behalf and such nominated officer shall, after giving an opportunity of being heard to the owner or occupier concerned, assess the damage and submit his recommendations in that behalf to the authority for its consideration. (3) Having regard to the recommendation made by such fire officer nominated by the Director or the Chief Fire Officer, as the case may be, and where the building or property to which such damage is caused is insured, the Insurance Company shall while determining and granting compensation to be paid to the owner or occupier take into account the damage caused to the premises or any other property by the fire officers or fire personnel during the conduct of fire fighting and rescue operations.
- 84. 25. Report ofaccident to fire officer or fire personnel during fire; and payment of compensation.- The fire officer in-charge of fire or natural calamity operations, shall submit a report of any accident occurring during such operation to the Director and also to the Chief Fire Officer; and the compensation payable to any fire officer, or fire personnel in the case of such accident, or to their dependents in the case of death or permanent disability, shall be such as the Director may, with the approval of the State Government, by any general or special order, determine. 26. Disciplinary or other action against fire officer or fire personnel.- Every fire officer or fire personnel who violates his duty or commits willful breach of any provisions of the Act or the rules or any order made by his superior officer, or exhibits or indulges in any cowardice or withdraws from duties of his office without permission or being absent on leave, fails without reasonable cause to report himself for duty on the expiry of such leave, or engages, without authority, in any employment other than his duty, shall be liable to be proceeded against for breach of discipline, and shall be liable for such disciplinary action, including action for breach of this rule. 27. Employment of fire officer or fire personnel for purposes other than fire fighting within or outside the sphere of their duties.- The fire officers or fire personnel may be engaged for the purposes other than fire fighting at the discretion of the Director or the Chief Fire Officer or any subordinate officer authorized by the Director or the Chief Fire Officer, in the case of all calls relating to natural calamities and rescue of life; 28. Rates for supply of water required on the occasion of fire fighting operations.- Where the officer in-charge of the fire fighting operations draws water, from any source in the area, which he considers necessary for such operations, the authority or owner or occupier having control over such water source shall be paid for the water so utilized,- (a) if water is drawn from an authority, then at the lowest rate of supply of water which is usually charged from the users of water in such area by such authority; (b) if water is drawn from any owner or occupier, then at the rate which shall not exceed the lowest rate referred to in clause (a),and where such rate is not available, then at such rate as may be determined by negotiation, subject, however, to the condition that where any dispute arises as to such rate, in the case of an authority, the decision of the Chief Executive Officer of the Authority concerned, and in the case of an owner or occupier, the decision of the Director, shall be final. 29. Terms for securing personnel or equipment or both for firefighting purposes.- The terms on which the Director or the Chief Fire Officer or any other fire officer authorized by any Authority may secure, by agreement, firefighting equipment or personnel from any person who employs and maintains personnel or equipment or both, for firefighting purposes, shall be as follows:- (1) As soon as may be, after the fire fighting operation is over, the Director or Chief Fire Officer or Fire Officer in charge of the fire fighting operation, as the case may be, shall release the personnel or equipment so secured and restore the same to the person (including the local authority, firm and institution or individual) from whose possession such personnel or equipment was secured. (2) There shall be paid to the employer of such personnel or owner of such equipment, compensation, the amount which is determined in accordance with the principles hereinafter set out, that is to say _ (a) where the amount of compensation is determined under the agreement, it shall be paid in accordance with such agreement; (b) where such compensation is not settled in the agreement or where no such agreement with regard to compensation can be reached, the matter shall be referred to the State Government and the decision of the State Government in that regard shall be final. (c) if any injury is caused to any personnel or any damage is caused to any equipment and the employee or the owner of the equipment, as the case may be, demands any compensation
- 85. separately in respectthereof, and no agreement can be reached , the matter shall likewise be referred to the State Government for determination and the decision of the State Government in that regard shall be final. 30. Appeal under section 32.- (1) Any aggrieved person may prefer an appeal in “Form-U” within 30 days from the date of receipt of notice or order or communication of refusal, as the case may be, as mentioned in clauses (a), (b) or (c) of sub-section (1) of section 32. (2) Such appeal shall bear a court-fee stamp of Rs.10 and shall be accompanied by a fee of Rs.500 to be paid in the office of the respective Local Authority or case may be planning Authority and a receipt in respect thereof shall be appended to the form of appeal. (3) Such appeal may be presented in person or may be sent by registered post or through courier agency. (4) On receipt of such an appeal, the nominated officer shall, as far as may be practicable, issue a notice of hearing to the appellant and the respective Local Authority or the planning Authority as the case may be, within 15 days from the date of receipt of such appeal and shall finally dispose of the appeal within 30 days after the date of hearing.
- 86. FORM – A {(seesection 3 (3) and rule 4 (1)} Certificate by the Licensed Agency regarding the compliance of the Fire Prevention and Life Safety Measures. C E R T I F I C A T E Certified that I / We have executed the works towards compliance in relation to Fire Prevention and Life Safety Measures to be provided, and performed other related activities required to be carried out, in the following building or premises as required under the provisions of the Maharashtra Fire Prevention and Life Safety Measures Act,2006 (Mah.III of 2007). Description of building or premises. ………………………………………………………………………………… …………. ………………………………………………………………………………… …………. The details of the work and related activities which I or we have executed or performed are mentioned in the list appended herewith. Place : Date : Signature and address of the Licensed Agency. Licence No………………...
- 87. FORM – B {(seesection 3 (3) and rule 4 (2)} Six monthly certificate to be given in every January and July by the owner or the occupier for compliance of the Fire Prevention and Life Safety Measures C E R T I F I C A T E Certified that I / We have carried out inspection of the Fire Prevention and Life Safety Measures installed in the following building or premises, namely :-. ……………………………………………………………………………………………. ……………………………………………………………………………………………. I / We further certify that these installations in the above mentioned buildings are maintained in good repair and efficient conditions during the period -------------------------------------, as required under the provisions of the Maharashtra Fire Prevention and Life Safety Measures Act, 2006 (Mah-III of 2007). The details of the inspection of installations carried out by me / us are mentioned in the report appended herewith. Place : Date : Signature and address of the Licensed Agency. Licence No………………...
- 88. FORM – C {(seesection 4 (2) and rule 5 (1)} Notice for removal of objects or goods likely to cause the risk of fire. To, Shri / M/s _________________ ________________________ ________________________ WHEREAS Government has, by notification, _______________ Department, Notification No.___________________ dated __________, published in the Maharashtra Govt. Gazette, Part_____ dated_________, required that the owners or occupiers of premises or any class of premises used in the following area, which in its opinion, are likely to cause risk of fire, take such precautions as have been specified in the said notifications and as are reproduced herebelow- …………………………………………………………………………………………….. …………………………………………………………………………………………….. …………………………………………………………………………………………… AND WHEREAS you are the owner or occupier of the following premises, which fall in the area mentioned in the said Government notification - …………………………………………………………………………………………… …………………………………………………………………………………………….. AND WHEREAS on inspection of the aforesaid premises, it is noticed that the objects or goods mentioned in the list appended herewith are such as are likely to cause risk of fire and are required to be removed to a place of safety; NOW,THEREFORE, in exercise of the powers conferred on me under subsection (2) of section 4 of the Maharashtra Fire Prevention and Life Safety 22 Measures Act, 2006 (Mah.III of 2007), I, ____________________________ hereby give you notice that you shall forthwith remove the said objects or goods to a place of safety and submit the report in respect of your having done so to the undersigned within ................ days. Place: Signature and Designation of the Officer. Date:
- 89. FORM – D {(seesection 4 (2) and rule 5 (2)} Notice to make representation on failure of the owner or occupier to comply with the notice issued under sub-rule (1) of rule 5. To, ………………………………. ………………………………. WHEREAS, by notice No.____________ dated _______ issued to you by ______________________and received by you on __________________, you were required to remove forthwith the objects or goods specified in the list appended to the said notice, to a place of safety and to submit a report in respect of you having done so to the undersigned. AND WHEREAS it is found that you have not complied with the said notice and have not removed forthwith the said objects or goods to a place of safety and they are still lying where they were which is likely to cause the risk of fire; NOW, THEREFORE, in exercise of the powers conferred by sub-section (2) of section 4 of the Maharashtra Fire Prevention and Life Safety Measures act, 2006 (Mah.III of 2007), I, _____________________________________ hereby call upon you to submit your say, if any, addressed to the undersigned so as to reach by or before 5.00 p.m. on__________________ , as to why the said objects or goods should not be seized or detained or removed by taking assistance of a Police Officer. Place: Signature and Designation of the Officer. Date:
- 90. CHAPTER - 3 EnvironmentProtection Legislations LAWS ON ENVIRONMENTAL PROTECTION: Water (Prevention and Control of Pollution) Act 1974 : This Act (No. 6 of 1974) was enacted by the Parliament on 23-3-1974. It is applicable to the States from their dates of their adoption. It was amended in 1978 and 1988. ' It has 8 chapters and 64 sections. It applies to certain States and the States who adopt it. The Act intends to provide for the prevention and control of water pollution, maintaining or restoring of wholesomeness of water. Boards, its powers and functions for matters connected therewith. Chapter-1 gives following definitions : Board means the Central or a State Board. Outlet includes any conduit pipe or channel, open or closed, carrying sewage or trade effluent or any other holding arrangement which causes or is likely to cause pollution. Pollution means such contamination of water or such alteration of the physical, chemical or biological properties of water or such discharge of any sewage or trade effluent or of any other liquid, gaseous or solid substance into water (directly or indirectly) as may is likely to create a nuisance or render such water harmful or injurious to public health or safety or to domestic, commercial, industrial, agricultural or other legitimate uses, or to the life and health of animals or plants or of aquatic organisms. Central Board, State Board, Sewage effluent and Trade effluent are also defined and distinguished. Stream includes river, water course, inland water, sub-terranean waters and sea or tidal waters to the extent notified. Sewer means any conduit pipe or channel, open or closed, carrying sewage or trade effluent. Subjects of other chapters are as under : Chapter I : Preliminary (S. 1,2) Chapter II : Central & State Boards (S.3 to 12) Chapter ID : Joint Board (S. 13 to 15). Chapter IV : Powers & Functions of Boards (S. 16 to 18). Chapter V : Prevention and Control of water Pollution (S. 19 to 33A) Chapter VI : Funds, Accounts & Audit (S. 34 to 40) Chapter VII : Penalties & Procedure (S. 41 to 50)
- 91. Chapter VIII :Miscellaneous including rule making powers of the Central and State Govt. (S. 51 to 64). Functions of the State Board given u/s 17 are more important. Some provision of Chapter-V are explained below - A State Board can require from any industry, operation, process, treatment and disposal system to furnish information regarding construction, installation or operation of such establishment (S.20), can take samples of effluents in a manner prescribed for analysis at the occupier's cost (S.21), shall send a copy of the report of analysis to the occupier (S.22), has power of entry and inspection of plant, record, register, document, material etc. (S. 23) and of prohibiting use of stream or well or sewer or on land for disposal of polluting matter by prescribing standards and no person shall make water pollution (R. 24) or make any new outlets or new discharges without previous consent of the State Board, which will make inquiry and grant consent with conditions imposed (which shall be binding to the applicant) or refuse it with reasons recorded in writing. If the consent is not given or refused within 4 months, it should be deemed to have been granted unconditionally (R. 25 & 26). An aggrieved person has right to appeal u/s 28. Revision is possible u/s 29. Any accident, act or event causing water pollution should be forthwith intimated to the State Board (S. 31). The State Board can take steps to remove pollution or such discharges (S. 32) or apply to courts for restraining apprehended water pollution and the court can order the person to remove that pollution or authorize the Board to do it at the cost of that person (S. 33). The State Board has power to give directions to any person, officer or authority for closure, prohibition or regulation of any industry, operation or process or the stoppage or regulation of supply of electricity, water or any other service (S. 33A). Annual report (financial year wise) to be submitted by SPCV to state Govt. and by CPCB to Central Govt. (S. 39) Water (Prevention and Control of Pollution) Rules 1975 : The Central Government u/s 63 of the Water Act made these rules effective form 27-2- 1975. The) were amended in 1976, 1978, 1986, 1987 and 1989. They have II chapters, 35 rules, 4 schedules and 15 forms under schedule 1. Their subject matter is a; under. Chap-1: Preliminary (R.1.2) Chap-2: Service conditions of Members (R. 3 to 6) Chap-3: Power & Duties of the Chairman and Member Secretary and appointments o ……………..officer and employees (R. 7 to 9) Chap-4: Temporary association of persons with Central Board (R. 10) Chap-5: Consulting Engineer (R. 11 to 16). Chap-6: Budget of the Central Board (R. 17 to 23) Chap-7: Annual Report of the Central Board (R. 24) Chap-8: Account of the Central Board (R. 25) Chap-9: Analyst of the Central Board (R. 26, 26A) Chap-10 : Central water laboratory (R. 27, 28) Chap-11 : Powers & functions of the Central Board in relation to Union territories (R. 29 to 35). In addition to above mentioned Central Rules, State Rules are also available as under. Gujarat Water (Prevention and Control of Pollution) Rules, 1976 :
- 92. They were notifiedand came into force from 268-1976. They have 25 Rules and Forms A to H-V. State water laboratory means that established u/ s 52 of the Act. Other provisions are pertaining to fees and allowances to members, quorum, order of business, minutes, appointment of consulting engineers, powers and duties of the chairman and those of member secretary, application for consent and its investigation, budget, annual report and statement of accounts etc. Air (Prevention and Control of Pollution) Act, 1981: This Act (No.l4 of 1981) was enacted on 293-1981. It came into force from 16-5-1981. It extends to the whole of India. It has 7 chapters and 54 sections. It was amended in l987. Chapter-1 gives following definitions (S I and 2): A. Air pollutant means any solid, liquid or gaseous substance including noise present in the atmosphere in such concentration as to be injurious to human beings, other living creatures, plants, property or environment B. Air pollution means the presence of any air pollutant in the atmosphere. C. Approved appliances means any equipment or gadget used for bringing of any combustible material or for generating or consuming any fume, gas or particulate matter and approved by the State Board for the purpose of this Act. Chimney includes any structure with an opening or outlet from or through which any air pollutant may be emitted. D. Control equipment means any apparatus, device, equipment or system to control the quality and manner of emission of any air pollutant and includes any device used for securing the efficient operation of any industrial plant. E. Emission means any solid, liquid or gaseous substance coming out of any chimney, duct or flue or any other outlet. F. Industrial plant means any plant used for any industrial or trade purposes and emitting any air pollutant into the atmosphere. The words 'approved fuel' and 'automobile' arc also defined. Other chapters are as under: Chapter - II: Central & State Board (S.3 to 15) Chapter - III: Powers & functions of Boards (S.16 to 18) Chapter – IV: Prevention & Control of Air pollution (S.19 to 31A) Chapter – V: Funds, Accounts & Audit (S.32 to 36). Chapter – VI: Penalties & procedure (S 37 to 46) Chapter - VII: Miscellaneous including rule making powers of the Central and State …………………… Govt. (S. 47 to 54). Functions of the central and State Pollution Control, Boards are given in Chapter III. Some provisions of Chapter-IV are as under: The State Government may after consultation with the State Pollution Control Board, notify any area as air pollution control area for the purposes of this Act, prohibit the use of any polluting fuel in any area, require use of an approved appliance, prohibit burning of any polluting material in any area (S.19) and instruct the motor vehicles authority to ensure compliance of the standards of automobiles emission laid down by the State Board (S.20).
- 93. No industrial plantshall be established or operated without the previous consent of the State Board. An application for consent should be in a prescribed form. The State Board can grant or refuse within 4 months, or cancel any existing consent or refuse further consent after expiry if the conditions are not fulfilled. Every person getting consent has to comply with the following conditions: 1. The control equipment approved by the State Board should be installed and operated. 2. The existing control equipment shall be altered or replaced as per the directions of the State Board. 3. The control equipment should be maintained at all times in good running condition. 4. Chimney, approved by the State Board shall be erected or re-erected. 5. Such other conditions as the State Board may specify. 6. The conditions should be fulfilled within a stipulated time. Due to any technological improvement or otherwise the State Board can vary its conditions. If the consent is transferred to another person, the transferee will be responsible for compliance (S. 21). Standards laid down by the State Board shall not be exceeded (S.22). The Board has power to approach the court for restraining persons from causing air pollution. The court can direct that person to stop pollution or authorize the Board to implement the direction at the cost of that person (S.22A). An accident, unforeseen act or event of emission beyond the prescribed standard shall be forthwith intimated to the State Board and to the prescribed authorities, who shall take, as early as practicable, remedial measures to mitigate that emission at the cost of the person concerned (S.23). Board officers have power of entry and inspection to check conditions, control equipment, industrial plant, record, register, document, material etc. (S.24) and can call for any information regarding types and level of emission and any compliance necessary (S.25), can take samples of air or emission in the manner prescribed and can send the sample to the laboratory for analysis (S.26). The Board analyst shall submit the report of analysis in triplicate to the Board, of which one copy will be sent to the occupier by the Board (S.27). The State Government can establish one or more State Air Laboratories (S.28) and can appoint analysts (Govt. analysts). The Board can also appoint analysts (Board analysts) (S.29) whose report can be used as evidence in any proceeding under this Act (S.30). An aggrieved person can appeal within 30 days to the prescribed authority (S.31). Central or State Board has power to give directions to any person, officer or authority who shall comply with such directions. Such power includes the power to direct closure, prohibition or regulation of any industry, operation or process or the stoppage or regulation of supply of electricity, water or any other service (S. 31A). Air (Prevention and Control of Pollution) Rules, 1982: The Central Government u/s 53 of the Air Act made these rules effective from 18-11-1982. They have 7 chapters, 17 rules, 3 schedules and 9 forms. The subject matter is as under: Chapter - I Preliminary (R.l,2) Chapter - II Procedure for the Board and its committees (R.3 to II). Chapter - III Allowances to a committee member to attend the meeting (R.12). Chapter - IV Temporary association of persons with the Central Board (R.13, 14). Chapter - V Budget of the Central Board (R.15). Chapter- VI Annual Report of the Central Board (R.16).
- 94. Chapter - VIIAccount of the Central Board (R.17). In addition to above mentioned Central Rules, State Rules are also available as under. Gujarat Air (Prevention and Control of Pollution) Rules, 1983. They were notified and came into force from II11-1983. They have 25 Rules, 2 Schedules and Forms I to II. Rule 2 gives 12 definitions. A. Furnace means any structure or installation where any form or type of fuel is burnt or otherwise a high temperature higher than ambient is maintained. B. State Laboratory means that established u/s 17 of the Act. Other provisions include terms, conditions and functions of the State Board, appointment, fees and tours of consultant, air pollution control area, application for consent and its inquiry, manner of taking samples of air, functions of state air laboratory, qualifications for Govt. analyst and board analyst, appeals, budget, annual report and statement of accounts etc. Environment (Protection) Act, 1986: This Act (29 of 1986) was enacted on 23-51986. It came into force, from 19-11-1986 in the whole of India. It has 4 chapters and 26 sections. The Statement of Objects and Reasons of the Act identifies the need for a general legislation on environmental protection to enable co-ordination of activities of the various regulatory agencies, creation of an authority which will assume a lead role for studying, planning and implementing long-term requirements of environmental safety and give direction to and co-ordinate a system of speedy and adequate response to emergency situations threatening the environment. Its preamble states that it is an Act to provide for the protection and improvement of environment and for matters connected therewith Chapter -I : Preliminary (S.I, 2) : Some definitions are as under: Environment includes water-air and land and the inter-relationship which exists among and between , air and land and human beings, other living creatures, plants, micro-organism and property [S.2(a)]. Environmental pollutant means any solid, liquid or gaseous substance present in such concentration as to be injurious to environment, [S.2(b)]. Environmental pollution means the presence of any environmental pollutant in the environment, [S.2(c)] Handling in relation to any substance, means the manufacture, processing, treatment, package, storage, transportation, use, collection, destruction, conversion, offering for sale, transfer or the like of such substance [S.2 (d)]. Hazardous Substance means any substance or preparation which by reason of its chemical or physiochemical properties or handling is liable to cause harm to human beings, other living creatures, plant, microorganism, property or the environment. [S.2(e)].
- 95. Chapter - II:General Powers of the Central Government (S. 3 to 6 ): The Central Govt. has power to take all necessary measures to protect and improve the quality of environment and to prevent, control and abate environmental pollution, co- ordinate action by the State Govt. officers and other authorities and has power of planning and execution of a Nationwide programme, laying down standards for the quality of environment, standards for emission of pollutants, procedures and safeguards for the prevention of accidents which may cause environmental pollution and for the handling of hazardous substances, examination of processes, materials and substances and empowering officers for that, carrying out research and investigation, establishing environmental laboratories, collection and dissemination of information, preparation of manuals, codes or guides for prevention, control and abatement of environment pollution and constituting authorities to carry out these functions (S.3). The Central Govt. can appoint officers for above purposes (S.4), can give directions to any person, officer or authority including direction of closure, prohibition or regulation of any industry, operation or process or stoppage or regulation of supply of electricity, water or any other service (S.5). It has power to make rules (S.6, 25, 26) and power to delegate its powers and functions (S.23). Chapter-III: Prevention, Control and Abatement of Pollution (S. 7 to 17): Environmental pollutants in excess of .standard prescribed shall not be discharged (S. 7). While handling hazardous substance prescribed procedure and safeguards shall be followed (S. 8). Excess discharge shall be forthwith reported to the authorities and steps shall be taken to prevent or mitigate such accidental pollution. The authorities shall also take similar steps at the cost of the person concerned (S. 9). Persons empowered by the Central Government have powers of entry and inspection, examination and testing of any equipment, industrial plant, record, register, document, material etc. (S. 10), to take samples of air, water, soil or other substance from any factory, premises or other place in a manner prescribed and to send them to the laboratory for analysis (S.ll), to establish environmental laboratories (S.12). Sec. 14 is regarding Central Analysts (S. 13) whose report can be produced as evidence in proceeding under this Act, (S. 14). Provisions are made for penalty (S. 15) and offences by companies (S. 16) and Government Departments (S. 17). Chapter - IV: Miscellaneous (S. 18 to 26): Provisions are made for protection of action in good faith (S.18). Cognizance of offences by the authority as well as any person who has given notice of at least 60 days of the alleged offence and his intention to complain, to the authority concerned (S.19). Information, reports or returns (S.20) and no civil court has any jurisdiction in respect of anything done by the authority or the Central Government (S.22). This Act has overriding effect notwithstanding anything inconsistent with any other Act but if any offence is punishable under this Act and also under any other Act, then the offender shall be punished under the other Act and not under this Act (S.24).
- 96. Environment (Protection) Rules,1986 : The Central Government u/s 6 & 25 of the Environment (protection) Act made these rules effective from 19-11-1986. They were amended in 1987, 1988, 1989, 1991,1992, 1993 and from 1996 to 2006 every year. They have 14 rules, 7 schedules, (No.2 omitted) 4 Annexure under schedule IV, 5 Forms under Annexure A and different Notifications dating from 212-1991 and onwards specifying guidelines, area categories, requiring environmental clearance from the listed projects (schedule) and forming the expert committees for environmental impact assessment. An abstract of provisions is as under: A. Areas means all areas where the hazardous substances are handled. B. Recipient system means the part of the environment such as soil, water, air or other which receives the pollutants. C. Central Board means the Central Pollution Control Board u/s 3 of the Water Act and State Board means a State Pollution Control Board u/s 4 of the Water Act or u/s 5 of the Air Act, D. Standards : The standards for emission or discharge of environmental pollutants are specified in schedule I to IV. The Central or State Board may specify more stringent standards. These standards shall be complied with by an industry, operation or process within a period of one year of being so specified. The board can reduce this period. Industries, operations or processes not mentioned in Sch. I shall not exceed the general standards specified in Sch. VI. No emission or discharge shall exceed the relevant concentration set out in column (3) to (5) of Sch. VH of National Ambient Air Quality Standards (NAAQS) (R. 3). See Parts (Tables) 10 to 14 of Chapter-32. Others: All directions u/s 5 should be in writing and specify action to be taken and its time of compliance. Procedure is prescribed (R.4). Factors to be considered while 'prohibiting or restricting the location of industries are given in R.5. Procedure for taking samples (R.6), Notice in Form I to take sample (R.7), Procedure for submission of samples along with From n and form of laboratory report in Form III (R'8), Functions of laboratories (R.9), Qualifications of Govt. Analyst (R.IO), Manner of giving notice of alleged offence in Form IV (R. II), Notice, of accidental discharge to the authorities (R.I 2) and Sch. V, Factors to be considered while prohibiting or restricting the handling of hazardous substances (R.13) and submission of Environmental Statement for the financial year ending 31st March in Form V before the next 30th September every year to the Board (R.14) are prescribed. Schedule-1 (Rule-3) : gives industry wise pollution parameters and their standards for 98 types of industries including stack height and test method for some parameters and also known as Minimum National Standards (MINAS). Schedule-II (Rules-3) : was inserted on 12-9-1996 and omitted on 31-12-1993. thus now it does not exist. Schedule-III (Rule-3) : gives ambient air quality standards for noise for 4 categories of area and time. Limits in dB vary from 40 to 75. Schedule-IV (Rule-3) : specifies standards for vehicular emission, types of fuel and tests and exhaust gas values in Annexure I to IV. Parameters considered are CO, HC and NO.. Schedule-V (Rule-12) : gives authorities to be informed in case of excessive discharge. This includes authorities under the Atomic Energy Act, Factories Act, Mines and Minerals Act, Ports Act, Plantations Labour Act, Motor Vehicles Act and Merchant Shipping Act.
- 97. Schedule-VI (Rule-3A) :gives general standards for discharge of pollutants in five parts : (A) Effluents (B) Waste water generation (C) Load based standards for Oil Refinery and large Pulp & Paper mill (D) General emission standards based -on concentration, equipment and load/mass (E) Noise standards for automobiles and domestic appliances and also gives guidelines in Annexure I fell for the purposes of Part A to D. See Table-14 in Chapter-32. Schedule-VII (Rule-SB) : gives National Ambient Air Quality Standards (NAAQS) in terms of time weighted average concentration in ambient air (ug or mg/nr") for six main pollutants – SO2, NO2, Pb, CO, SPM (Suspended particulate matter) and RPM (respirable particulate matter) with their method of measurement. This table may be useful in keeping work environment record (e.g. Form 37 GFR). See 2nd Sch. under the Factories Act for in- plant exposure limits. See Table-15 in Chapter-32. Appendix -A prescribes Form I (R.7), II & III (R.8), IV (R.11) and V, Annual Environmental Statement (R.14). Manufacture, Storage and Import of Hazardous Chemicals Rules 1989 : U/s 6, 8 and 25 of the Environment (Protection) Act. 1986, these rules were made enforceable from 27-11-1989. They were amended in 1994 & 2000. They have 20 Rules and 12 Schedules asunder: R1 - Short- title and commencement. R2 - Definitions. R3 - Duties of Authorities: To inspect the industrial activity at least once in a year ……………...and to perform duties mentioned in Sch. 5. R4 - General responsibility of the occupier. R5 - Notification of major accident. R6 - Industrial activity to which rules 7 to 15 apply. R7 - Approval & Notification of sites. R8 - Updating of the site notification following changes in the threshold quantity. R9 - Transitional provisions. R10 - Safety Reports and Safety Audit Report. R11 - Updating of reports u/r 10. R12 - Requirement for further information to be sent to the authority. R13 - Preparation of On Site emergency plan by the occupier. R14 - Preparation of Off Site emergency plan by the authority. R15 - Information to be given to persons liable to be affected by a major accident. R16 - Disclosure of information. R17 - Collection, Development and Dissemination of information. R18 - Import of hazardous chemicals. R19 - Improvement notices. R20 - Power of the Central Government to modify the schedules.
- 98. Then schedules asunder - Sch.1 - Indicative criteria and list of chemicals. Part-I Toxic, flammable & Explosive chemicals. Part-II List of 684 hazardous chemicals. Sch.2 - Isolated storage other than those covered by Sch. 4. Threshold quantities of 30 chemicals are given. Sch. 3- List of hazardous chemicals for application of R. 5 and 7 to' 15. Part - I named chemicals, 179. Part - II classes of chemicals not named in Part - I (flammable gases and liquids) Sch.4 - Hazardous operations and processes. Sch.5 - Authorities and their duties (addition). Sch.6 - Notification of a major accident. Sch. 7- Notification of sites. Part-I regarding site, Part-II regarding pipeline. Sch. 8- A safety report. Sch. 9- Safety data sheet (MSDS). Sch. 10 - Record of hazardous chemicals imported. Sch. 11 - Details of on - site emergency plan. Sch. 12 - Details of off-site emergency plan. Thus these rules impose greater duty on occupiers and authorities in identifying major accident hazard (MAH) installations and taking safety measures for them. Noise Pollution (Regulation and Control) Rules, 2000 U/s 3, 6 & 25 of the Environment (Protection) Act 1986 these rules were made. They came into force from 14-2-2000. They were amended in 2000 & 2006. Its objective is to (1) regulate and control noise producing and generating sources and to (2) maintain ambient air quality standards in respect of noise as specified in the Schedule. They have 8 rules and I schedule. Rule 2 has 8 definitions including zone, court, educational institution, hospital etc. Area within 100 mts around hospitals, educational institutions and courts may be declared as silence zone. Area categorization should be made as industrial, commercial, residential or silence zone as shown in the Schedule (R.3) Noise levels shall not exceed levels specified in the Sch. as under (R.4) Area Code Category of Area/ Zone Limits in dB (A) Leq* Day Time Night Time A Industrial area 75 70 B Commercial area 65 55
- 99. C Residential area55 45 D Silence Zone 50 40 Leq* =It is energy mean of the noise level over a specified period. Day time 6 am to 10 pm Nigh time 10 pm to 6 am. See similar table 12.8 in Chapter-12. Written permission is necessary to use loud speaker or public address system. They cannot be used between 10 pm and 6 am except in closed premises like auditoria, conference rooms, community halls, banquet halls etc. State Govt. has power to permit use between 10 pm to 12 midnight subject to terms and conditions (R.5) Authority has power to prohibit vocal or musical sound also if it causes annoyance, disturbance, discomfort etc to any person or public (R.8) Bio-Medical Waste (Management & Handling) Rules, 1998 : Wastes generated from hospitals, medical & health institutions, R & D organization, laboratories and slaughter houses etc., where biological organisms are involved, have become an important source of environmental and public health problems. Generally these wastes are being disposed in the Municipal dumps. The public have become aware of this problem and the issue was discussed in various forums. The major concern is proper disinfection, treatment and disposal of bio-medical wastes. To evolve a proper system for regulation of treatment and disposal of medical wastes and in exercise of the powers conferred by Sections 6, 8 & 25 of the Environment (Protection) Act, 1986, the Ministry of Environment & Forests, Govt. of India framed these rules and made effective from 27-7-1998. They were amended in 2000 -& 2003. There are 14 Rules with 6 Schedules and 5 Forms. These Rules provide Duty of Occupier, Treatment & Disposal, Segregation, Packing, Transportation &: Storage, Prescribed Authority, Authorization, Advisory Committee, Monitoring in Armed forces medical centers by CPCB, Annual Report, Maintenance of Records, Accident Reporting, Appeal and common disposal/ incineration sites. Out of 19 definitions, some areas under: A. "Animal House" means a place where animals are reared/kept for experiments or testing purposes; B. "Authorization" means permission granted by the prescribed authority for the generation, collection, reception, storage, transportation, treatment, disposal and/or any other form of handling of bio-medical waste in accordance with these rules and any guidelines issued by the Central Government. C. "Biological" means any preparation made from organisms or micro-organisms or product of metabolism and biochemical reactions intended for use in the diagnosis, immunization or the treatment of human beings or animals or in research activities pertaining thereto;
- 100. D. "Bio-medical waste"means any waste which is generated during the diagnosis, treatment or immunization of human beings or animals or in research activities pertaining thereto or in the production or testing of biological. There are ten categories of wastes and are listed in the Schedule-1. "Bio-medical waste treatment facility" means any facility wherein treatment, disposal of bio-medical waste or processes incidental to such treatment or disposal is carried out and includes common treatment facilities; The Schedules are as under : Sch. No. Title I Categories of Bio-Medical waste. II Colour coding and type of container for disposal of Bio-Medical wastes. III Label for Bio-Medical waste containers / bags. (As shown below) IV Label for Transport of Bio-Medical waste containers / bags. V. Standards for Treatment & Disposal of Bio-Medical wastes like incineration, autoclave, liquid wastes, microwave system and deep burial; VI Schedule for Waste Treatment facilities like Incineration/ Auto Clave/ Microwave system. The Forms are: I Application for Authorization II Annual Report III Accident Reporting IV Authorization V Application for Appeal
- 101. Schedule-I : Categoriesof Bio-Medical Category No. Waste Category Treatment & Disposal 1 Human Anatomical Waste incineration@/ deep burial* 2 Animal waste incineration@/ deep burial* 3 Microbiology & Biotechnology waste Local autoclaving / microwaving / incineration @ 4 Waste Sharps Disinfection (chemical treatment@ / autoclaving/ microwaving & mutilation / shredding* 5 Discarded medicines and Cytotoxic Drugs (wastes comprising of outdated, contaminated and discarded medicines) incineration@/destruction and drug disposal in secured landfills 6 Solid Waste incineration@/autoclaving/ microwaving 7 Solid waste Disinfection by chemical treatment@ / autoclaving / microwaving and mutilation / shredding## 8 Liquid Waste Disinfection by chemical treatment@@ and discharge into drains 9 Incineration Ash Disposal in municipal 10 Chemical Waste Chemical treatment @ & discharge into drains for liquid and secured landfills for solids @@ Chemicals treatment during at least 1% hypochlorite solution or any other equivalent chemical reagent. It must be measured that chemical treatment ensures disinfection. ## Multination / shredding must be such so as to prevent unauthorized reuse. @ There will be no chemical pre-treatment before incineration. Chlorinated plastics shall not be incinerated. * Deep burial shall be option available only in towns with population less than five lakhs and rural areas.
- 102. Duty of Occupier:It shall be the duty of every occupier of an institution generating bio- medical waste which includes a hospital, nursing home, clinic, dispensary, veterinary institution, animal house, pathological laboratory, blood bank by whatever name called to take all steps to ensure that such waste is handled without any adverse effect to human health and the environment. Treatment and Disposal: 1. Bio-medical waste shall be treated and disposed off in accordance with Schedule-1, and in compliance with the standards prescribed in Schedule-V. 2. Every occupier, where required, shall set up in accordance with the time schedule in Schedule VI, requisite bio-medical waste treatment facilities like incinerator, autoclave, microwave system for -the treatment of waste, or ensure requisite treatment of waste at a common waste treatment facility or any other waste treatment facility. (R.5) Segregation, Packaging, Transportation and Storage: Biomedical waste shall not be mixed with other wastes. Segregation as per Sch.U and labeling as per Sch. III. For wastes being transported information as per Sch. III. Use of authored vehicle only. Untreated wastes not to be stored beyond 48 hrs. Role of municipality (R.6). Maintenance of Records: 1. Every authorized person shall maintain record related to the generation, collection, reception, storage, transportation, treatment, disposal and /or any form of handling of biomedical waste in accordance with these rules and any guidelines issued. 2. All records shall be subject to inspection and verification by the prescribed authority at any time. (R.11) Accident Reporting: When any accident occurs at any institution or facility or any other site where bio-medical waste is handled or during transportation of such waste, the authorised person shall report the accident in Form-III to the prescribed authority forthwith. (R.12) SC Judgement: In WP (Civil) No. 286/94 between BL Wadherav/ s Union of India, while monitoring its own judgement of 11-3-96, the Supreme Court went through 14 directions issued to various authorities and their compliance. Most of the Hospitals and Nursing homes in Delhi, agreed to provide incinerators or equally effective alternative for waste disposal. E-WASTE(MANAGEMENT) RULE 2015 1) The e-waste (Management) Rules, 2015 rules shall apply to every manufacturer, producer, consumer, bulk consumer, collection centres, dealers, e-retailer, refurbished, dismantler and recycler involved in manufacture, sale, transfer, purchase, collection, storage and processing of e-waste or electrical and electronic equipment listed in Schedule I, 2) Collection of e-waste generated during the manufacturing of any electrical and electronic equipment and channelizing it for recycling or disposal. 3) Obtain the authorization form from the concerned State Pollution Control. form-1 4) Maintain records of the e-waste generated, handled and disposed in Form-2 and make such records available for scrutiny by the concerned State Pollution Control Board. 5) Fluorescent and other mercury containing lamps, where recyclers are not available, channelization may be from collection centre to Treatment, Storage and Disposal Facility.
- 103. 6) A pre-treatmentis necessary to immobilise the mercury and reduce the volume of waste to be disposed of for disposal in Treatment, Storage and Disposal Facility 7) ensure that no damage is caused to the environment during storage and transportation of e-waste 8) Every manufacturer, producer, bulk consumer, collection centre, dealer, refurbished, dismantler and recycler may store the e-waste for a period not exceeding one hundred and eighty days and shall maintain a record of collection, sale, transfer and storage of wastes and make these records available for inspection [RULE: 15- procedure for storage of e-waste] 9) The transportation of e-waste shall be carried out as per the manifest system whereby the transporter shall be required to carry a document (three copies) prepared by the sender, giving the details as per Form-6. [RULE: 19- Transportation of e-waste] 10) Provided that the transportation of waste generated from manufacturing or recycling destined for final disposal to a treatment, storage and disposal facility shall follow the provisions under Hazardous Wastes (Management, Handling and Transboundary Movement) Rules, 2008. 11) Storing of E-Waste in landfills - environmental & health hazard Incineration - environmental & health hazard Reusing and recycling-limited life span, hazardous in unorganised sector 12) Government assist by encouraging setting up of integrated Transport, Storage and Disposal Facilities (TSDF) for hazardous waste management on Public Private Partnership (PPP) mode 13) The Ministry of Environment, Forest and Climate Change has notified E-Waste (Management) Rules, 2016. The rules - for the first time in India - introduced Extended Producer Responsibility (EPR). 14) The EPR is an environment protection strategy that makes the producer responsible for the entire life cycle of the product, especially for take back, recycle and final disposal of the product. 15) DISPOSING E-WASTE (a) Donate working older equipment to schools’ colleges or government entities in need. (b) If PCs are out of order then return it to the manufacturers. (HCL and Wipro in India have best take back service). (c) Send waste goods to authorised recycling facility for proper disposal. BATTERIES (MANAGEMENT AND HANDLING) RULES, 2001 U/s 6, 8, & 25 of die Environment (protection) Act 1986, these rules were made and brought into force from 16-5-2001. They have 14 rules, I schedule and 9 forms. They apply to every manufacturer, importer, reconditioner, assembler, dealer, recycler, auctioneer, consumer and bulk consumer involved in manufacture, processing, sale, purchase and use of batteries or components thereof. There are 19 definitions u/r 3 some of which are as under - "Battery" means lead acid battery which is a source of electrical energy and contains lead metal; "Consumer" means a person using lead acid batteries excluding bulk consumers;
- 104. "Re-conditioner" means aperson involved in repairing of lead acid batteries for selling the same in the market; "Recycler" means an occupier who processes used lead acid batteries or components thereof for' recovering lead; Responsibilities of manufacturer, importer, assembler and re-conditioner are stated in R.4 and those of dealer in R. 7, of recycler in R.8, of consumer in R. 10 and of auctioneer in R. II. Importers have to register themselves (R.5 & 6). Registration procedure for recyclers is given in R. 9. Prescribed authority is State Pollution Control Board (R.12). Duties of CPCB are mentioned in R. 13 and those of MoEF in R. 14 for records and returns. Used batteries are to be collected back by the manufacturer and dealer and appropriate discount shall be given to the consumer. Safe transportation, no damage during storage and transportation and collected batteries are to be sent only to the registered recyclers. Recycler shall mark 'Recycled' on lead recovered by him and create public awareness regarding hazards of lead and obligations of consumers to return used batteries only to the registered dealers or at the designated collection centers. HAZARDOUS WASTES (MANAGEMENT AND HANDLING) RULES, 1989: The Central Government u/s 6,8& 25 of the Environment (Protection) Act made these rules effective from 28-7-1989. They were amended in 1996, 2000, 2003 I They have 21 rules, 8 schedules and 13 forms. Application (R.2) : These rules apply to hazardous wastes as specified in Schedules, but do not apply to Waste water and exhaust gases, wastes arising out of operation from ships beyond 5 km, radio-active wastes, biomedical wastes, municipal solid waste; lead acid batteries wastes as there are separate rule for them. Definitions (R.3): There are 36 definitions some of which are a under: Applicant means a person or organization the applies in Form-1 for granting authorization for handling of hazardous waste. Authorization means permission for collection transport, treatment, reception, storage and disposal of hazardous wastes granted by the competent authority in Form-2. Hazardous waste means any waste which b reason of any of its physical, chemical, reactive, toxic, flammable, explosive or corrosive characteristics causes danger or is likely to cause danger to health or environment, whether alone or when in contact with other wastes or substances, and shall include wastes listed in Sch. 1, 2 & 3. Disposal means deposit, treatment, recycling and recovery of any hazardous wastes; Facility means a location wherein the processes incidental to the waste generation, collection, reception, treatment, storage and disposal are carried out.
- 105. Hazardous Wastes Sitemeans a place duly approved by the competent authority for collection, reception, treatment, storage and disposal of hazardous wastes. Operator of a facility means an owner or operator of the facility defined above. The occupier generating hazardous wastes listed in the Schedules 1, 2 & 3 shall take all practical steps for safe disposal of the wastes either himself or through an operator of a facility. The occupier should supply specified (safety) information to the operator of a facility (R. 4). Application for authorization in Form-1 by the occupier or a facility operator and grant of such authorization with conditions in Form-2 after satisfying that they possess appropriate facilities, technical capabilities and equipment to handle the wastes safely. Such authorization lasts for validity specified by SPCB unless sooner suspended or cancelled and then needs renewal in Form-1. It can be refused also (R. 5). If the conditions are not fulfilled, the granted authorization can be cancelled or suspended by the State Pollution Control Board or Committee after a show cause notice and subsequent instruction for the safe storage of the hazardous wastes (R. 6). Packing, labeling and transport of such wastes should, be in accordance with the Motor Vehicle Act and rules made there under and in a condition to withstand physical and climatic factors. Label as in Form 8 necessary (R. 7). The occupier or operator of a facility shall identify wastes disposal site. EIA and public hearing are necessary (R.8). Design and operation of the landfill site shall be as approved by SPCB (R. 8A & B). The occupier generating waste and operator of a facility shall maintain records in Form-3 and shall send annual returns in Form-4. (R.9). Any accident during transport or at the facility shall be reported immediately to the State Pollution Control Board or Committee in Form-5. (R.1O). Import and export of hazardous wastes specified in Sch. 8 is not permitted for dumping and disposal. It may be permitted for processing or re-use as raw material and after getting necessary information in Form 6 & 6A from the exporter and importer both and after examining each case on Jnerit. The importer shall maintain records in Form-7A""and allow inspection by the authority (R.II& 12). Rule 13 to 15 are also for import and export. Rule 19 and 21 are for re-refining and recycling. R.20 states responsibility of wastes generator. An appeal shall lie before the State or Central Government depending on order and as provided in R. 18.
- 106. Subjects of Schedulesare as under: Sc h. No . Subject 1 Process wise list of hazardous wastes 2 Concentration wise list of hazardous wastes 3 List of wastes for import and export 4 & 6 Recycling of wastes 5 Re-refining of wastes 7 Authorities 8 List of wastes prohibited for import and export. CHEMICAL ACCIDENTS (EMERGENCY PLANNING, PREPAREDNESS AND RESPONSE) RULES, 1996 : The Central Govt. u/s 6, 8 and 25 of the Environment (Protection) Act, 1986 made these rules. They were notified and brought into force on 1-8-1996. They were amended in 1998. They contain 13. rules and 8 schedules. Their abstract is as under : Definitions (R. 2): They contain 12 definitions some of which are as under: Chemical accident - See part 3.8 of Chap-2. Industrial pocket means any industrial zone earmarked by the Industrial Development Corporation of the State Government or by the State Government. Major Accident Hazards (MAH) Installation See part 3.55 of Chapter 2. Off-site emergency plan means the plan prepared as per Sch. 12 u/r 14(1) of the MSIHC Rules. (similarly On-site emergency plan means that prepared as per Sch. II u/r 13(1) of the MSIHC Rules.). 'Major Chemical accident" See Part 3.54 of Chapter 2. Different Crisis Groups : The constitution of the Central, State, District and Local Crisis Group shall be as specified in Sch. 5,6,7 &: 8 respectively. The members of the Central, State and District Crisis Groups are empowered u/s 10(1) of the EP Act 1986 to enjoy those powers. The MAH installations shall aid, assist and facilitate the functioning of the District and Local Crisis Groups. Meeting of the Central, State, District and Local Crisis Group shall be held at 6 months, 3 months, 45 days and 30 days respectively. Functions of the Central, State, District and Local Crisis Groups given in Rule 5, 7, 9 and 10 respectively are summarised in the following Table.
- 107. Functions of theCrisis Groups (Rule 5, 7, 9 & 10): Central Crisis Group (Rule 5) State Crisis Group (Rule 7) 1 Expert guidance Same as functions No. 1 to 7 mentioned for group 2 Monitoring of post accident situation and 8 Assistance of the State Govt. in remedial measures to prevent recurrence. plan nin g, prepared ness a n d mitigation of major accidents. 3 Post accident analysis and evaluation of 9 Quarterly report to the CCG. responses. 4 Review of District offsite emergency plans and reports received. 5 Respond to queries 6 Statewise list of experts. 7 Financial and other help. 8 Informatin to public. District Crisis Group (Rule 9) Local Crisis Group (Rule 10) 1 Expert guidance. 1 Pre para tion of local emergency plan for the industrial pocket and dovetailing of this plan with the Dist. Off-site emergency plan. 2 Preparation of Dist. Off-site emergency 2 Training of persons and public plan. 3 Review of all on-site emergency plans of 3 Half-yearly mock drill and report MAH units. to DCG. 4 Management of chemical accidents in the 4 Respond to public inquiries. district.
- 108. + 5 Monitoring of everychemical accident 5 Information to public. 6 Continuous information to the CCG and 6 Assistance to MAH units for SCG. informing persons likely to be affected. 7 Report of chemical accident within 15 days to SCG. 8 Yearly mock drill and report to SCG.
- 109. Information to thePublic :The Central, State and Local Crisis Group shall provide informationon request regarding chemical accident prevention, preparedness and mitigation to the public in their respective jurisdiction. The Local Crisis Group shall assist the MAH installations in taking appropriate steps to inform persons likely to be affected by a chemical accident (R. 13). Crisis Alert system :The Central Govt. shall set up functional control room, informationnetwork with state and district control rooms, appoint staff and experts in control room, publish lists of (i) MAH installations (ii) Major chemical accidents in chronological order (iii) Members of the Central, State and District Groups and take measures to create awareness amongst the public to prevent chemical accidents (R. 4). Schedules: Sch.I to 4-the same as Sch.I to 4 of the MSIHC Rules 1989 or R 68J, GFR 1963. Sch. 5 to 8- List of members for CCG, SCG, DCG and LCG respectively.
- 110. CHAPTER 4 LAWS ONBOILER SAFETY BOILERS ACT, 1923: The Boilers Act (No. 5 of 1923) was notified on 4-12-1923. It came into force from 1- 1-1924. It has 34 sections. It is amended by the Act No. 49 of 2007 which became effective by Notification dtd. 13-12-2007. Section 2 of the Act defines as under : Boiler means a pressure vessel in which steam is generated for use external to itself by application of heat which is wholly or partly under pressure when steam is shut off but does not include a pressure vessel- 1. with capacity. < 25 ltrs (such capacity being measured from the feed check valve to ,the main steam stop valve) 2. with < I kg/cm' design gauge pressure and working gauge pressure or 3. in which water is heated below 100 °C. Boiler Component means steam piping, feed piping, economiser, super heater, any mounting or other fitting and any other external or internal part of a boiler which is subject to pressure exceeding I kg/ cm2 gauge. Economiser means any part of a feed-pipe that is wholly or partially exposed to the action of flue gas for the purpose of recovery of waste heat. Super heater means any equipment which is partly or wholley exposed to flue gases for the purpose of raising the temperature of a steam beyond the saturation temperature at the pressure and includes a reheater. Steam Pipe : means any pipe through which stream passes if (i) The pressure at which steam passes through such pipe exceeds 3.5 kg/ m2 above atmospheric pressure or (ii) Such. pipe exceeds 254 mm in internal diameter and pressure > I kg/cm2 and includes, in either case any connected fitting of a steam pipe. Accident as defined u/s 2(a) means an explosion of boiler or boiler component which is calculated to weaken the strength or an uncontrolled release of water or steam therefrom, liable to cause death or injury to any person or damage to any property. Sec. 18 requires report of accident and inquiry in case of fatal accident. New definitions of Competent authority, Competent person.Inspecting authority. Technical advisor and structural alteration, addition or renewal are added. Now not only boiler inspector but competent person can also inspect and certify boiler and its components during manufacture, erection and use. Inspecting authority can do this job during manufacture. Unregistered or uncertified boiler shall not be used save as otherwise provided in the
- 111. Act. Prior sanctionof the Chief Inspector is necessary before carrying out any structural alteration, addition or renewal in or to any boiler or steam pipe. Any accident to a boiler or steam pipe shall be reported to the Inspector within 24 hours. His report shall be in form E (Rule 48). Section 27A provides to form a Central Boiler Board consisting of members, nominating by the Central Government the representatives from the Central Government, Bureau of Indian Standards, Boiler and boilar component manufacturers. Users and other interests. Section 28 provides power and matters of regulations by the Board. Sec. 28Aand 29 are for the rule making power of Central and State Govt. respectively. Central Boilers Board makes and notifies regulations consistent with this Act. The main duties of the Boiler Inspector are the inspection and examination of boilers and steam-pipes in accordance with chapter IX of the Regulations and Chapter IV and V of the Gujarat Boiler Rules 1966. Reduction of pressure can be suggested. Sanction for repairs to boilers shall be obtained beforehand. Provisional orders should be issued after hydraulic tests. Penalties have been increased up to Rs. 1 lac or /and 2 years imprionment u/s 24. INDIAN BOILERS REGULATIONS, 1950 (IBR): The Central Boilers Board u/s 28 of the Boilers Act, 1923 published the Indian Boiler Regulations 1950. They came into force from 15-9 -1950. They were amended in 1990, 1993, 1994, 1995, 1996, 1997 and 2004. They have 15 chapters, 635 regulations, forms up to XVIG and Appendices A to M. Definitions: Definitions of accident, boiler. Chief Inspector, economizer, feed-pipe and owner are the same as given in the Act. Competent Authority means an authority recognized by the Central Boilers Board to issue certificates to welders for the purposes of regulation 4(b)(ii) and 605. Inspecting Authority means an authority recognized by the Board as competent to grant a certificate in Form II, IIA or IIB and specified in Appendix-C, which includes Chief Inspectors of boilers of various states of our country as well as foreign and many foreign companies. Inspecting Officer means an officer appointed by the Inspecting authority or an officer acting on their behalf for the purposes of approval of drawings, stage wise inspection of manufacture, examination of repairs, signing and issue of certificates, material manufactured and boilers constructed. Thus the central boilers board and authorities and officers recognised by them provide the backbone of boilers safety and checking from design to operation, maintenance and repair stages.
- 112. Boilers are classifiedas under : Cl as s Limits of application Minimum thickness Constant I No limit 0.25 Inch 32 II ( a ) WP < 105 psi IF ID is upto 36” 5/16 27 ( b ) WP in psi x ID < inch 5250 inches. III ( a ) WP < 30 psi ID over 36”, 3/8 inch 23 if stress relieved 21 if ( b ) WP in psi x ID < stress not relieved 3000 inches. Working pressure (WP) of the cylindrical shell W P( ps i) = (t-2)SC D W he re t = Min. plate thickness in 30 seconds of an inch. D = Max. ID in inches. S = Min. tensile strength in T/in' C = Constant as given in above table In no case, the thickness should be less than that mentioned in above table or the factor of safely less than 4. Form -6 is the certificate for use of a boiler (reg. 389) with conditions. Appendix-J gives a long list of stages for inspection and testing by the Inspecting Authority. Appendix L provides for testing procedure for safety valve discharge efficiency. Regulation 396 is regarding safety of persons inside boilers. Effective disconnection from steam or hot water, discharge arrangement for leakage, hand lamp of < 24 volt with lamp guard, key less socket, insulated handle and extension cord' of approved type are required. Power driven equipment should have effective earthing. Method of disconnection should be got approved from the CIB.
- 113. Chapter XIV (Reg.618 to 622) was substituted with effect from 9-10-1993 and renamed as 'Small Industrial Boilers' (SIB). Shell type SIB should have volumetric capacity > 22.75 ltrs. but< 500 ltrs, pressure up to 7 kg/cm2 or coil type or water tube boiler with capacity < 150 ltrs., pressure < 12 kg/cm2 Guidelines for registration, operation and maintenance are given in Reg. 622. Relaxations are given. ELECTRICITY ACT, 2003: Replacing the Indian Electricity Act 1910, this Electricity Act 2003 (No. 36 of 2003) came into force on 10-6-2003. It was amended in the same year with effect from 21-1-2004. It has 18 parts, 185 sections and a Schedule. Its preamble runs as under : An Act to consolidate the laws relating to generation, transmission, distribution, trading and use of electricity and generally of taking measures conducive to development of electricity industry, promoting competition therein, protecting interest of consumers and supply of electricity to all areas, rationalisation of electricity tariff, ensuring transparent policies regarding subsidies, promotion of efficient and environmentally benign policies, constitution :)f Central Electricity Authority, Regulatory Commissions and establishment of Appellate Tribunal and for matters connected therewith or incidental thereto. Section-2 gives 77 definitions like board, captive generating plant, cogeneration, conservation, dedicated transmission lines, distribution system, electric line, electricity, electricity system, generating station, grid, high voltage line, line, main, overhead line, power system, service-line, street, sub-station, transmission lines and works etc. Sections 3 toll are pertaining to grant of license and its revocation, amendment, purchase etc. Section 161 regarding Notice of Accidents & Inquiries provides that (1) an accident to any person or animal resulting or likely to result in death or any injury is to be reported to the Electrical Inspector and other authorities in a prescribed time and (2) inquiry and report by the Electrical Inspector into the cause of accident affecting safety of the public and manner of compliance of statutory requirements. Section 162 is regarding appointment of Chief Electrical Inspector and Electrical Inspector. Subjects of this Act are asunder:
- 114. Pa rt Sec tio ns Subject N o. 1 1-2Preliminary 2 3-6 National Electricity Policy and Plan 3 7-11 Generation of Electricity 4 12-24 Li ce ns in g 5 25-41 Transmission of Electricity 6 42-60 Distribution of Electricity 7 61-66 T ar iff 8 67-69 W or ks 9 70-75 Central Electricity Authority 10 76- 109 Regulatory Commissions 11 110- 125 Appellate Tribunal for Electricity 12 126- 130 Investigation and Enforcement 13 131- 134 Reorganisation of Board 14 135- 152 Offences and Penalties 15 153- 157 Special Courts 16 158 Dispute Resolution 17 159- 165 Other Provisions 18 166- 185 Miscellaneous INDIAN ELECTRICITY RULES, 1956: U/s37 of the Electricity Act, 1910, the Central Electricity Board, made these rules which were published and came into force from 26-6-1956. The rules were amended in 1991, 1993, 2000, 2002. It has II Chapters, 143 rules and 15 Annexure. From safety point of view following two chapters are more important. Ch Rul Title
- 115. apt er es IV 29- 46 General SafetyRequirements. X 109 - 132 Additional Precautions to be adopted in Mines & Oil-fields. A short summary of the rules is given below. For full details, the statute book should be referred. Rule 2 gives 57 definitions. 'Danger' is defined as danger to life or body part from shock, burn, fire, and explosion, injury to persons or property because of the electrical energy. Flameproof enclosure means an enclosure for electrical machinery or apparatus to withstand internal explosion due to flammable gas or vapour entered inside and preventing this internal flammation to come out to the external flammable gas or vapour in which it is designed to be used. Guarded means covered, shielded, fenced or otherwise protected by means of suitable casing, barrier, rails or metal screens to remove the possibility of dangerous contact or approach by persons or objects to a point of danger. 'Intrinsically safe' as applied to apparatus or associated circuits shall denote that any sparking that may occur in normal working is incapable to cause explosion of inflammable gas or vapour. Voltage category is defined as low<250V, medium<650V, high<33KV, extra high> 33KV. Rule 4 prescribes appointment and qualifications for Electrical Inspectors that degree in electrical engineering with at least 8 years practical experience. For assistant inspectors BE(E) + 3 years experience or DME + 6 years experience is prescribed. Rule 5 gives their powers of entry and inspection. Chapter-3, rules II to 28 prescribes licensing procedure including maps, forms and conditions. Chapter-4, rules 29 to 46, give following general safety provisions: General Safety Provisions: 6.2 Electric supply lines and apparatus, shall be of sufficient ratings, mechanical strength and so constructed, installed, protected, worked and maintained to ensure safety of human being, animals and property. IS and National Electrical Code shall be followed (R.29). 6.3 Supplier and consumer, both, will take due precautions to avoid danger from service lines and apparatus on consumer's premises (R.30). 6.4 Suitable cut-outs (e.g. fuse) in fireproof receptacles shall be provided in every service line (other than earth lines) at consumer's premises (R.31).
- 116. 6.5 Earth andneutral conductors shall be identified to distinguish from live conductor and position of switches and cut-out shall be safe (R.32). 6.6 Earth connection (terminal) shall be provided near the point of start of supply and the consumer shall take steps to protect it from mechanical damage (R.33). 6.7 Bare conductors should be inaccessible with readily accessible switches to cut off power supply (R.34). 6.8 Danger notice in Hindi, English or local language with a sign of skull and bones (IS- 2551) and the words 'danger and 'volts' is necessary near medium and higher voltage installation (i.e. above 250V). (R.35). 6.9 For the safety from supply lines and apparatus, earthing of lines, PPE to workers (gloves, rubber shoes, safety belts, ladders, earthing devices, helmets, line testers and hand lamps, for protection from electrical and mechanical injury), and authorised working on live lines are necessary (R.36). 6.10 Voltage cut off switch (in one operation) is a must in every electric vehicle, crane, etc. and the metal rails, if any, should be electrically continuous and earthed (R.37). 6.11 Flexible cables to portable apparatus should be heavily insulated and well protected from mechanical damage. For single phase line the cable should be of 3 core and for 3 phase line, it should be of 4 core type with the distinguished ground connection. Metal covering, if any, should be earthed (R.38). 6.12 Insulating or protecting material of electric line should not be of such material that may produce noxious or flammable gases on excessive heating (R.39). 6.13 Street boxes should be free from influx of water or gas. They should be inspected regularly for that (R.40). 6.14 Different circuits should be distinguished from each other (R.41). 6.15 Voltage should not exceed the limits and AC-DC circuits should not come into contact with each other when live (R.42). 6.16 Fire extinguishers for electric fire, fire buckets with clean, dry sand, first-aid boxes, two or more gas masks to be used in the event of fire or smoke are necessary (R.43). 6.17 Notice of instructions to restore person from electric shock and an artificial respirator (resuscitation) 6.18 necessary (R.44). 6.19 Fatal accident should be reported within 24 hours and non-fatal accident, in Annex- XIH, in 48 hours (R.44A). 6.20 Electric work shall be carried out by licensed electrical contractor under direct supervision of a competent person and a person holding permit by the State Government. Unauthorized work shall not be energised (R.45). 6.21 Inspection of installation at every 5 years by the Inspector. Annex-IXA is an inspection report Form (R.46). Chapter-V (R.47 to 59) gives general conditions relating to supply and use of energy. Rule 51 for medium, high and extra high voltage installations should be referred. . Chapter-VI (R.60 to 62) for low and medium voltages (upto 650V) and Chapter-VU (R.63 to 73) for high and extra high voltage (more than 650V) provide for insulation resistance test, earth connection, ELCB, testing, operation and maintenance, condensers and supply to high voltage installation including X-ray unit, etc. Chapter-VIII (R.74 to 93) gives important safety clearances (see Part 4.6 of Chapter- 11) above ground and between conductors and provisions for material strength, stresses, joints, guarding, earthing, safety and protective devices (R.91 for safety of line when it breaks, unauthorized entry near overhead lines) etc.
- 117. Chapter-IX (R.94 to108) is for electric traction, and provides for voltage supply to vehicle, insulation of lines, returns and sections, current density (less than 1.4 Amp/cm2) in rails, height of trolley-wire (more than 5.2 m high) etc. Chapter-X (R.109 to 132) is regarding safety precautions while working in mines and oil-fields. They include plans, notices, lighting, communications, fire precautions, earthing, protective equipment, voltage limits (Hand lamp or electric interlocking 30V, portable apparatus 125V, at surface or in open 250V), safety with gas supervision etc. Chapter-XI (R.133 to 143) gives relaxation and penalty provisions. ELECTRICITY RULES, 2005 U/s 176 of the Electricity Act, 2003 these rules were made and they came into force from 8-6-2005. They were amended in the same year with effect from 26-10-2006. They have 13 rules. Rule 3 gives requirements of captive generating plant. Other provisions are regarding distribution system, surcharge u/s 38, consumer redressed forum, tariff u/s 79, interstate trading license etc. EXPLOSIVES ACT, 1884: This Act (4 of 1884) was enacted on 26-2-1884. It came into force from 1-7-1884. It extends to the whole of India. It has 18 sections. Its object is to regulate the manufacture, possession, use, sale, transport, import and export of explosives. Explosive as defined in Sec, 4(d) means gunpowder, nitro-glycerine, nitroglycol, guncotton, di-nitro-toluene, tri-nitro-toluene, picric acid, di-nitrophenol, tri-nitro resorcinol (styphnic acid) cycio trimethylene-tri-nitroamine, penta- erythritol tetranitrate, tetryl, nitro guanidine, lead azide, lead styphynate, fulminate of mercury or any other metal, diazo-di-nitro phenol, coloured fires or any other substance, whether a single chemical compound or a mixture of substances, whether solid or liquid or gaseous used or manufactured with a view to produce a practical effect by explosion or pyrotechnic effect and includes fog-signals, fire works, fuses, rockets, percussion-caps, detonators, cartridges, ammunition of all descriptions and every adaptation or preparation of as an explosive as defined in this clause. Aircraft carriage and vessel are also defined in this section. Main Provisions: 1. A person below the age of 18 years, offender of violence or moral turpitude, who is ordered to keep peace or good behaviour or whose licence is cancelled for any offence under this act, cannot manufacture, sell, transport, import or export, deliver or dispatch or possess any explosive defined or notified. (Sec. 6A) 2. Licence can be granted, refused, varied, suspended, revoked and conditions can be imposed (Sec. 6B to 6E). Appeal can be preferred as per sec. 6F. 3. The Central Government has power to make rules regarding inspection, search, seizure, detention and removal (Sec. 7).
- 118. 4. Notice ofaccident is required u/s 8 and its inquiry shall be conducted u/s 9. The Central Government can inquire into more serious accidents (Sec. 9A). 5. Explosives with receptacles shall be forfeited by the court after conviction (Sec. 10). 6. Abetment and attempt to commit offence under this Act or Rules is punishable (Sec. 12). 7. Any person found committing any offence punishable under this Act can be arrested without warrant, be removed from the place and conveyed before a magistrate (Sec. 13). 8. The Central Government can delegate its power to State Government or an officer u/s 17A. EXPLOSIVES RULES, 1983 : U/s 5 and 7 of the Explosives Act, 1884, these rules were published on 2-3-1983. They have 10 chapters, 186 rules, 8 Schedules, 40 Forms under Schedule V and 8 specifications (guidelines) under schedule VII. Last schedule VIII gives safety distances in two tables. Five annexure are given at the end. Exhaustive details are provided of which a short abstract is given below : Definitions :Chief Controller of Explosive (CCE) is the main authority. He can recognise acompetent person by giving him a certificate of competency. Prohibited explosives mean that u/s 6, authorised explosives mean those published by the Government and permitted explosives mean those permitted by the Director General of Mines Safety to be used in underground coal mines. Detonator, safety cartridge, safety fuse, safety zone etc. are defined. Magazine means a building to store more than 5 kg of explosive and specially constructed as approved by the CCE. Protected works include a dwelling house, college, school, hospital, theatre, factory, storage of hazardous substances, public road, railway, waterways, dams, reservoirs, high tension power lines. Safety zone is a distance required between such protected work and a licensed factory, magazine or store-house. Safety Distance Categories of Explosives :According to the risks, they are as under : Cat ego ry Explosives X Which have a fire or slight explosion risk or both but the effect is local. Y Which have a mass fir risk or a moderate explosion risk but not the risk of mass explosion. Z Which have mass explosion risk and major missile effect. ZZ Which have mass explosion risk and minor missile effect. On any question of category, decision of the CCE shall be final. General Provisions (Chap-11, Rule 5 to 20) : 1 Import, export, transport, manufacture, process, use or sell of unauthorised explosives
- 119. is prohibited. Testingand trial are permitted in a licensed factory. (R.5). 2 Application for authorisation of explosives is necessary. Particulars are prescribed for submission. A sample shall be sent as per instruction from CC (R. 6). 3 Tests prescribed [R. 6 (6)] 1. Physical properties including consistency, reaction, tendency to absorb moisture, segregation of the constituents, exudation, behaviour at low temperature, specific gravity etc. 2. Chemical composition- percentage and quality of ingredients. 3. Stability - effect of environmental conditions which would produce spontaneous ignition or variation in sensitiveness. 4. Ignition characteristics- ignition point, behaviour, liability to spontaneous ignition. 5. Mechanical sensitiveness to friction and impact. 6. Air gap sensitivity and transmission of detonation.. 7. Velocity of detonating. 8. Strength determination. 9. Gases evolved upon explosion. 10. Such other tests specified by the CCE. 11. Any other test required by CCE. 12. Delivery and Dispatch under licence and not exceeding the quantity (R.7). 13. Packing as per Schedule H and after approval of the sample (R. 8). 14. Marking of packages should mention the word "EXPLOSIVES" (not required for fireworks and safety fuse), name of the authorised explosive, class number and division, safety distance category, names of manufacturer, consignor and consignee, net weight and letter 'V for permitted explosive (R.9) 15. Weight of explosive shall not include the weight of the packing box (10.) 16. Competent person should be in-charge of operations (R.11) 17. Precautions in handling- Floor should be checked, cleaned and swept before and after use. The packages shall not be thrown, dropped, rolled or pulled but shall be passed from hand to hand and carefully deposited. A slung package should be prevented from fall (R. 12). B. Handing between sunset and sunrise is restricted unless proper lighting and guarding is provided. (R. 13). C. Within 15 mt. of an explosive storage or at its place of handling or transport, smoking, fires, lights and flammable substances or substances to cause fire or explosion such as acids, petroleum, calcium carbide, compressed gases shall not be allowed (R. 14) D. No person will carry matches, knives, fuses, iron or steel or wear shoes with iron nails (R. 15). E. Split explosive shall be safely destroyed (R. 16). F. Employment of person below 18 years, intoxicated persons and persons of unsound mind is prohibited (R. 17). G. Precautions against danger from water (in compatible) or exposure to sun or heat are necessary (R. 18). H. Special precautions against accident (fire or explosion), thefts, entry of unauthorised person near explosives are necessary. (R. 19). 5. Nitro-glycerine or Ethylene glycol dinitrate or explosives of Class-5, unauthorised, deteriorated or damaged explosives shall not be transported without approval of CC, except within the licensed factory solely for the purpose of manufacture of explosives (R. 20).
- 120. For classes ofexplosives see Sch. 1. Import & Export (Chapter-111, Rule 21 to 31) : Licence necessary (R. 21). Rules for import and export by sea, land and air are prescribed. Transport (Chapter-IV, R 32 to 86): Licence necessary (R. 32). Certain explosives cannot be transported together (R. 33). Safety certificate is required (R. 34). No transport of explosives with passengers (R. 35). Maximum weights as per R. 36.Loading and unloading procedure (R. 38 to 45.). Transport by water (R. 46 to 61) Transport by Rail (R. 62 to 74). Transport by Road (R. 75 to 86). Licence for road van necessary. Towing not allowed. Four wheel chocks to be carried all the time. In case of fire, traffic to be stopped 300 metres away. Accident to be reported. Two fire extinguishers of 2 kg or ..more capacity required with road van. Manufacture (Chapter-V, Rule 87 to 112) : Licence necessary (R.87) and not necessary (R. 88). Approval of CC required (R. 89) Factory should have a wall or fencing 2 mt. high to prevent unauthorised entry (R. 90). Interior should be free from grit, iron or steel and kept clean (R. 92) .Surrounding mound or blast wall as approved by CC (R. 93). Oiled cotton, rags or waste not allowed to avoid spontaneous ignition (R. 94). Non-sparking tools made of wood, copper, brass or soft metal should be used (R. 95). Notice of maximum quantity of material and persons in a work room to be exhibited on process building (R. 96). Smoking prohibited (R. 97). Lightning conductor as per IS 2309, yearly checking of earth resistance and its notice are necessary (R.98). During thunder -storms work should be suspended and workers to be withdrawn to a safe place (R.99). Foreign matter in ingredients to be removed (R.IOO). Protection against fire. Cloths without pockets (R.IOI) Residues will be quickly removed (R.102). Before carrying out repairs to building, explosives shall be removed (R.103). Employment of competent person for process supervision (R.104). Birth or fitness certificate is necessary for age between 18 to 21 (R.105). Every vehicle, trolley or receptacle to carry explosives shall be free from iron steel etc. and be covered or closed (R.106). Maintenance of building, plant and equipment should be regular and good. (R.107). Testing facilities as approved by CC (R.108).Safe disposal of waste explosives (R.109). Unsafe process to be stopped (R.IIO). Up to date records to be maintained for 2 years (R. 112). Possession, Sale and Use (Chapter-VI, Rule 113 to 153): Licence necessary (R.113) and not necessary (R.114). Use of licensed premises only (R.115).Protection from lightning (R.116).Precautions during thunderstorm (R.117).Building to be kept clean (R.118 & 120).Maintenance of records (R.119).Hazardous articles not to be carried. Search for them and for cloths without pockets and suitable shoes (R.121). Premises to be kept locked (R.122). Security Guards for .round the clock (R.123). Repackaging or opening at safe place and safe distance (R.124). Explosives not to be kept in damaged boxes (R.125) No storage exceeding licensed quantity (R.126). Magazine storage in mode A or B as specified in Sch. VII (R.129). Surrounded by mound (R.131) and on ground floor only
- 121. (R.132).Storehouse of sound.construction (R.134). Type of premises, ground level minimum floor area 9m2, separate entry and exit (R. 135). Special precautions to be observed for fire works (R.136).Safety distance 15 mt. or more from storage of explosives, flammable or hazardous materials (R.137). No sale of other articles (R.138). Use of Explosives :Competent person to be employed (R.144). Restrictions on preparation ofcharges (R.145).Restriction to carry at the blasting site (R.146).Examination before use (R.147). Precautions at site (R. 148),.Warning procedure (R.149). Precautions while firing (R.150), against stray currents (R.151) fire, or accident (R.152). Blasting, operations under the Mines Act, 1952 are allowed. Licences (Chapter VII, R 154 to 174). Fees (Chapter VIII, R. 175 to 177). Powers and Penalties (Chapter IX R. 178 to 181). Accidents and Enquiries (Chap. X, R. 182 to 186). Notice forthwith to the CCE, Nagpur, CE under jurisdiction and nearest police station (R.182). Procedure at courts of inquiry (R.183).Inquiry by a District Magistrate or a Police Commissioner (R. 184).Inquiry into more serious accidents (R. 185). Schedule I (R. 3) Classes of Explosives : Class 1 Gun-powder. Class 2 Nitrate-mixture Class 3 Nitro-compound Class 4 Chlorate-mixture Class 5 Fulminate Class 6 Ammunition Class 7 Fireworks Class 8 Liquid Oxygen Explosives. Detailed list of chemicals is given under each of these classes. Schedule II (R. 8) Packing of explosives Schedule III (R. 21) Methods of Testing Schedule IV (R.155) Licensing Authority Schedule V Forms 1 to 40 Schedule VI Explosives permitted to be imported and transported by air Schedule VII Specifications as under
- 122. Specification No. For 5.1Road Van to carry explosives 5.2 Motor truck together with compressor unit 3,4& 5 Metal cases for conveyance of explosives 1. Magazines (Storage), Mode A&B 2. Store-house 8 Compressor mounted motor truck or tractor Sch. VIII Safety distances PETROLEUM ACT, 1934: This Act (No. 30 of 1934) came into force from 303-1937 (enacted on 16-9-1934) to consolidate and amend the law relating to import, transport, storage, production, refining and blending of petroleum. It extends to the whole of India. It has 4 chapters and 31 sections. Its abstract is as under : Definitions : Petroleum means any liquid hydrocarbon or mixture of hydrocarbons and any inflammable mixture (liquid, viscous or solid) containing any liquid hydrocarbon. Flashpoint of petroleum means the lowest temperature at which it yields a vapour which will give a momentary flash when ignited, determined in accordance with chapter - II and rules made there under: Petroleum class F.P. Range A <23°C B 23 to < 65°C C 65 to < 93°C Motor Conveyance means any vehicle running on land, water or air and in which petroleum is used to generate the motive power. Control over Petroleum (Chap. 1, Sec. 3 to 13) : The Central Government may make rules for import, transport, production, refining and blending of petroleum (Sec. 3 to 5).
- 123. On receptacles ofclass A petroleum the words "Petrol" or "Motor Spirit" should be mentioned. This is not required where quantity is less than 10 litres or on a fuel tank attached with a motor conveyance or engine, a pipeline, underground tank or exempted by the Central Government (S. 6). Licence is not required (i) for class B petroleum if it is contained in a receptacle having less than 1000 litres capacity and total quantity at any one place does not exceed 2500 litres or (ii) for class C petroleum if total quantity at any one place does not exceed 45000 litres and stored or transported as per rules u/s 4 (S. 7).- No licence is necessary to keep less than 30 litres class A petroleum not intended for sale. Then it can be stored in metal container of maximum 25 litres capacity and non-metal container of maximum I ltr capacity (S. 8). To use as a fuel in a motor conveyance, not more than 100 litres class A petroleum can be stored or conveyed (S. 9). No licence is needed by Railway to carry petroleum (R.IO). This chapter is not applicable to any petroleum having flash point above 93°C (S. II). Testing of Petroleum (Chap. II Sec. 14 to 22) : The Central Government can make rules for taking samples for testing and authorise any officer for that purpose (S. 14 to 17) to give certificate of testing (S.19) or retesting (S. 20). The officer shall use a standard test apparatus (S.15, 16 & 18). The Central Government has rule making powers u/s 21 and 22. Penalties & Procedure (Chapter III S. 23 to 28): General penalty is up to Rs. 1000 or one month or both and enhanced (for repeated offence) penalty up to Rs. 5000 or 3 months or both (S. 23). Petroleum together with receptacles can be confiscated (S. 24). Authorised officer has power of entry and search (S.26) Notice of accident shall be given to the nearest magistrate, police station and to the Chief Controller of Explosives (S. 27). In case of death or serious accident, inquiry u/s 176 of the Cr. P. C., 1973 shall be held by a Magistrate or a Police Commissioner. Supplemental (Chapter -IV S. 29 to 31): Rule making power and procedure and inclusion of rules to provide for protection of public from danger of petroleum (S. 29). The Central Government can limit or restrict the powers of any local authority (S. 31). PETROLEUM RULES, 2002: These rules were enacted u/s 29 of the Petroleum Act, 1934. They came into force on 13-3- 2002. They have 12 chapters, 202 rules, 5 Schedules and 20 Forms under the 2nd Schedule. Its abstract is give below
- 124. Chapter -I :Preliminary (R. I to 13) : Definitions: There are 35 definitions. Some are given below. 'Adequate' in relation to ventilation, means the flammable gas-air mixture below the lower explosive or inflammable limit (LEL) or in relation to fire fighting facilities, those as per prevalent recognised standards or codes of safety. Competent person means a person recognised by the Chief Controller of Explosives (CCE) or by an institution recognised by the CCE. Container means a receptacle for petroleum of less than 1000 ltr. capacity. Tank means a receptacle for petroleum of more than 1000 ltr. capacity. Electric apparatus includes motors, starters, lamps, switches, junction boxes, fuses, cut- outs or any other appliance, equipment or fitting which operates electricity. Hot work means any work which involves welding, burning, soldering, brazing, blasting, chipping by spark producing tools, use of certain power driven tools, non-flameproof electrical equipment or equipment with internal combustion engines and including any other work which is likely to produce sufficient heat capable of igniting inflammable gases. Protected area means the safety distance 'specified by the licence condition under these rules. Protected Works include dwelling house, assemble, dock, fuel yard, furnace, kiln, chimney, petroleum storage, public road, railway siding for oil and overhead high tension power lines. Inspector, Sampling officer and Testing officer are those authorised u/s 13, 14 and 17 respectively. There are many other definitions also like installation, OISD, petroleum inbulk, service station, storage shed and some vehicles with tank (R.2). General Provisions (R 3 to 13): Delivery and despatch not possible without storage licence. Class B petroleum up to 15000 litres in air tight approved container can be despatched to a person not holding a storage licence for immediate disposal. DCP extinguisher should be carried with a container of more than 2500 litres. Rule not applicable for despatch to the Defence Forces (R.3). Approval of CC is necessary for class A petroleum container of more than 1 litre capacity and class B & C petroleum container of more than 5 litre capacity (R.4). Containers for Class A petroleum should be of sound material an construction, approved type and of the following minimum thickness of iron or steel sheet – Container Capacity in litres, exclusive of Minimum thickness in
- 125. 5% mm free Space Upto 10 0.443 (27 BG) Exceeding 10 and up to 25 0.63 (24 BG) Exceeding 25 and up to 50 0.80 (22 BG) Exceeding 50 and up to 200 1.25 (18 BG) Exceeding 200 and up to 300 1.59 (16 BG) The capacity of any container (Class A) shall not exceed 300 litres. Higher capacities for specified purposes need approval by CC. 5% air space necessary (R.5). Minimum 5% and 3% air space are necessary for class B and C petroleum respectively (R.6). Empty receptacles of class A or B petroleum should be kept securely closed if they contain vapour inside (R. 7). Repair or hot work should be carried out after full cleaning of petroleum and its vapour or after certified by a competent person (R. 8). Escape of petroleum to be prevented (R. 9). No person below the age of 18 or intoxicated shall be employed (R. 10). Smoking, fires, lights, matches etc. prohibited (R. II). No person shall commit or allow other to commit any act which may lead to any accident by fire or explosion. Compliance of these rules necessary.(R. 12).Fees (R. 13). Chapter -II : Importation of Petroleum (R. 14 to 27): Import licence necessary save as otherwise exempted. Rules for importation by sea requires fire fighting facilities as per OISD Std. .156, plans of unloading facility, protected works within 500 mt, EIA and Risk Analysis Report, failure scenarios, LEL distances, damage distances, control measures, anchorage of ships, production of certificate and licence to the Collector of Customs, no landing without his permission, of barges or lighters and transhipment from one ship to another (R. 14 to 24.). Rules by importation by land also specify fixed places, submission of declaration (Form-1) certificate of storage accommodation (Form-H) and the licence to the Collector of Customs and no unloading without his permission (R. 25 to 27). Chapter - III : Transport of Petroleum (R.28 to 101) : Part - I : General (R.28 to 32): No leaky tank or container containing petroleum shall be tendered for transport (R. 28). Filled containers should be kept upward (R. 29). Petroleum in bulk should riot be carried with passengers or combustible cargo (R. 30). Smoking, matches, lighters etc. prohibited (R. 31). Loading or unloading should not be done between the hours of sunset and sunrise unless adequate lighting and FFE are kept ready .(R. 32). Part - II : Transport by Water (R. 33 to 50) :
- 126. Licence from thelicensing authority is necessary (R. 33). Vessel should be made of iron or steel and of ample dimension (R. 34). All tanks on ships should be fitted with manholes with screw cover, air tight joints, filling and suction pipes and valves nearby to the bottom and filling and discharge through pipes and valves only. For class A petroleum,. Tanks should have vent or relief valve with wire mesh (more than II meshes per linear centimetre) and similar ventilators to all spaces around tank (R.35). Other provisions include exhaust outlet with spark arrester, no petrol driven engine, quick action closing valve on fuel feed pipe, suitable ventilators four or more fire extinguishers, 0.20 I113 of dry sand, non-sparking hammer, red flag, life-boats, ventilation and cleaning of holds and tanks, responsibility of master of vessel, loading/unloading through armoured hose and metal pipes electrically continuous and free from leakage, prohibition of naked lights, fire, and smoking, FFE in ready condition, no conveyance of petroleum class A with class B or C and no transport of un-tested petroleum (R. 36 to 50). Part-111 : Coastwise Transport of Class A Petroleum not in bulk: Rules 51 to 61 provide conditions and precautions for such transport. Part-IV: Transport on Land by Vehicles (R. 62 to 86): Applicable to transport of petroleum class A in more than 100 ltr (R. 62). Tank vehicles should be built, tested and maintained as provisions in 3rd schedule and of the type approved by the CC. Special safety fittings should be got approved (R.63). Class A and B petroleum can be filled up to 97% and Class C petroleum up to 98% of the gross carrying tank capacity (R.64). Tank vehicle should not be used for other purpose or carry other articles except authorised by the CC (R.65, 69). Trailers (R.66). For every mechanically propelled vehicle used to carry petroleum otherwise than class B or C, the eftgine should be diesel engine or internal combustion engine, exhaust pipe should be in front of the tank or load and fitted with an approved spark arrester and silencer or muffler, the engine intake or air cleaner should have flame arrester, fire resisting shield between the cab and the tank or load (i.e. rear side), fuel tank with stout steel guard and lock in the filling caps (R.70). Electrical installation should not exceed 24 volts, wiring should be heavily insulated and adequate for maximum load, should have over current protection (fuses or automatic circuit breakers) encased in covering, sealed junction boxes, heavy duty switch to cut off battery and generators, motors and switches of flameproof type if not installed within engine compartment (R.71). Portable fire extinguisher necessary (R.72). Vehicle should be constantly attended by a person who knows these rules (R.73). No parking on a public road or in congested area or in 9 mt. of any source of fire (R.74). Licence to transport necessary (R.75).Loading, unloading in a licensed premises only (R.76). Leaky, defective or unlicensed tank vehicle should not be filled (R.77). Precautions against static charges include earthing and electrical continuity of pipelines, earth boss with a flexible cable and clamping device, earthing of tank, filling pipe and chassis during loading, dip-rod should not be completely raised above the liquid level during or within one minute of the completion of loading. Filling rate should not exceed I mt/sec until the filling pipe is completely submerged and there after it may be gradually
- 127. increased but shallnot exceed 6 mt/sec at the delivery end. The CC can permit a faster loading rate in case of petroleum having higher conductivity rate (R.78). Loading/unloading after stopping of the engine and battery isolated. Restart only after the tank and valves are securely closed (R.79). No movement of vehicle during loading/unloading (R.80). Product contamination to be avoided by selecting correct filling hose and refilling of tank of class A petroleum with any other petroleum only after draining of residual oil (R.81). Except during loading/unloading, the filling pipe, discharge faucet and dip pipe shall be kept securely closed (R.83). No loading/unloading during night hours except approved electric lights provided (R.83). No fire, light, smoking or articles to cause fire allowed on vehicle (R.84). No repair of tank unless certified by a competent responsible person (R.85). No petroleum to be carried with passengers save as provided (R. 86). Part -V : Transport by Pipelines (R.87 to 101) : This part is applicable to petroleum pipe lines other than those in the area of operation of natural gas and/or oil or within refineries and installations (R.87). It provides for right of way to be acquired (R.88), approval from the CC obtained (R.89), design as per standard code or OISD Std. 141, made of suitable steel which is safe for conditions under which it is to be used, provision for expansion, contraction, prevention of excessive stresses, by pass relief valves, pressure limiting stations, automatic shut down equipment to prevent pressure rise more than 10% of the designed internal pressure, isolation valves at different locations (R.90), laying criteria (underground as far as possible) (R.91), protection against corrosion (R.92), hydraulic test (at I.I times the design internal pressure and maintaining for 24 hours) at an interval of 12 months (R.93), shut down procedure (R.94), patrolling of pipeline, communication facilities at frequent intervals along the pipeline of length more than 2 km (R.95), checking of gauges at tanks or booster pump stations at least once a year (R.96), addition, alteration only after approval from the CC (R.97) and power of the CC to require relay or repair for public safety (R.99) and of inspection and examination (R.IOO). The fire or major leakage in a pipeline or connected facilities should be reported immediately by the person in-charge of the pipeline to the nearest magistrate or police station and by telegram to the CC, Nagpur (R.IOI). Repair and maintenance of pipeline u/r 98 includes 6.5 Inspection by an experienced engineer for assessment of work. 6.6 written work permit specifying precautions to be observed and procedure to be followed. 6.7 The section of the pipeline shall be isolated, drained and purged with inert gas or steam or kept filled with water or treatment approved by the CC. 6.8 Work of cutting or welding to be carried out by an experienced person in accordance with the permit 6.9 Only mechanical cutters shall be used for cutting the pipeline or any connection thereof unless it has been purged with an inert gas. 6.10 Separation of pipeline or valve fitted to it only after providing electrical bond between the parts, to be separated and the bond shall not be broken till the parts have been rejoined. 6.11 Reuse of the repaired section only after hydrotest as stated in rule 93. Chapter-IV : Electric Installation (R. 102 to 115) :
- 128. Electric wiring andapparatus to be used in any place where petroleum is refined, blended, stored, loaded or unloaded, should be in accordance with this chapter (R.102). Classification of Hazardous Area (R. 103, 104) : Hazardous area means where (i) Petroleum having FP below 65bC or any inflammable gas or vapour capable of ignition is likely to be present or (ii) Petroleum or any inflammable liquid having FP above 65°C is likely to be refined, blended, handled or stored at or above its FP. (R. 103). It is classified as under : Z o n e Condition 1. Where inflammable gases / vapours are likely to be continuously present. 2. Where they are likely to be present under normal operating conditions. 3. Where they are likely to be present only under abnormal operating conditions to failure of rupture of equipment. Thus zone 0 is more hazardous than zone 1 an zone 1 more hazardous than zone 2. On any question regarding applicability of these divisions, the decision of the CC shall be final (R.104). Extent of hazardous area is laid down in the 4th Schedule. The CC can increase or reduce it based on special circumstances (R.105). Fixed Electrical Apparatus (R.106) : Zone Type of Apparatus approved by CC. 6.6 Intrinsically safe 6.7 (i) Intrinsically safe or a flameproof type, or Industrial type apparatus housed ii enclosure or in a room made safe b" purging or pressurising atmosphere and interlocked to stop electric supply automatically or to give warning to stop it in case of failure of the purging or pressurising system. 6.8 (i) Non sparking apparatus or Apparatus permitted in Div. 1. Fixed Electric Wiring (R.107) : It should be effectively sealed at all joints, mechanically protected, adequately supported and consisting of approved armoured cable or metal sheathed cable or insulated cables in a galvanised conduits with approved flame proof fitting or mineral insulated cable of approved type with flameproof glands at all joints and details mentioned in the rule. Earthling and Bonding (R. 108) : Electric systems and equipment should be earthed with resistance of 4 ohms or a value
- 129. that ensures thesafe operation of the protective device in the circuit whichever is lower. All non-current carrying metallic parts of electric apparatus or other metallic objects should be earthed with resistance of 10 ohms. All joints in pipelines, valves, plants, storage tanks, associated facilities and equipment for petroleum shall be electrically bonded with the resistance value between each joint not exceeding I ohm. Other Provisions: Cathodic protection as in rule 109. Electrified railway systems (overhead lines and live contact rails) are not allowed within a refinery or an installation. They should be terminated outside the area where tank wagons are loaded or unloaded. Both the rails of spur lines shall be insulated from a railway siding which is used for the loading or unloading of tank wagons (R.IIO). Portable electric apparatus or lamp of 25 volts, approved by the CC (Who can permit up to 55 volts) can be used in a hazardous area (R.lll). Maintenance to retain characteristics (R.112). Repair and test after cutting off voltage. In zone I area, after gas-testing and certified safe by a competent person (R.113). Certificate of electric installation by a competent person (R.114).Precautions against corrosion (R.115). Chapter -V : Storage of Petroleum requiring licence (R.116 to 135): Licence necessary (R.116). Precautions against fire OISD Std. 117, DCP and other fire extinguishers (R.117).Experienced supervisor necessary (R.118).Cleanliness (R.119).Drainage (R. 120). Wall or fence of at least 1.8 mt. height to prevent unauthorised entry 1.2 mt height for service stations (R.121).Marking of capacity on tanks (R.123).Construction of tank by iron or steel and as per IS.Foundation of non combustible material. Air space 75% or as per Code (R.124)and protection against corrosion by protective coating or cathodic protection etc. (R.125). Before use the tank should be tested by water pressure by a competent person. It shall not be passed through any pipe or pump ordinarily used for the conveyance of petroleum. Proforma of certificate of such testing is given u/r 126. Tanks should be earthed by two separate connections placed at opposite extremities. The resistance to earth shall be less than 7 ohm and that of the earth plate shall be less than 2 ohm, (R.127.) Testing of earth connection necessary once in I year by a competent person. Its record should be maintained (R.128). No night working unless approved electric lights provided as per chapter - IV (R.129) . Certificate of Safety is required from a competent person by the licensing authority in a proforma given u/r 130. Prior approval of specifications and plans of premises required u/r 131. Electric motor or internal combustion engine to drive pumps for pumping petroleum should be got approved by the CC (R.132). Licence number should be marked on premises (R.133). An extract of certain rules to be displayed (R.134) .
- 130. Chapter - VI: Storage of Class - C Petroleum not requiring licence (R. 136 to 140) : Provisions of previous chapter-V are not applicable to class-C petroleum to be stored without licence u/s 7 (R.136). It shall not be stored together with other class of petroleum except as permitted by licence (R.137). Bulk storage tank should be approved by the CC. Tanks of more than 5000 litres capacity should have dyke or be placed inside a pit to contain at least the volume of the largest tank within it. A drainage pipe with valve fitted outside shall be provided and kept closed. A distance of more than 1.5 mt. shall be kept between the edge of dyke and any protected works (R. 138). Class-C petroleum not in bulk, if exceeds at any one time 2500 litres be stored in a storage shed of which either the door way or openings are built up to a height 30 cm above the floor or the floor shall be sunk to a depth of 30 cm,. (R.139). Prior report to store class C petroleum exceeding 5000 litres without licence shall be sent to the CC staling the location of the premises (R.140). Chapter-VII of licences (R.141 to 161), Chap. IX of Tetraethyl lead mixtures (R.181 to 185),Chap. X of testing of petroleum (R.186 to 199), Chap. XI of notice of accident (R.200) and Chap. XII of exemption (R. 201, 202) are not discussed here. But abstract of Chap. VIII is given below. Chapter-VIII: Refining of Petroleum (R. 162 to 180): Project report with specifications and plans showing the arrangements of tanks, stills, furnaces,electric installations, pump houses, drainage, ETP, FFE, fencing, gates and all plants and buildings where it is proposed to refine, crack, reform or blend, petroleum (it is called refinery in this chapter) shall be sent to the CC in triplicate arid a scrutiny fee of Rs. 5000 (R.162). A copy each of the approved plans shall be kept at the refinery (R.163). Alterations are also to be approved (R. 164). Fireproof materials should be used in buildings where petroleum is to be handled (R.165). Storage tanks should be more than 90 mt. away from any still, boiler or furnace (not applicable to class C fuel tank for a boiler if the tank capacity not exceeding 24 hours stock) (R.166). Storage tanks of LPG or its filling facility should be more than 90 mt. away from any still, boiler or furnace or 30 mt. away from any storage tank, pump-house or facility for blending or filling of petroleum or from any protected work (R.167). Flare shall also be 90 mt. away from any tank, still, pumphouse or any refinery activity or LPG (R.168) . Effluents and drainage should not cause any pollution or harmful effect on animal or vegetable life. Weekly samples shall be drawn and tested in the refinery laboratory for their oil content, acidity, alkalinity and record be maintained (for at least 6 months) and shown to an Inspector. The sewerage shall be independent of other drainage system. All drains shall have adequate capacity to prevent any flooding or backing up and of such construction to prevent leakage or be affected by the chemicals in contact. Trash racks (grills) to be fitted to prevent entry of rubbish to form a plug. Manholes, verits to release gases, fire-traps and gas traps on the upstream side of the oil interceptors and fitted with vents to liberate gas at a safer height are also to be provided (R.169). No fire/source of heat or light capable of igniting inflammable vapours shall be allowed except in the firing spaces, stills or boilers. Smoking not permitted except in places specially approved by the CC (R.170) .
- 131. Work permit froma competent person is necessary for maintenance and repair work and entry into confined spaces, closed drain or manhole. It shall be issued for a limited period during which known conditions will remain safe and after inspection and testing by the competent person, for gases and lead content will be carried out by suitable trained persons and with standard instrument (R. 171). For fire control a well organised and trained fire fighting service with necessary materials and fixed, mobile and portable equipment is required. OISD Std. 116 should be followed. Adequate water supply should be available at all strategic points by means of an independent ring main or grid with isolating valves. The main shall be kept constantly pressurised by two or more boosting pumps of adequate capacity and working automatically when pressure drop occurs in the main. At least one boosting pump should be independent of power supply (e.g. diesel driven). All mains shall be fitted with hydrants at convenient places not more than 30 mt. apart. If mains water supply is likely to be interrupted, static water supply of adequate capacity shall be provided. Training for personnel necessary (R. 172). All petroleum as it leaves the stills may be pumped back to services tanks for fuel or refinery storage tank and not be stored in the vicinity of stills and boilers (R. 173) Danger from static electricity shall be prevented (R. 174). Warning notices to be displayed (R. 175). All above ground pipelines and cables shall be identified by taping, stencilling, colouring etc. Pipelines, valves, route of underground cables and route of overhead pipelines and cables crossing roads shall be protected against damage (R. 176). All plants, instruments and equipment shall be inspected, tested and records maintained (R. 177). All operators shall be trained in safe operation. Written procedures shall be established to start up, shut down, gas free plants and emergency actions. Supervisors shall ensure safe operation and safety facilities (R. 178). An occurrence of fire shall be reported immediately to the CC and to the nearest police station (R. 179). When refinery is closed down the area within the fence shall be cleared of all petroleum having FP < 93°C as soon as possible (R. 180). Table 1, 2 & 3 for safety distances are important for plant layout. Third schedule gives design and construction of 'Tank vehicles' for transporting petroleum in bulk. GAS CYLINDERS RULES, 2004: Replacing Gas Cylinders Rules, 1981, these rules of 2004 came into force from 21-9- 2004. It has 10 Chapters, 73 Rules, 6 Schedules and Forms A to G u/sch. V. Chapter-1: Preliminary (R 1, 2): Definitions (R. 2): Out of 43 definitions majority are scientific definitions. Therefore, they should be referred from the statute book. Some definitions are given below.
- 132. (1) "Auto LPG"means liquefied petroleum gas meant for automotive fuel conforming to specification IS : 14861; (2) "Composite Cylinder" means a cylinder made of resin impregnated continuous filament wound over a metallic or a non-metallic liner. Composite cylinders using non- metallic liners are referred to as all-composite cylinders; (3) "Compressed Natural Gas (CNG)" means mixtures of hydrocarbon gases and vapours,consisting mainly of Methane in gaseous form, which has been compressed for use as automotive fuel; (4) "Gas Cylinder" or "Cylinder" means any closed metal container having a volume exceeding500 ml. but not exceeding 1000 litres intended for the storage and transport of compressed gas, including any liquefied petroleum gas (LPG) container/compressed natural gas (CNG) cylinder fitted to a motor vehicle as its fuel tank but not including any other such container fitted to a special transport or undercarriage and includes a composite cylinder, however, the water capacity of cylinders used for storage of CNG, nitrogen, compressed air, etc. may exceed 1000 litres up to 2500 litres provided the diameter of such cylinder does not exceed 60 .cm.; = "Liquefied Petroleum Gas" (LPG) means any material, which comprises predominantly of any of the following hydrocarbons or mixture of them with vapour pressure not exceeding 16.87 kg/Cm2 (gauge) at 65° C:- Propane (C3H8), propylene (C3H6), butane (C4H10), (n-butane and isobutene) and butylenes (C4H8); = "Poisonous (toxic) gas" means a gas which has a maximum allowable concentration in air for human respiration not exceeding 100 mg/ 3 at 15"C and I kgf/.cm2 absolute pressure; = "Yield strength" means the stress corresponding to a permanent strain of 0.2 per cent of the original gauge length in a tensile test. For practical purposes it may be taken as a stress at which elongation first occurs in the test piece without the increase of load in a tensile test. Chapter-II : General Provisions (R. 3 to 28) : (1) Cylinders and valves should have been constructed as specified in Sch. I, test and inspection certificate should be available with information in Sch. II. Any person desiring to fabricate cylinders valves regulators and other fittings should apply in Sch. Ill (R.3). (2) Valves should be of the IS, type and design prescribed in R.4. (3) Safety Relief Devices fitted on cylinders should be as per IS 5903. Cylinders containing poisonous or obnoxious gases (as named) should not have such device (R.5). (4) Marking on Cylinders: as per rule 6. (5) Markings of Valves: as per R.7. (6) Identification Colours :as per IS:4379 for industrial cylinders and IS 3933 for medical cylinders. New gases and gas mixtures for which such colours are not provided in IS, shall be painted with following colours. Type of Gas Cylinder Shell Band at neck Non-flammable & non- Toxic White - Non-flammable but Toxic White Yellow (IS 356)
- 133. Flammable & Non-toxic (otherWhite Red (IS 537) than LPG) Flammable & Toxic White Red & Yellow (IS 537 & 356) Cylinders of gas mixtures should be marked "Gas mixture" or "mixed Gas" (R. 8). (B) Labeling of cylinder shall show the name of the gas and address of its filler. A warning notice should be attached to it with instructions that : (i) the colour of the cylinder will not be changed. (ii) No other gas will be filled in it. (iii) N o flammable material should be stored in or near die room of the cylinder, (iv) No oil or lubricant should be applied on valves or fittings, (v) No cylinder should be accepted whose test date is over(R.9). 1. Restriction ;No delivery or dispatch except to licence holder, defense forces, port or railway authorities (R.IO). Restriction on filling named gases and to endanger serviceability (R.19). 2. Repairing :not allowed except as otherwise provided in R.ll & 12. 3. Prohibition of employment of a person below 18 years or intoxicated (R.13) and on smoking orallowing fires, lights, or flammable substances, except blow pipe flame for repairs (R. 14). 2. General Precautions are that the cylinders should be maintained in good condition, oil, or lubricant not to be used on valves or fittings, no exposure to sun, high temperature of flammable/explosive material, security nut on a compressed gas cylinder and uncontrollable leaky cylinder to be removed in an open space and the filler be informed (R.15). 3. Special precautions are to avoid accident due to fire or explosion and to comply with these rules and license conditions (R.I 6). 13 Competent person should supervise operations (R.17). ' 3. Handling & Use include proper support, adequate strength of trolley and cradle, careful handling to avoid shock, no sliding, dropping, knocking, rolling or playing with cylinders, liquefied gas cylinders to be kept upright and work places should not be shown as storage places for the purpose of licensing (R.I 8). 4. Storage precautions to be observed are : To store in a dry, cool, under cover, well ventilated place and away from source of heat or ignition. Room of fire resistant construction. LPG and dissolved gas cylinders should be kept in upright position., Flammable and toxic gas cylinders should be kept separate by a partition wall. Conditions to cause corrosion or fire should be avoided. 1. Filled and empty cylinders should be segregated (R.21).
- 134. F Electrical installationshould be flameproof conforming to IS 2148 and effectively earthed(R.22). G Impurities in gas to cause corrosion or explosion should be avoided. The gas should be dry, moisture less than 0.02 g/m' of gas, aqueous phase cannot be separated at 0"C and free from sulphurous impurities (R.23). H Cylinder subjected to fire shall not be reused except after proper repairs and testing. Suchacetylene cylinders are to be condemned or destroyed safely (R.24). I Charging after prescribed periodical re-testing only (R.26). J Owner has to keep prescribed record (R.27). E Conversion to cylinder not allowed without permission (R.28). Chapter - III : Importation of Cylinders (R. 29 to 34): Licence necessary (R.29). Importation by sea, land and air after permission from the Custom Collector, Central Government and Director General Civil Aviation only (R.30 to 34). Chapter - IV : Examination & Testing (R. 35-36) : Periodicity as per 15 or approval by the CC, testing station should have facilities set forth in Sch. IV (R.35). Condemning of cylinders as prescribed. Any cylinder which fails to pass any test or examination or loses its tare weight by over 5% or found unsafe, shall be destroyed by flattening or cut into pieces so that it cannot be joined to form a cylinder. All markings shall be defaced and record be kept. Service life of CNG cylinders 20 years and that of LPG containers 15 years (R.36). Chapter-V is for dissolved Acetylene gas cylinders (R.37 to 42). Chapter- VI is for filling, possession and their licence procedure (R.43 to 65), Chapter-VII onpower to exempt (R.66) Chapter- VIII on Accidents and Inquires (R. 67 to 69) and Chapter-IX on powers of Controller of Explosives (R.70 to 73) CALCIUM CARBIDE RULES, 1987 INTRODUCTION OBJECTIVE, DEFINITION, ENFORCEMENT, EXEMPTION ETC. IN THE CALCIUM CARBIDE RULES, 1987. (A) Objective: Compressed gases filled in metallic container pose potential hazard and the container explodes. Hence, the Govt. of India vide Notification No.G.S.R. 105(E) dated 28/09/1938 has declared compressed gas filled in a metallic container to be deemed to be an explosive under Petroleum Act, 1934. Subsequently, in exercise of powers vested in Section 4 of the Petroleum Act, 1934, the Govt. framed the CALCIUM CARBIDE RULES, 1987 to regulate filling, possession, transport and import of compressed gases in pressure vessels. (B) Definitions. — In these rules, unless the context otherwise required—
- 135. (a) “Act” meansthe Petroleum Act, 1934 (30 of 1934); (b) “Carbide” means Calcium Carbide; (c) “Chief Controller” means the Chief Controller of Explosives; (d) “Conservator of the Port” includes any person acting under the authority of the officer or body of persons appointed to be Conservator of a Port under section 7 of the Indian Ports Act, 1908 (15 of 1908); (e) “Controller of Explosives” includes a Joint Chief Controller of Explosives, Deputy Chief Controller of Explosives and Deputy Controller of Explosives; (f) ‘District Authority” means— (a) a Commissioner of Police or Deputy Commissioner of Police in any town having a Commissioner of Police; and (b) in any other place, the District Magistrate; (g) “District Magistrate” includes an Additional District Magistrate and in the State of Punjab and Haryana and in the Karaikal, Mahe and Yanam areas of the Union territory of Pondicherry, also includes a Sub-divisional Magistrate; (h) “Form” means a Form as given int he Second Schedule; (i) “Inspector” means an Officer authorised by the Central Government under Subsection (1) of Section 13 of the Act. (j) “Prescribed receptacle” means a receptacle which— (i) is made of steel or any other material approved by the Chief Controller but has no copper in its composition; (ii) is hermetically closed at all times except when its contents are being placed within it or withdrawn from it; and (iii) bears a stamped embossed, painted or printed warning exhibiting in conspicuous characters the words “Calcium Carbide”— Dangerous if not kept dry” and the following caution :- “The contents of this package are liable, if brought into contact with moisture, to give off a highly inflammable gas” : Provided that of the containers of carbide imported, the warning shall be according to relevant international Code. (k) “Sampling Officer” means an officer authorised by the Central Government under Sub-section (1) of section 14 of the Act. (C) Enforcement : Under the Calcium Carbide Rules, the following enforcement are provided :- 1) Importation of carbide 2) Transportation of carbide. 3) Storage of carbide Authority in enforcement is Chief Controller of Explosives or any other officer uthorized by him. The District Authority is required to take penal action for infringement of rules reported to him by Chief Controller of Explosives. (D) Exemptions: Repeal and savings _ (1) The Carbide of Calcium Rules, 1937 are hereby repealed. (2) Notwithstanding such repeal - (i) all licenses or duplicates granted or renewed under the said rules and all fees imposed or levied shall be deemed to have been granted,renewed, imposed or levied as the case may be,
- 136. under the correspondingprovisions of these rules. (ii) all approvals given and all powers conferred by or under any notification or rule shall, so far as they are consistent with the provisions of the Act and these rules, be deemed to have been given or conferred by or under these rules. FORMS OF LICENCES/APPROVAL, PURPOSE AND LICENCING/APPROVAL AUTHORITY PROCEDURE ADOPTED FOR GRANT, RENEWAL, AMENDMENT ETC.OF VARIOUS TYPES OF LICENCES UNDER CALCIUM CARBIDE RULES, 1987 (PRIOR APPROVAL). (I) Any person desiring to store Carbide is required to obtain a prior approval from Chief Controller of Explosives by submitting following documents. (a) DOCUMENTS TO BE SUBMITTED FOR PRIOR APPROVAL : i) Application in Form I. ii) A Copy of the drawing drawn to scale as per specification & rules of the premises to be licensed. iii) Details regarding the surrounding i.e. nearby roads, buildings, etc., within 50M from the proposed site. iv) Scrutiny fee of Rs.10/- drawn on Nationalised bank in favour of Chief Controller of Explosives payable at Nagpur. DEPARTMENTAL ACTION: On scrutiny of the documents and if found in order prior approval will be given. If however any discrepancy is being noticed, the same will be communicated to the party and after rectification of the defects; action towards approval will be initiated. (b) GRANT OF LICENCE: After completion of the proposed premises as per approved plan, the applicant is required to submit to Chief Controller of Explosives the following documents :- 1) Application in form I. 2) 4 copies of site and layout drawing as approved.
- 137. 3) Licence feeof Rs._______/- DEPARTMENTAL ACTION : The documents submitted by the licensee, if found in order licence in form III /IV is granted and sent to the Circle/ Sub-circle office having jurisdiction for inspection of the facilities. If on inspection the facilities are found in order, the nspecting officer endorses the licence and sends to the licensee. In case of minor deviations he points it out to the licensee and on receipt of compliance further action of endorsement of licence is taken. In case major deviations, the matter is referred back to the Chief Controller of Explosives for further action as desired fit. In case deviations are of such nature which endangers safety and which cannot be complied by the licensee, the licence is revoked. (II) RENEWAL OF THE LICENCE: The applicant is required to submit the following documents for renewal of licence in form III & IV to the Jt.Chief Controller of Explosives of respective Circle Offices at least 30 days before the date on which the licence expires. The licence is renewable for a maximum period of 3 years. 1) An application in form I duly filled and signed. 2) The original licence. 3)` Demand draft drawn in favour of Jt. Chief Controller of Explosives of respective Circle Office for amendment. DEPARTMENTAL ACTION (1) The licence may be renewed by the licensing authority empowered to grant such a licence: Provided that a licence which has been granted by the Chief Controller may be renewed without alteration by the Controller of Explosives duly authorised by the Chief Controller. (2) Every licence granted under these rules may be renewable for three calendar years where three has been no contravention of the Act or of the rules framed there under or of any condition of the licence so renewed. (3) Where a licence which has been renewed for more than one year is surrendered before its expiry, the renewal fee paid for the unexpired portion of the licence shall be refunded to the licensee provided that no refund of renewal fee shall be made for any calendar year during which (a) the licensing authority receives the renewed licence for surrender, or (b) any carbide is received or stored on the authority of the licence. (4) Every application under sub-rule (2) shall be made in Form I and shall be accompanied by the licence which is to be renewed together with approved plans attached to the licence and the renewal fee. (5) Every application for renewal of the licence shall be made so as to reach the licensing authority at least 30 days before the date on which it expires, and if the application is so made, the licence shall be deemed to be in force until such date as the licensing authority renews the licence or until an intimation that the renewal of the licence is refused has been communicated
- 138. to the applicant. (6)Where the renewal of the licence is refused, fee paid for the renewal shall be refunded to the licensee after deducting therefrom the proportionate fee for the period beginning from the date from which the licence was to be renewed upto the date on which renewal thereof is refused. (7) The same fee shall be charged for the renewal of the licence for each calendarear as for the grant thereof : Provided that :- (i) if the application with the accompaniments required under sub-rule (4) is notreceived within the time specified in sub-rule (5), the licence shall be renewedonly on payment of a fee amounting to twice the fee ordinarily payable ; (ii) if such an application with accompaniments is received by the licensingauthority after the date of expiry but not later than 30 days from the date ofexpiry, the licence may without prejudice to any other action that may be taken in this behalf, be renewed on payment of twice the fee ordinarilypayable : Provided further that in the case of an application for the renewal of thelicence for a period of more than one calendar year at a time, the fee prescribedunder clause (i) or (ii) of the first proviso, if payable, shall be paid only for the first calendar year of the renewal. III) AMENDMENT OF LICENCE The applicant is required to submit the following documents for amendment oflicence in form III & IV to the Jt.Chief Controller of Explosives of respective CircleOffices at least 30 days before the date on which the licence expires. 1) An application in form I duly filled and signed. 2) The original licence. 3) Demand draft drawn in favour of Jt. Chief Controller ofExplosives of respective Circle Office for amendment. DEPARTMENTAL ACTION On scrutiny of the documents submitted by the licensee and the sameis found in order action towards amendment of the licence is initiated. If,however, any discrepancy is noticed the same is communicated to thelicensee and after compliance of the same, further action towardsamendment of licence is taken. Question ? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department. 4. What are your specific suggestion to improve it? Give suggestions withreasons. 5. Has this chapter helped you in filing/making proper documents or will yourthink that you may still face difficulty in filling/making proper forms anddocuments after reading this chapter? 6. Do you have specific suggestions to make it more user friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation ? Give details with
- 139. reasons. 9. Give briefdetails of your organization/yourself through the suggestion formwhich can be had by clicking the feedback button. FORM – II STORAGE OF CALCIUM CARBIDE IN A GODOWN (Not forming part ofAcetylene Generation) For storage exceeding 200 kg and not exceeding 500 kg,licence is issued bythe District Authority The related matter is available in the hard copy of the manual which can behad by placing an order(by letter or through e- mail) to the following addressDy. Chief Controller of Explosives Testing Station Amravati Road, Gondkhairy NAGPUR 440 023 E- mail address: ccoe.ngp@nag.mah.nic.in FORM – III STORAGE OF CALCIUM CARBIDE IN A GODOWN (Not forming part of Acetylene Generation) For storage exceeding 500 kg, licence is issued by the Circle office Applicants Action Any person desiring to store Carbide is required to obtain a prior approvalfrom Chief Controller of Explosives by submitting following documents. (a) Documents to be submitted for prior approval : v) Application in Form I. vi) A Copy of the drawing drawn to scale as per specification & rules of thepremises to be licensed. vii) Details regarding the surrounding i.e. nearby roads, buildings, etc., within50M from the proposed site. viii) Scrutiny fee of Rs.10/- drawn on Nationalised bank in favour of ChiefController of Explosives payable at Nagpur. DEPARTMENTAL ACTION: On scrutiny of the documents and if found in order prior approval will be given. If however any discrepancy is being noticed, the same will be communicated to the partyand after rectification of the defects; action towards approval will be initiated. (b) GRANT OF LICENCE: After completion of the proposed premises as per approved plan, the applicant is required to submit to Chief Controller of Explosives the following documents :- 1) Application in form I. 4) 4 copies of site and layout drawing as approved. 5) Licence fee of Rs._______/- DEPARTMENTAL ACTION : The documents submitted by the licensee, if found in order licence in formIII /IV is granted and sent to the Circle/ Sub-circle office having jurisdiction forinspection of the facilities. If on inspection the facilities are found in order, theinspecting officer endorses the licence and sends
- 140. to the licensee.In case of minordeviations he points it out to the licensee and on receipt of compliance further actionof endorsement of licence is taken. In case major deviations, the matter is referredback to the Chief Controller of Explosives for further action as desired fit. In case deviations are of such nature which endangers safety and which cannot be compliedby the licensee, the licence is revoked. (II) RENEWAL OF THE LICENCE: The applicant is required to submit the following documents for renewal of licence in form III & IV to the Jt.Chief Controller of Explosives of respective CircleOffices at least 30 days before the date on which the licence expires. The licence isrenewable for a maximum period of 3 years. 1) An application in form I duly filled and signed. 2) The original licence. 3)` Demand draft drawn in favour of Jt. Chief Controller of Explosives of respective Circle Office for amendment. DEPARTMENTAL ACTION (4) The licence may be renewed by the licensing authority empowered to grant such alicence: Provided that a licence which has been granted by the Chief Controller maybe renewed without alteration by the Controller of Explosives duly authorised bythe Chief Controller. (5) Every licence granted under these rules may be renewable for three calendar yearswhere three has been no contravention of the Act or of the rules framed thereunder or of any condition of the licence so renewed. (6) Where a licence which has been renewed for more than one year is surrenderedbefore its expiry, the renewal fee paid for the unexpired portion of the licencehall be refunded to the licensee provided that no refund of renewal fee shall bemade for any calendar year during which (c) the licensing authority receives the renewed licence for surrender, or (d) any carbide is received or stored on the authority of the licence. (7) Every application under sub-rule (2) shall be made in Form I and shall be acompanied by the licence which is to be renewed together with approved plansattached to the licence and the renewal fee. (8) Every application for renewal of the licence shall be made so as to reach thelicensing authority at least 30 days before the date on which it expires, and if theapplication is so made, the licence shall be deemed to be in force until such dateas the licensing authority renews the licence or until an intimation that therenewal of the licence is refused has been communicated to the applicant. (9) Where the renewal of the licence is refused, fee paid for the renewal shall berefunded to the licensee after deducting therefrom the proportionate fee for theperiod beginning from the date from which the licence was to be renewed upto thedate on which renewal thereof is refused. (10) The same fee shall be charged for the renewal of the licence for each calendaryear as for
- 141. the grant thereof: Provided that :- (iii) if the application with the accompaniments required under sub-rule (4) is not received within the time specified in sub-rule (5), the licence shall be renewed only on payment of a fee amounting to twice the fee ordinarily payable ; (iv) if such an application with accompaniments is received by the licensing authority after the date of expiry but not later than 30 days from the date of expiry, the licence may without prejudice to any other action that may be taken in this behalf, be renewed on payment of twice the fee ordinarily payable : Provided further that in the case of an application for the renewal of the licence for a period of more than one calendar year at a time, the fee prescribed under clause (i) or (ii) of the first proviso, if payable, shall be paid only for thefirst calendar year of the renewal. III) AMENDMENT OF LICENCE The applicant is required to submit the following documents for amendment of licence in form III & IV to the Jt.Chief Controller of Explosives of respective Circle Offices at least 30 days before the date on which the licence expires. 1) An application in form I duly filled and signed. 2) The original licence. 4) Demand draft drawn in favour of Jt. Chief Controller of Explosives of respective Circle Office for amendment. DEPARTMENTAL ACTION On scrutiny of the documents submitted by the licensee and the same is found in order action towards amendment of the licence is initiated. If, however, any discrepancy is noticed the same is communicated to theicensee and after compliance of the same, further action towards amendment of licence is taken. Question? 1. Was it useful in your work activities connected to this department? 2. Are you a frequent visitor to this manual site? 3. Are you a frequent visitor to the offices of this department? 4. What is your specific suggestion to improve it? Give suggestions with reasons. 5. Has this chapter helped you in filing/making proper documents or will your think that you may still face difficulty in filling/making proper forms and documents after reading this chapter? 6. Do you have specific suggestions to make it more users friendly? 7. Do you think of unnecessary element in this chapter which can be avoided/deleted ? 8. Do you have any suggestion (s) for change in Legislation? Give details with reasons. 9. Give brief details of your organization/yourself through the suggestion form which can be had by clicking the feedback button. VARIOUS MODEL DRAWINGS WILL BE PROVIDED AT WEB-SITE FORM – IV STORAGE OF CALCIUM CARBIDE ATTACHED TO ACETYLENE GENERATOR For storage of calcium carbide attached to acetylene generator, licence is issued by the ChiefController of explosives, Nagpur.
- 142. The related matteris available in the hard copy of the manual which can be had by placing an order(by letter or through e- mail) to the following address Dy. Chief Controller of Explosives Testing Station Amravati Road, Gondkhairy NAGPUR 440 023 E- mail address: ccoe.ngp@nag.mah.nic.in VARIOUS MODEL DRAWINGS WILL BE PROVIDED AT WEB-SITE INSECTICIDES ACT, 1968: This Act (46 of 1968) was enacted on 2-9 -1968. It came into force from 1-3-1971 (Sec. 4,7,8, & 36) and 1-8-1971 (remaining part). It extends to the whole of India. It has 38 sections and a .schedule listing insecticides amended from time to time. It is an Act to regulate the import, manufacture, sale, transport, distribution and use of insecticides with a view to prevent risk to human beings or animals and matters connected therewith. Provisions are made for the Central Insecticides Board, its committees, procedure and officers (S.4 to 8), Registration of insecticides, appeal and revision (S.9 toll), Licensing (S.12 to 15), Central Insecticides Laboratory (S.16), Prohibition of import and manufacture (S.17), Sale, stock, distribute, transport, use etc. (S.18) Insecticide Analysis (S.19), Inspectors (S.20 to 23). Report of Insecticides Analyst (S.24), Confiscation of stock (S.25) Notice of poisoning (S.26), Prohibition of sale etc. for reasons of public safety (S.27), Cancellation of registration (S.28), Offences & punishment (S.29), Defences which may or may not be allowed (S.30), Cognisance & trial (S.31), Special courts (S. 31A), Offences by companies (S.33), Power of Central Govt. and State Govt. to make rules (S.36 & 37) and Exemption (S.38). By various notifications from 1989 to 1996, many insecticides are banned or restricted in India, e.g. DDT, chlorobenzilate, BBCP, PCNB, Toxaphene, Aldrin, Chlordane Heptachlor, Titration, Nitrofen, Benzene Hexachloride etc. Insecticides Rules 1971 : These rules came into force on 30-10-1971. They have 9 chapters, 46 rules, 2 schedules and 22 forms. Chapter-1 gives definitions. Tests' means any insects, rodents, fungi, weeds and other forms of plant or animal life not useful to human being s [R. 2 (h)] 'Laboratory' means the central insecticides laboratory. [(R. 2(e))]. Commercial Pest Control Operation means any application or dispersion of insecticide(s) including fumigants in household or public or private premises or land and includes pest control operations in the field including aerial applications for commercial
- 143. purpose but excludesprivate use. Pest Control Operator means any person who undertakes pest control operations and includes the person or the firm or the company or the organisation under whose control such a person(s) is operating. Chapter-n is regarding the Board and its functions (R.3 to 5), Chapter-111 regarding registration of insecticides (R.6 to 8), Chapter-IV for grant of licences (R.9 to 15), Chapter -V for packing & labelling (R.16 to 20), Chapter-VI for insecticides analysts and Insecticides Inspectors (R.21 to 34), Chapter-VII for transport & storage (R. 35 to 36), Chapter-VIII for protective clothing, equipment and other facilities for workers (R.37 to 44) and Chapter-IX miscellaneous (R.45 to 46). The first schedule prescribes 22 forms of which the last one (for medical examination of workers) is reproduced in this part. Second schedule u/r 25 prescribes fees for testing or analysing the samples of insecticides. Insecticides cannot be manufactured, stored or handled with any consumable article (R IO-Q. Packing and Labelling (R. 16 to 20): Every container package should be of the approved type. A leaflet should be put inside containing particulars about the plant disease, insects, animals or weeds for which it is to be applied, manner of application, symptoms of poisoning, safety measures and first-aid treatment necessary, antidote, decontamination or safe disposal procedure, storage and handling precautions, effect on skin, nose eye, throat etc. and common name of the insecticide (R. 18). In labelling, warning and cautionary statement should be included. 1. For category-I (Extremely toxic) insecticides, the symbol of a skull and cross-bones and the word 'POISON' should be printed in red. Statement "Keep out of the reach of children and if swallowed or if symptoms of poisoning occur call physician immediately" should be added. 2. For category II (Highly toxic) insecticides, the word TOISON' in red and statement "Keep out of the reach of children" should be printed. 3. For category III (moderately toxic) the word 'DANGER' arid statement "Keep out of the reach of children". 4. For category IV (Slightly toxic) the word 'CAUTION' should be mentioned. Category classification is as under – Classificati on o f O r a l r o u t e (ac ute Dermal route (dermal Colour of band on the
- 144. insecticides toxicit y) LD50 mg /kg of toxicity LD50 mg/kg oflabel. test animal test animal. Extremely toxic 1 - 5 0 1-200 Bright red Highly toxic 5 1 - 5 0 0 201-2000 Bright yellow Moderately toxic 501- 5000 2001-20000 Bright blue Slightly toxic > 5 0 0 0 > 20000 Bright Green See Part 24 of Chapter-23 for pesticide industry. Transport and Storage (R. 35, 36) : Packages for rail transport shall be packed as per Red Tariff by Railways. No transportation or storage in such a way that insecticides may come in contact with food stuffs or animal feeds. If it is mixed up due to any damage to packages during transport or storage, it shall be examined by competent authorities notified by the State Govt. and safely disposed. If any leak occurs, the transport agency or the storage owner shall take urgent measures to prevent poisoiling and pollution of soil, water etc. The packages of .insecticides should be stored in separate rooms or almirahs under lock and key. Such rooms shall be well built, dry, well-lit, ventilated and of sufficient dimension. Protective Equipment and other Facilities for Workers (R. 37 to 44) : All persons engaged in handling, dealing or otherwise coming in contact with insecticides during manufacture/formulation or spraying shall be medically examined before employment and then periodically once in a quarter by a qualified doctor who is aware of risks of pesticides and report be kept in Form XXII given below. For persons working with organ phosphorous or carbamate compound, their blood cholinesterase level shall be measured monthly. The blood residue estimation shall be done yearly of persons working with organo- chlorine compound. Any person showing symptoms of poisoning shall be immediately examined and given proper treatment. First-aid treatment shall always be given before the physician is called. IS 4015 part I
- 145. and II shallbe followed in addition to any other books on the subject. The workers shall be educated regarding effects of poisoning and the first-aid treatment to be given. Protective clothing which shall be washable (to remove toxic exposure) and not allowing penetration by insecticide shall be given to workers. A complete suit shall consist (a) Protective outer garment/overalls/ hood/hat, (b) rubber gloves extending half-way up to fore- arm (c) dust-proof goggles and (d) boots. For prevention of inhalation of toxic dusts, vapours or gases, the workers shall use (a) chemical cartridge respirator, (b) supplied air respirator. (c) Demand flow type respirator (d) full or half face gas mask with canister as per requirement. In no case the exposure in air should exceed the maximum permissible level. Sufficient stocks of first-aid tools, equipment, antidotes, medicines etc. should be kept. The workers shall be trained for safety precautions and use of safety equipment. The packages and surplus materials shall be safely washed and disposed to prevent pollution. The packages shall not be left outside to prevent re-use. They shall be broken and buried away from habitation. Aerial spraying precautions are given 'in rule 43. Form XXII : Form of Medical Examination For the Year............ Serial No. ……………….. Name ……………………………… Age………….. Father's/Husband's Name ……………………… Full Address ……………………………….
- 146. Sex ……………….. Identificationmark ……………………… Date of appointment ……………… Occupation : (Pleas specify the nature of duty) PAST HIST Ill ne ss Pois onin g A ll er g y Exposur e to No. of years / Remar ks, if Pesticide s reaso ns any (Compou nd) ( 1 ) (2) (3) (4) (5) ( 6 ) FAMILY HISTORY Allergy Psychological disorders Gaemorhagic disorder (1) (2) ( 3 ) PERSONAL HISTORY Smoking Alc oho l Other addiction (1) (2) ( 3 ) OBSERVATIONS Me dica l Pre- End of 1st Aft er 2nd After 3rd End of the Rema rks Exami nation emplo yment quart er i.e. quart er i.e. quart er i.e. year exami nation after 3 afte r 6 after 9 mont mo mont
- 147. hs nth s hs ( 1 ) (2) (3 )(4) ( 5 ) (6) ( 7 ) I GENERAL EXAMINATION General body limit Anae mia Fatiga bility Weight Dade ma Sweati ng Pules Jaundi ce Sleep Blood pressure Skin conditi on Urinati on Respiration Tempe rature I I GASTRO INTESTINAL Nausea Taste Liver Vomiting Pain in abdomen Spleen Appetite Bowel movement I I I CARDIO RESPIRATORy Nasal discharge Tightness of chest Heart Wheeze Dyspn oea Cyano sis Cough Palpit ation Tachyc ardia Expectorati on I V NEURO MUSCULAR Headache Tremors Unconsciousness Dizziness Convulsion Deep reflexes Irritability Paranesthesia Superficial reflexes Pulse Hallucination Co-ordination
- 148. Twitchings V EYE Pupil Doublevision Lachrymation Clumped vision V I PSYCHOLOGICAL Temperament Judgement Nervousness V I I KIDNEY Kidney condition V I I I INVESTIGATION Blood Hb % Serum Bilirubin Urine microsopic Blood B.C. Urine routine examination X-ray of chest * Serum cholinesterase
- 149. *Serum cholinesterase levelshould be measured in monthly intervals in case of organophosphorus/carbamatic group of insecticides. General remarks of the Doctor in the light of the above examination; Advice given to : ( 1 ) the Patent: …………… ……….. ( 2 ) the Employer : …………… ……….. Steps taken by the Employer as per Doctor's advice Signature/Thumb impression of: 1. Doctor: 2. Employee: 3. Employer/manufacturer: 4. Licensing officer at the time of inspection. N.B.: In organochlorme group of insecticides the blood residue estimation should be done once a year RADIATION PROTECTION RULES, 1971: The Central Government u/s 30 of the Atomic Energy Act, 1962, made these rules applicable from 3010-1971, to the whole of India. A summary of these 56 rules is, given below: Section-2 defines adequate protection, competent authority, contamination, employer, radiation worker, operational limits, radiation installation, radiation surveillance, Radiological Safety Officer, sealed and unsealed source, source housing, useful beam etc. Other provisions are as under : (5) Radioactive material is to be handled as per terms and conditions of a licence. (6) Luminous compounds on watches, instruments etc. are exempted. (7) No person below the age of 18 years can be employed as a radiation worker. (8) Licence can be issued on request under the Act, if the equipment, facilities and work practices afford adequate protection and if the incharge person has adequate qualification to direct the work. The validity of licence is 3 years. It can be revoked, modified or withdrawn by the competent authority after giving a show cause notice and an opportunity to make a representation. Radioactive material shall be used only for the purpose, location and quantities specified in the licence. (6) Radiological Safety Officer shall be designated by the employer (himself or an employee) with the approval of competent authority to perform following duties and
- 150. functions (R. 13): Steps to ensure that operational limits are not exceeded. To instruct the radiation workers about hazards of radiation and safety measures to minimise exposure to radiation and contamination. To carry out leakage tests on sealed sources as specified in rule 34. To regulate the safe movement of radioactive materials including waste. To investigate and suggest remedial measures in frespect o any situation that could …………… lead to radiation hazards. To make available' necessary reports and remedial measures to his employer. To ensure the safe disposal of radioactive wastes in a manner approved by the competent authority. 1. Hazardous situation is to be reported to the competent authority. 2. Radiation surveillance procedure notified by the competent authority is to be followed by the employer. This may include (R. 15) : Design, construe don, operation and use as per specifications and prior approval of the competent authority. Working conditions, monitoring and personal protective equipment. Personal monitoring of radiation workers. Medical examinations of the radiation workers as per rule 19 or 20. Records of radiation and radioactivity level measurements, personal monitoring and medical examinations stipulated by the competent authority. Any other procedure specified by the competent authority. 3. Prior approval before any modification to the plant or any change in working conditions. 4. Radiation symbol to be displayed at workplaces and on containers containing radioactive materials. Its colour shall be as may be specified by the competent authority. 5. History records of radiation workers to be maintained in a form specified by the competent authority. 6. Pre and periodical yearly medical examinations of radiation workers, of blood, excreta, skin, hands, fingers, finger nails, eyes and chest (X-ray). The frequency* and types of above examinations may be modified by the competent authority where necessary (Rule 19 & 20). Complete records of above examinations shall be maintained. Its excerpts shall be sent to the competent authority in the form specified by him. The competent authority shall preserve such records for the life time of the worker or for 20 years after he ceases to do work of radiation, whichever is shorter. 7. The competent authority may specify steps to reduce the excessive exposure and the employer shall comply with them and also provide the exposed worker an alternative work not involving radiation exposure. If such worker is declared fit to resume radiation work, his employer shall permit him to do that work. Then his work shall be planned by the competent authority. 8. The competent authority or a person duly authorised by him has wide power to inspect new, modified or running radiation installation, work being conducted, protective device, transport etc. and make tests, measurements and other things to verify adequate protection. Power includes power to seal or seize radioactive material or equipment and give directions for compliance. 9. Registers of particulars of sealed and unsealed sources shall be maintained (Rule 33). 10. In case of leakage of a sealed source, the Radiological Safety Officer shall place that leaking source in a properly shielded leak-proof container with care to prevent spread of contamination, act to safeguard the workers and others, vacate affected area, clean
- 151. up contamination ifany, and inform the employer. 9. Lost or missed radioactive material shall be searched and the competent authority shall be informed immediately. 10. Telegamma sources shall be covered with appropriate source housing. In case of power failure, the useful beam should be automatically cut off. Manual device to interrupt the useful beam is required (Rule 37 to 39). 11. In medical institutions where radioactive material remains on or inside the body of the patient, separate rooms and wards for the treatment shall be provided. 12. Where gamma radiography is done, the area shall be cordoned off to control entry into it of other persons. 13. Sealed source devices such as static eliminators, thickness, density or level gauges, package monitors shall be provided with efficient cover plate, shutter or shield capable of being easily operateable to attenuate the useful beam. 14. Interlock switches in radiation installations should be of the fail-safe type. 15. Unsealed sources shall be kept in securely closed container and properly labelled. Radiological Safety Officer has to take more precautions where unsealed sources are handled such as safe working methods, facilities to minimise radiation level and airborne contamination, forbidding wrong working habits (mouth operated devices, open wounds, smoking, eating, drinking, application of cosmetics etc.), appropriate protective clothing, safe use of PPE and checking contamination on it and safe collection of radioactive wastes .(R.44 & 45). 9.1 Ventilating systems should be enclosed with ducts and filters to avoid spread of any airborne contamination. 9.2 In case of spillage, steps to arrange decontamination of affected personnel and areas, steps to prevent further spread of contamination and informing the employer. 9.3 Other provisions for experiments on animals, luminising compounds, approved procedure for mining, processing etc., disposal of animal carcasses, autopsies of cadavers, licence, personnel monitoring and power to exempt are given in rules 48 to 56. Notes on Regulatory Aspects Radioisotopes and radiation have found a variety of applications in industries, such as non-destructive testing, level indication system, thickness gauges, density gauges, etc. There are over 1200 industrial institutions in India, employing radiation source, in one form or the other. It is a well known fact, that ionising radiation such as X-rays, gamma rays, beta rays, etc. are deleterious to health. It is therefore, essential to minimise radiation exposures to the user as well as to the public. If the use of these radiation sources is not adequately controlled, it is likely to result in unnecessary radiation exposures to individuals. However, if necessary safety precautions, as per the stipulated norms, are observed by the user, the ill- effects of radiation can be minimised, thus, rendering the application quite safe for the user. The prospective user should approach the Competent Authority for obtaining permission to handle radiation sources. He must give the requisite details in the prescribed application form regarding the type of source, its activity, proposed use, name of the. user, his qualification and experience in the handling of radiation sources, etc. A precommissioning inspection of the installation is properly done by members of Radiation Protection Services Division (RPSD), Bhabha Atomic Research Centre (BARC),
- 152. Bombay-400 085, inorder to confirm the above. A separate storage enclosure should be available at the site for safe storage of the source housings, prior to their installation and also to store, spare source housings and decommissioned gauges awaiting ultimate disposal, if any. The source storage should be so chosen, that it would be free -from potential fire
- 153. hazard, flooding, waterlogging, pilferage etc. Advice on the nature of storage facility required may be obtained from the Competent Authority. All the persons who are involved in the operation and maintenance of these gauges, should have adequate knowledge' in the design, construction and principle of the gauges and they should have undergone appropriate training on the radiation safety aspects. Further, if deemed necessary, all those persons who are involved in the maintenance of radioisotope gauge may have to be monitored regularly, by the personal monitoring service, run by RPSD, in order to, ensure that dose limits are not exceeded. The decision regarding the need for the persons to be monitored by the personnel monitoring service will be taken after the precommissioning inspection of the installation by members of RSPD. A GM type radiation survey meter (model MR 121) manufactured by the Electronic Corporation of India Ltd. (ECIL), Hyderabad or its equivalent should be available with the user of the nucleonic gauges, for regular monitoring of radiation levels around the gauge installation and also for deciding the area to be cordoned off around the source, if an emergency arises. The user should designate a Radiological Safety Officer, who possesses a certificate in radiation safety which is recognised by RPSD and who has received instructions in the Radiation Protection, Rules 1971 and all notifications and orders issued there under, relevant to the proposed application of radiation and who has demonstrated competence in the handling of radiation exposure devices and related instruments and radiation survey meters, which would be used in the course of this assignment. Formal approval should be obtained by the user, from the Competent Authority, for the appointment of Radiological Safety Officer. The requisite authorisation for the procurement of nucleonic gauges from any Indian manufacturer or the requisite 'No Objection Certificate' for the import of nucleonic gauges of specific type from abroad will be issued by the Competent Authority after the fulfilment of the above requirements by the applicant. All these regulatory controls have been evolved, in order to ensure safety to persons and property, during the use of these gauges. STATIC AND MOBILE (UNFIRED) PRESSURE VESSELS RULES, 1981: U/S.5 and 7 of the Explosives Act 1884, the' Central Government notified these rules w.e.f. 5-2-1981. They have 8 chapters, 69 rules, 3 appendices, 2 schedule and 5 forms. The rules were amended in 1993, 2000 and 2002. Chapter-1: Preliminary (R.I to IIA): Definitions: Out of (a) to (z) definitions, majority are scientific and therefore they are reproduced below. 6. "Permanent Gas" means a gas whose critical temperature is lower than 10°C. 7. "Liquefiable Gas" means any gas that may be liquefied by pressure above 0°C, but will be completely vaporised when in equilibrium with normal atmospheric pressure (760 mm HG) at 30°C; 8. Cryogenic liquid means liquid form of permanent gas having normal boiling point
- 154. below minus 165°C. 9. Critical temperature means the temperature above which gas cannot be liquefied by the application of pressure alone. 10. "Compressed gas" means any permanent gas, liquefiable gas or gas dissolved in liquid or cryogenic liquid under pressure or gas mixture, which in a closed pressure vessel exercises a pressure exceeding one atmosphere (gauge) at the maximum working temperature and includes Hydrogen fluoride. In case of vessels without insulation or refrigeration, the maximum working temperature shall be considered as 55°C. 11. “Design" includes drawings, calculation, specifications, models, codes and all other details necessary for the complete description of the pressure vessel and its construction; 12. LPG i.e. Liquefied Petroleum Gas includes hydrocarbon gases in liquefied state at normal ambient temperature by the application of pressure, and conforming to the IS : 4576. 13. Dispenser means an equipment installed in LPG dispensing station, meant for dispensing LPG as automotive fuel to motor vehicles; 14. "Design pressure" means the pressure used in the design calculations of a vessel for the purpose of determining the minimum thickness of the various component parts of the vessel; 15. "Filling density" means the ratio of weight of liquefiable gas allowed in a pressure vessel to the weight of water that the. vessel will hold at 15°C; 16. "Flammable compressed Gas" means gas 13 percent or less of which when mixed with air forms a flammable mixture or whose flammable range with-air is greater than 12 percent; 17. "Gas Free" in relation to a pressure vessel means the concentration of flammable or toxic gases or both if such pressure vessel is within the safe limits specified for persons to enter and carry out hot work in such vessels; 18. "Pressure Vessel or Vessel" means any closed metal container of whatever shape, intended for the storage and transport of any compressed gas which is subjected to internal pressure and whose water capacity exceeds 1000 litres and includes inter connecting parts and components thereof up to the first point of connection to the connected piping and fittings but does not include containers wherein steam or other vapour is or is intended to be generated, or water or other liquid is or is intended to be heated by the application of fire or the product of combustion or byelectrical means, heat exchangers, evaporators, air receivers, steam-type digesters, steam-type sterilises, autoclave, reactors, calorifiers, pressure piping components such as separators or strainers and vessels containing a liquid under a blanket of compressed inert gas. 1. "Safety relief device" means an automatic pressure relieving device actuated by the pressure upstream of the valve and characterised by fully opened pop action, intended to prevent the rupture of a pressure vessel under certain conditions of exposure; 2. "Source of ignition" means naked lights, fires, exposed incandescent materials, electric welding arcs, lamps other than those specially approved for use in flammable atmosphere, or a spark or flame produced by any means; 3. "Water Capacity" means capacity in litres of the pressure vessel when completely filled with water at 15°C.
- 155. The vessel shouldbe manufactured as per IS 2825 or code specified u/r 12 and approved by the CC, otherwise it cannot be filled or transported. Any person seeking to manufacture such vessels should apply to the CC in Appendix. I with a scrutiny fee of Rs. 500 (R.4). Storage, delivery and dispatch as per licence only (R.5). Repair after approval from CC and as per IS-2825 (R.6). Before using or refilling any vessel for flammable gases, purging by an inert gas or by the gas to be filled with safe venting is necessary (R.7). Prohibition of employing a person under 18 years or intoxication and smoking or allowing source of ignition or any flammable gas (R.8 & 9). These rules are to be complied with and precautions to prevent accident are necessary (R.IO). Supervision is also necessary (R. 9A). Procedure for paying fees is given u/r II and that for applying recognition as competent person or Inspector in Appendix III to the CC is -given u/ r II-A. Chapter-II : Construction and Fitments of Pressure Vessels (R. 12 to 20): Design Code - For design, construction and testing IS:2825 or other code approved by CC. Testand Inspection certificate issued by the manufacturer and countersigned by an Inspector shall be sent to CC. (R. 12). Design pressure should not exceed the vapour pressure at 55°C if liquefiable gas is to be storedor the developed pressure at 55°C if permanent gas (whose critical temp. is < 10°C) is to be stored. For an insulated vessel it may be reduced corresponding to the maximum temperature likely to be attamed by the gas in the vessel. Maximum allowable service pressure with allowances for cryogenic liquid (R. 13). Design for low temperature should be as per code mentioned in R.12. Refrigeration capacityshould be adequate to maintain the vapour pressure below the design pressure and the set-pressure of a safety valve. Insulation material should be approved by CC,' cladding thickness more than 3 mm, water-tight and thermal conductance at 15°C should not exceed the limit prescribed by the CC (R. 14). Filling capacity & pressure as per rule 15. The maximum quantity of liquefiable gas to be filledshould not exceed the filling density (i.e. the ratio of the weight of the gas to the weight of water that the vessel will hold at 15°C) and the vessel should not become liquid full due to expansion of the gas at 55°C if the vessel is un-insulated or at such highest temperature attainable incase of refrigerated or insulated vessel. A permanent gas shall not be filled in excess of design pressure of the vessel (R. 15). Marking on Vessels should indicate (1) Manufacturer's name and identification (2) Standard orcode (3) Official stamp of the Inspector (4) Design pressure (5) Date of tests (6) Hydrostatic test pressure (7) Water capacity (8) Gas capacity and (9) Name or chemical symbol of the gas. (R. 16.) Painting with reflecting surface (R. 17)
- 156. Fittings should includePressure Gauge, Temperature Indicator, Safety Valve, Level Indicator anddrains. Connections as per code in rule 12. There should be two (or more) pressure relief valves (SV) spring loaded type, set to start at a pressure below 110% of the design pressure and total relieving capacity to keep the pressure inside the vessel less than 120% of the design pressure. Connections to these Safety Valve should be of sufficient size to allow the required rate of discharge. There should be shut off valve between Safety Valve and the vessel. For static (not mobile) vessels of more than 4500 lit. water capacity, outlet of Safety Valve should extend 2 mt. above the top of the vessel and at least 3.5 mt. above the ground level. They should have loose fitting rain caps. Safety Valve should be tested once in a year by a competent person and record be kept. All liquid and vapour connections on vessels (except Safety Valve, plugged openings and where diameter is less than (1.4 mm) should have shut-off (stop) valves as close to the vessel as practicable. There should be an emergency shut off valve (for both liquid and vapour phase) such as an excess flow valve, automatically operated valve or a remotely controlled valve which can be operated from a safe place and which shall not fail. Such emergency shut off (stop) valve is not required if liquid connection is of less than 3 mm dia and vapour connection is of not more than 8 mm dia. Excess flow rate should easily allow the normal flow rate (should not cause valve chatter) but should have closing rate below the rate of discharge from a fracture of the line it is protecting, calculated under the worst condition possible. Liquid level gauge should show a ready amount of liquid at any time. One maximum level indicator should also be provided. Bleeding device (rotary tube, fixed tube, slip tube) cannot be completely withdrawn in normal gauging operations. (R. 18). Hydraulic testing of all vessels by a competent person at a pressure marked on the vessel isnecessary .at 5 years intervals (2 years for corrosive or toxic gases.). Where water test is not possible or tolerable, CC may permit pneumatic testing along with NDT. Pneumatic test pressure for cryogenic pressure vessel shall be I.I times MPWP. Before each pressure test, the vessel shall be thoroughly cleaned and examined internally and externally for surface defects, corrosion, foreign matter and hazardous material (e.g. pyropheric sludge). After test it shall be thoroughly dried internally and stamped with marks, figures and test date. A vessel failing to pass hydraulic test or found unsafe for use shall be destroyed or rendered unsuitable under intimation to the CC. The competent person shall give a test certificate in prescribed proforma. A record shall be kept of all such tests ( R. 19, 20). Chapter -III : Storage (R. 21 to 33): General :Compressed gas vessels shall be aboveground, first stage regulating equipment in open,vessels should not be one above the other, vessels in a group should have their longitudinal axes parallel, no location within petroleum or flammable liquid area, sufficient space between two vessels to permit fire fighting operations, two or more vessels in batteries should have their top surface on the same plane and vessels facing their dished ends should have screen wall in between them. Floor slope, sump, dyke and dimensions for corrosive, flammable or toxic gases in liquefied state (R. 21).
- 157. Minimum Safety Distances; Seetable I to 7 u/r 22. Foundations as prescribed in R. 23. Supports should be so anchored, weighed or at height toavoid flotation due to flood waters. Bottom supports upto 45 cm (max.) shall be encased in fire-resisting materials of adequate thickness. Fencing of at least 2 mt. height with 2 exits opening out wards and not self locking. The fencingshould enclose vessels, pumping equipment, vaporisers and loading/unloading facilities. (R.24). Cleanliness An area of 3 mt. around the vessel shall be free from combustible material such asweeds and grass (R. 25). Earthing Vessels and pipelines should be efficiently earthed and bonded (R. 26). No smoking Notice with letters at least 5 cms size fixed on fence surface visible from outsidewhere flammable or oxidising gases are stored (R. 27). Fire Protection for the storage of flammable compressed gases should include sufficient supplyof water, hydrants, hoses, mobile equipment, fixed monitors or automatic spray systems, control valves outside the danger area, jet & fog nozzles and at least 2 DCP type fire extinguishers of 9 kg each near each point of access to the installations. Special provision for LPG station (R. 28). Loading and Unloading Facilities like pumps, compressors, transfer systems and hoses asprescribed in R.29. Remotely controlled shut-off valve for the vessel being filled or emptied. High level alarm interlocked with automatic shut off valve to prevent overfilling. The hoses should withstand not less than 4 times the maximum operating flow pressure in them and should be mechanically and electrically continuous (R.29). Transfer operation should follow the detailed instructions u/r 30. Supervision by a competentperson for compliance of these rules is necessary. Precautions to check vessel before and after filling, condition of piping, valves, fittings, hoses, vehicle and its earthing, prevention of overfilling, removal of spillage etc (R. 30). Provisions for LPG stations (R.30A & B). Electrical wire should not pass over any storage vessel and all electrical wires installed within the safety zone or storage of flammable gases should be of approved insulated cables type. In a pump room for pumping flammable gases, all electric apparatus and fittings should be flameproof conforming to IS:2148 and frames shall be earthed. Lamps should have flameproof glass fittings conforming to IS:2206 (Part1) . Portable hand lamps should have been approved by the CC (R.31). Classification of hazardous area in Zone 0, I & 2 (R. 31 A& B). Lighting should be of approved type, other wise no operation to be carried out during night (R.32).
- 158. Safety Certificate inthe prescribed proforma signed by a competent person should be furnished to the licensing authority (R.33). Chapter - IV : Transport (R. 34 to 44): This chapter is applicable for the transport of compressed gas by vehicles (R.34). Drawings of the vehicle and its special fittings should be got approved by the CC (R.35). Design considerations are given in rule 36 to 39. Protection of valves, accessories, piping, fittings, pumps and vessel are suggested. Mechanical, electrical and general design safety requirements arfe prescribed- Product should be marked on the vessel (R.40). Fire protection includes prohibition of smoking or carrying matches, lighters or any flammable substance (R.41). Driver should be a trained one. While loading/unloading presence of a competent person is necessary. Safe parking during overnight stop (R.42). A safety certificate in prescribed proforma signed by a competent person shall be furnished to the licensing authority before using any vehicle for such transport (R.43). The vehicle shall be maintained in a fit condition and examined every 6 months by a competent person and certified in a prescribed proforma (R. 44). Chapter-V (R. 45 to 64) is regarding Licences, Chapter VI (R. 65) for exemption. Chapter VII(R. 66 to 68) for Accidents and Inquires and Chapter VIII (R. 69) for powers of CC and subordinate controllers, of District Magistrates, the Police Commissioners and their subordinates. Accident should be reported to the CC (by Telegram and a letter within 24 hours) and forth with to the nearest police station. Appendices are as under : Appendix – I : Application to manufacture a vessel. . Appendix – II : Qualification and Experience of Inspector and Competent person. Appendix – III : Application for recognition as competent person. DOCK WORKERS (SAFETY, HEALTH & WELFARE) ACT, 1986: This Act (No. 54 of 1986) was enacted on 712-1986. It came into force from 15-4- 1987. It extends to the whole of India. It has 25 sections. It provides for the Safety, Health and Welfare of dock workers and for matters connected therewith. Definitions (S.2): Appropriate Government means, in relation to any major port, the Central Govt., and, in relation to any other port, the State Govt. Cargo includes anything carried or to be carried in a ship or other vessel. Dock Work means any work in or within the vicinity of any port in connection with loading, unloading, movement or storage of cargoes and includes preparation of ship or. other vessel and cleaning, painting, chipping of any hold, tank, structure or lifting machinery or any other storage area in board, ship or dock. Dock Worker means a person employed or to be employed directly or through any agency, on dock work.
- 159. Inspectors and theChief Inspector of Dock Safety (S. 3 to 8) : The appropriate Govt. can appoint them. They can enter any ship, dock, warehouse to check any dock work, make examination of the ship, dock, lifting machinery, cargo, gear, staging, transport equipment, premises etc, require documents, take evidence, copies, photograph, sketch, sample etc., hold inquiry into any accident, issue show cause notice relating to safety, health and welfare provisions, prosecute or prohibit any dock work in dangerous condition until measures have been taken to remove that danger. Inspector will not disclose information or complaint received by them. Appeal to the Chief Inspector should be made within 15 days. Other Provisions: The appropriate Govt. may constitute an Advisory Committee for advice regarding administration of this Act and the regulations (S. 9). It can also appoint a competent person to inquire into any accident or occupational disease to dock workers (S. 10). Dock workers will not misuse anything provided to secure health, safety and welfare of dock workers, will not do anything to endanger self or others and, will not neglect to make use of anything provided as mentioned earlier. Subjects of Regulations (S. 21): Regulations may provide for safety of working place, approaches, lighting, ventilation, temperature, fire & explosion prevention and protection, safe means of access, opening and closing of hatches and protection of dangerous openings, safety from fall, lifting and cargo handling appliances, workers employed in terminals, fencing of machinery, live electrical conductors, steam pipes, hazardous openings, staging, rigging and derricks, testing of lifting m/c, ropes, slings etc., escape routes, safe methods of working and handling dangerous substances or working in harmful environment, employing persons for handling cargo or any work on ship, transport of dock workers, precautions against noise, vibration and air pollution at workplace, protective equipment and clothing, sanitary, washing and welfare facilities, medical supervision, ambulance room, first-aid and rescue facilities, safety and health organisation,' training of dock workers, investigation of accidents, dangerous occurrences and diseases, forms of notices, authorities to be reported, submission of statement of accidents, man-days lost, volume of cargo handled and particulars of dock workers. Other Acts, Rules & Regulations for Dock Workers: DOCK WORKERS (SAFETY, HEALTH AND WELFARE) REGULATIONS, 1990: They came into force from 16-3-1990. They apply to major ports in India as defined in the Major Ports Act, 1963. They have 7 parts, 112 regulations, 14 forms and 4 schedules. Regulation 2 has 27 definitions including container, container terminal, conveyor, dangerous goods, dock, hatch, lifting appliance, loose gear, pulley block, responsible person, safe
- 160. working load, transportequipment etc. Reg. 3 is regarding power of inspectors. • Part 3 (Reg. 9-94) is on safety containing subjects of fencing, railings, staging, life savingappliances, illumination, fire protection, excessive noise, means of access, ladders, lifting appliances and gear, test and examinations, winches, ropes, heat treatment of loose gears, marking of SWL, pulley blocks, power trucks, hand trucks, fork lifts, dock railways, conveyors, handling of cargo, stacking and unstacking, cargo platforms, winch and crane operations, signaller, handling of dangerous goods, general precautions, explosive and inflammable cargo, broken or leaking containers, toxic solvents, fencing of terminals, stuffing and destuffing, fencing of motors, transport of dock workers by land .and water, reporting of accidents, notification of diseases, safety officers and renewal of licences. Part 4 (Reg. 95-99) is on Health containing provisions of cleanliness, drinking water, latrinesand urinals, spittoons and ventilation and temperature. Part 5 (Reg. 100-109) is on Welfare containing provisions of washing facilities, first aid boxes,ambulance rooms, shelters, canteens, medical examinations/notices and welfare officers. Part 6 (Reg. 110-118) is on Special provisions like statement of accidents, training, emergencyaction plans, safety committees, occupational health services and general safety. DOCK WORKERS (SAFETY HEALTH AND WELFARE) SCHEME, 1961: Under section 4 of the Dock Workers (Regulation of Employment) Act, 1948 this Scheme is formed. It came into force on 1-10-1961. It has 5 parts, 60 paras, 4 schedules and 2 forms. Para 2 gives 8 definitions including competent persons, dock, port authority etc. The scheme contains the provisions of - powers of inspectors, notice of accidents and dangerous occurrences, diseases, duties of port authorities, obligations of dock workers and provisions regarding health and welfare of dock workers. Part 4 on Safety (Para 22 to 57) contains provisions of fencing of dangerous places, gates, floor loading, stairs, means o escape in case of fire, testing, annealing, special gear, ropes, drivers of cranes, cargo platforms, conveyors, power trucks, and hand trucks, locomotives and wagons, stacking and un stacking, precautions against falling material, corrosive and caustic substances, dust fume, etc., oxygen deficiency, fumigated spaces, machinery, ladders, fire protection and rescue.
- 161. CHAPTER 5 SOCIAL SECURITYLEGISLATIONS WORKMEN'S COMPENSATION ACT, RULES & WORKED EXAMPLES WORKMEN'S COMPENSATION ACT, 1923: This Act (8 of 1923) came into force from 1-71924. It was lastly amended by the Act 46 of 2000 w.e.f. 08-12-2000. It has 4 chapters, 36 sections and 4 schedules. The Act is made to provide compensation for accidental injury to workmen. Under Sec. 4, while calculating compensation, maximum limit of 'monthly wages' to be considered is Rs. 4000/ - if monthly wages exceed Rs. 4000. Short summary is given below: The Act extends to the whole of India. A list of 'dependants' is given u/s 2(1) (d). Definitions (Sec. 2):
- 162. Definition of employeris very wide and includes his managing agent; legal representative of a deceased employer, contractor etc. 'Workmen' includes employees working in railway, ship, aircraft, motor vehicle, abroad or as in Schedule-11 wherein some 48 categories are specified. "Wages' excludes travelling allowance or concession, special expenses and contribution towards any pension or P.P. Partial disablement (temporary or permanent) and total disablement (temporary or permanent) are defined as same in the ESI Act and the W.C. Act. See part 7 also. Employer's Liability (Sec 3) : He is liable to pay compensation if accident arises out of and in course of employment He is not liable for injury - 1. If disablement lasts less than 3 days 2. If the workman takes drink or drugs, or 3. Willfully disobeys any order or a rule of safety, or 4. Willfully removes or disregards any safety guard or device provided for his safety, But he is liable even under such conditions if injury results in death or permanent total disablement. If a workman contracts any occupational disease (i) in Part-A of Schedule III or (ii) in Part B of Schedule III if he is in continuous service of more than 6 months or (iii) in Part C of Schedule III if he is in the service of one or more employers for such continuous period as may be specified, it shall be deemed to be an injury by accident arisen out of and in course of the employment and makes the employer(s) liable for compensation. The disease should be directly attributable to his employment. If a workman claims or agrees to take compensation under this Act, his suit for damages in a Civil Court is not maintainable [Sec 3(5)]. Amount of Compensation (Sec. 4): Type of Injury Amount ( a ) Death 50% of monthly wages X Relevant factor based on age (from Schedule IV) or Rs. 80,000/- whichever i s m o r e
- 163. . ( b ) Permanent totaldisablement 60% of monthly wages X Relevant factor from Schedule – IV or Rs. 90000/- whichever is more. ( c ) Permanent partial disablement 1 For injury in part II of Schedule I, such % of compensation payable in item (b) above as % of loss of earning capacity mentioned in Column-3. 2 For injury not specified in Schedule – J, such % of compensation payable in item (b) above as proportionate to the loss of earning capacity (permanent) certified by the medial practitioner. ( d ) Temporary disablement (total of Half monthly payment of the sum equivalent to partial) 2 5 % o f monthly wages till the ceasing of the disablement or 5 years whichever is shorter. In case of death, the funeral expenditure of Rs. 2500/- shall be deposited with the Commissioner. Maximum limit of 'monthly wages' is Rs. 4000/- in above calculation. Compare Schedule I and III of W.C. Act, Schedule II and III of ESI Act and the Schedule of the Personal Injuries (Compensation Insurance) Act, 1963. They seem to be similar. Penalty for late payment (Sec. 4A) :Compensation shall be paid as soon as it falls due. Jf it is paid after I month simple interest of 12% or maximum bank interest is payable. If delay is not justified, penalty up to 50% of the compensation is also payable. A show-cause notice to the employer is necessary before passing an order for penalty. The interest and penalty both shall be paid to the workman or his dependent, as the case may be. Distribution of compensation (Sec. 8) : Compensation payable in case of death, payable to woman or legally disable (e.g. minor) person, shall be paid through
- 164. Commissioner (Court) onlyand not directly. Direct payment shall not be deemed compensation. An employer can give advance up to 3 months' wages which is deductible and the Commissioner shall repay it to the employer. The Commissioner shall give receipt to the depositor, notice to dependant(s), make inquiry and if satisfied that no .dependant exists, he shall repay the balance to the employer. If the dependant is women or legally not eligible, the same may be investigated and mode of payment during non eligibility may be directed for the welfare. In other cases direct payment is possible. The Commissioner has power to change or amend his order for investment if satisfied with the reason. Others: Method of calculating 'monthly wages' is prescribed u/s 5. Half monthly payment can be reviewed u/s 6 and converted into lump-sum u/s 7. Compensation is protected and cannot be assigned, attached or charged (sec. 9). Claim is to be made within 2 years (sec. 10). Delay may be justified. A Commissioner can directly send a notice to an employer to furnish within 30 days information of death of his workman or his explanation (sec IOA). Reports of fatal accident or serious bodily injury shall be given to the Commissioner within 7 days (sec. IOB). An injured workman will not refuse to undergo medical examination, otherwise his compensation may be suspended for the period of his refusal, or for the period of his return if he has left the premises without examination. In case of a contract labour, the principal employer is liable if the contractor fails to pay compensation (sec. 12). Where any employer has entered into any contract with any insurer for liability to a workman, the insurer will pay to the workman as per liability accepted. The workman has to give notice to the insurer for his claim as soon as he becomes aware that his employer has become unable to pay (sec. 14). Compensation can become first charge on assets transferred by employer (sec. 14-A). Prescribed return is to be sent to authority u/s 16. Any contract or agreement of relinquishing right of compensation is null and void u/s 17. Maximum penalty for offences is Rs. 5,000/-, Limit of filing complaint is 6 months and sanction of commissioner is necessary for prosecution (see ISA). Special provisions are made for other workmen. Chapter-3 (sec. 19 to 31) is regarding Commissioners, their appointment, venue, power, appearance of parties, evidence, registration of agreements, appeals, recovery etc. Chapter-4 gives rule making powers to the State and procedure (sec. 32 to 36) Schedule I to 4 are regarding (1) Injuries and loss of earning capacity, (2) List of different, 48, workmen (3) List of Occupational Diseases and (4) Age factors to calculate compensation, respectively. THE WORKMEN'S COMPENSATION RULES, 1924: Under section 32 of the WC Act, these rules were notified on 26.6.1924. Deposit of compensation (Rules 6 to 10) : In a death case the compensation shall be deposited with Form-A and in other cases with Form-AA. The receipt will be in Form-B. The statement of disbursements to be given to the employer (by commissioner) shall be in Form-C. A dependant's application for order to deposit compensation shall be in Form G.
- 165. Deposit u/s 8(2)i.e. any sum more than Rs. 10/shall be in Form-D and its receipt shall be in Form-E. The Commissioner shall display a list of deposits received by him and invest for the benefit of dependants in Government securities or Post Office cash certificates or Post Office Savings Bank. Reports of Accidents (Rules II &. 12) : Report of accident u/s IOB shall be in Form EE. An employer can present a memorandum of inquiry of any accident. Medical Examination (Rule 13 to 18) : The employer shall arrange free of charge medical examination at his premises or at the workman's residence. Time will be between 6 a.m. to 7 p.m. if the workman does not consent to other time. A workman receiving half monthly payment will be examined at his residence and not more than twice in the first month or more than once in any subsequent month. After suspension of right to compensation, if the workman offers himself for examination, he shall be examined within 72 hours at the place and time fixed by the employer. Woman shall be examined by in presence of a female doctor. Others : Chapters 5 to 8 are for procedure, transfer, appointment of representatives and memorandum of agreement (Forms K, L or M and notice to party in Form-0) respectively. For figures of compensated injuries and amount of compensation paid under the WC Act see Table 5.11 of Chapter 5. See IS'.3786 for injury rates and accident classification (Part 9 & 10 of Chapter 5). Compensation for Occupational Diseases: Compensation for occupational diseases is payable u/s 3 of the Workmen's Compensation Act, 1923. Subsections (2 to 4) provide as under: 3.8 Contracting of the disease peculiar to the employment and specified in Part A, B & C of Schedule III (mentioned in foregoing part 7.2.4) is to be considered as an injury by accident arisen out of and in the course of the employment. 3.9 For Part A diseases, compensation is payable irrespective of any length of service as the incidence rate or possibility of such diseases is high and very obvious. 3.10 For Part B diseases, compensation is payable provided a service of 6 months is completed, as these diseases are very specific to certain chemicals and their incidence rate is slightly lower than that of Part A diseases. 3.11 For Part C diseases, compensation is payable, irrespective of length of service and even if the affected worker has worked under one or more employers, as these are lung diseases and their Effect is delayed i.e. visible after 5 to 10 years of service. 5. Compensation is payable for Part B & C diseases even after the cessation of the service. 3.9 For Part C diseases and for working under more than one employer, all the employers are liable to pay compensation in proportions decided by the W.C. Commissioner. 7 . For any other disease, if it is directly attributable to a specific injury by accident arising out of
- 166. and in thecourse of employment, the compensation is payable. 9. Compensation is not payable if any suit for damages is filed in the court or a suit for damages shall not be maintainable if a claim for compensation is filed before the W.C. Commissioner, or if any agreement is made between the workman and his employer to pay in accordance with the WC Act. - The doctor shall refer Schedule I while assessing percentage loss of earning capacity. 4 The maximum period of half-monthly payment for temporary disablement is 5 years, and wage limit of Rs. 4000 is not applicable in this case. 3. Worked Examples : Section 4 and Schedule I, III and IV are to be seen simultaneously. Monthly wage limit is Rs. 4000. For example, if death occurs due to any disease mentioned in Sch. Ill, payment should be as per section 4 (1) (a). Example I : A worker of 24 years (completed) and drawing monthly wages of Rs. 3800, dies due to any disease mentioned in Part A or C or any disease in Part B if his service is of more than 6. months, amount of compensation shall be 15. 0.50 x 3800 x 218.47 (Age factor) 16. 1900 x 218.47 = Rs. 4,15,093 or Rs. 8,000 whichever is more.. Note : If monthly wages are more than Rs. 4000 per month, consider Rs. 4000/- only for the purpose of calculation. Age factor is derived from Schedule IV based on completed years of age. Example 2 :A worker gets any of the permanent total disablement mentioned in Part I of Sch. I, due to occupational disease in Part III, and his age and monthly wages are 48 and Rs. 5600 respectively. Compensation will be 1.0.60 x 4000 x 159.80 2.2400 x 159.80 = Rs. 3,83,520 or Rs. 90000 whichever is more. Example 3 : A worker loses partial vision of one eye (item 26A, part II, Sch. 1) due to occupational cataract by infrared radiation (item II, Part B, Sch. Ill) at the completed age of 40 with monthly wages Rs. 6500. Compensation shall be 4. 0.10 x 4000 x 184.17 5.400 x 184.17 = Rs. 73668. Example 4 :A worker suffering from silicosis (e.g. any lung disease) - injury not specified in Sch. I, but certified by a doctor as '80% loss of earning capacity (permanent partial disablement)' at his age of 58 and monthly wages Rs. 9600, his compensation shall be 1.0.80 x 4000 x 124.70 2.3200 x 124.70 = Rs. 3,99,040. Example 5 : A worker's whole middle finger is amputated (item 31, Part II, Sch. 1) due to chrome ulceration and his lung damaged by 30% permanent partial disablement as assessed by the doctor, due to exposure to chromium vapors, and his age and monthly wages being 38 and Rs. 5600 respectively, his compensation shall be -
- 167. 5. For fingerdamage 0.12 x 4000 x 189.56 480 x 189.56 = Rs. 90988.80 6. For lung damage 0.30 x 4000 x 189.56 1200 x 189.56 = Rs. 2,27,472 Total Rs. 90988.80 + 227472.00 = Rs. 3, 18,460.80 Comparing with permanent total disablement [Sec 4(1) (C), Explanation - 1] 19. 0.60 x 4000 x 189.56 20. 2400 x 189.56 = Rs. 4, 54,944 or Rs. 90000 whichever is more. As amount Rs. 318460.80 does not exceed Rs. 454944, total compensation payable in this case is Rs. 318460.80. Example 6 :A worker worked in three sugar mills in a continuous period of 16 years and it was detected that he was suffering from bagassosis due to sugarcane dust. This was found at his age of 45 and monthly wages Rs. 7800. The lung damage (permanent partial disablement) assessed by a doctor is 50%. Calculate the compensation payable by each, of the three employers. Compensation 4.0.50 x 4000 x 169.44 5.2000 x 169.44 = Rs. 338880 As per Section (2-A), each employer may pay Rs. 338880/3 = Rs. 112960 to the worker, or in the proportion decided by the WC Commissioner depending on the facts of his case. The employer in whose sugar mill suppose the dust concentration was higher or for longer duration, may be directed by the Court to pay more proportion of the total amount. Example 7: A worker while handling organo phosphorous compound, undergoes toxic effect and remains absent for 3 months as per medical finding of this cause and advice. To what compensation he is entitled for this temporary disablement? He is drawing Rs. 4500 per month. As per Section 4 (1) (d), he is entitled to a half monthly payment of 25% of his monthly wages i.e.. 0.25 x 4500 = Rs. 1125 from the 16th day from the date of disablement. Here ceiling of Rs. 4000 per month is not applicable. It is applicable to death or permanent total disablement only [Explanation II to Sec 4 (1)].
- 168. EMPLOYERS' LIABILITY ACT,1938 This Act (24 of 1938) came into force from 249-1938. It was lastly amended by an Act 51 of 1970. It is a small Act of five sections only. Its preamble declares that certain defences shall not be raised in suits for damages in respect of injuries sustained by workmen. It extents to the whole of India and applies to all employers including contractors and agents who employ workmen-(including apprentice) under a contract which is express or implied. Defence of common employment barred : Where personal injury is caused to a workmen because of the act or negligence or omission of the employer or of any person in service of the employer and acting in obedience or performing duty by the workman, a suit for damages by the injured workman or by his legal representative in case of his death, shall not fail by reason only of the fact that the workman was in the service (duty bound to do so and in common employment or he has accepted that risk) of the employer at that time. Any term in contract of service or apprenticeship that excludes or limits liability of the employer in respect of personal injury caused to the workmen or apprentice by the negligence of persons in common employment with him, shall be void. In any such suit for damages, it shall not be presumed that the workman undertook the risk attaching to the employment unless the employer proves that the risk was fully explained to and understood by the workman and that the workman voluntarily undertook the same. This Act gives support to the claim (damages) of the worker in civil suits. Plea of the employer of 'contributory negligence by the worker or his knowingly acceptance of the risk as an integral part of his employment' is prohibited and this defence is not permitted for him. Though after fully amending ESI Act and WC Act and covering large scope of injuries and compensation, utility of this Act is diminished. EMPLOYEES' STATE INSURANCE ACT & RULES THE EMPLOYEES' STATE INSURANCE ACT, 1948: This Act No. 34 of 1948 (in force from 31-31948) was modified in 1950,1956 and 1957 and amended in 1951, 1966, 1970,1975,1984 and 1989. It has 8 Chapters, 100 Sections and 2 Schedules. Chapter 4 of contributions and Chapter 5 of Benefits are more important. Preliminary (Sec. 1) : The Act applies to the whole of India and to all factories other than seasonal factories. It can be applied to establishment industrial, commercial, agricultural or otherwise with six months' notice. Once the Act applies it shall continue even if the number of employees falls below the limit or the manufacturing process (with power)
- 169. ceases. Definitions (Sec. 2): Contribution means the sum of money payable to the ESI Corporation by the principal employer in respect of an employee and an amount payable by or on behalf of the employee. Dependent includes many relatives as prescribed by Sec.2 (6-A). Employment injury means an injury to employee caused by accident or occupational disease arising out of and in course of his employment (insurable) whether the accident or disease takes place within or outside India. Employee includes direct, contract or hired persons at main factory or establishment or its department, branch or a place for sale/purchase and also an apprentice (not under the Apprentices Act, 1961). His wage limit (excluding overtime wages) be prescribed by the Central Government. Family is defined u/s 2(11) Permanent partial disablement means such disablement of a permanent nature as reduces the earning capacity of an employee in every employment which he was capable of undertaking at the time of the accident resulting in the disablement (All injuries in Part II of the 2nd Schedule). . Permanent total disablement means such disablement of a permanent nature as incapacitates an employee for all work which he was capable of performing at the time of the accident resulting in such disablement (All injuries in Part I of the 2nd schedule or from combination of injuries in Part II thereof). Temporary disablement means a condition which requires medical treatment and makes the employee temporarily incapable of doing the work which he was doing prior to the time of injury. Wages includes all remuneration except contribution to any pension fund or provident fund or under this Act, travelling allowance, gratuity and special expenses. Corporation's Power for Health Measures (Sec. 19) : The Corporation may, in addition to the scheme of benefits, promote measures for the improvement of health and welfare, rehabilitation and reemployment of insured persons from the funds of the Corporation. Purposes of the ESI Fund (Sec. 28) : (5) Payment of benefits and medical treatment to insured persons and their families. (6) Expenditure of hospitals, dispensaries, medical and ancillary services for the insured persons and their families. (7) Contribution to State Govt., local authority or any private body or individual towards cost of medical treatment to insured persons and their families, including cost of building and equipment. = Expenditure for improvement of health, welfare, rehabilitation and re-employment of
- 170. insured or injuredpersons. = Payment of fees, salaries, allowances of the members, officers and staff. = Payment of cost of auditing accounts, courts set up under the Act, contract and cost of any legal or court proceedings. Contributions (Chapter- 4, Sec. 38 to 45-1) : Two types (i) Employer's contribution and (ii) Employee's contribution. Rates may be prescribed by the Central Government. Payment becomes due on the last day of the wage period. Interest 12% p.a. or more for the late payments. It is recoverable as an arrears of land revenue. The principal employer shall pay both the contributions and can recover from the employees or their immediate employer (e.g. contractor) their part. Register of- employees, contributions necessary and returns are also required. ESI Inspectors have powers to visit factories, establishments etc. and to ask any principal or immediate employer to furnish necessary information, account books, records etc. regarding employment of persons, payment of wages etc. and can make copies also for the purposes of this Act. Benefits (Chapter-5, Sec. 46 to 73 1) : Insured persons, their dependants or other persons mentioned can get following benefits under the Act and no similar benefits under any other Act. Though they can get similar benefits available under service conditions, customary concession, sickness leave, motor accident claims under the Motor Vehicles Act and damages/compensation for injuries due to the negligence of the employer (Judgements). 1 . Sicknessbenefit : Periodical payments for sickness certified by a Doctor. Eligibility, rates and conditions may be prescribed by the Central Government. (2) MaternityBenefit : Periodical payments to an insured woman in case of confinement, misscarriage, sickness due to pregnancy, premature birth etc. on medical certificate. Eligibility, rates, period and conditions may be prescribed by the Central Government. (3) Disablementbenefit : Periodical payment to an insured person for disablement due to employment injury and certified by a doctor. For temporary disablement of more than 3 days (excluding the day of accident) and For permanent disablement - total or partial - this benefit is available at the rate, period and condition prescribed by the Central Government. An accident shall be presumed as arisen in course of employment, in the absence of evidence to the contrary. Benefit is available for accident happening while acting inbreach of regulation or while travelling in employer's transport or while meeting emergency and acting for the employer's trade or business. 3.77 Dependants'benefit : Periodical payments to the dependants of an insured person who dies due to employment injury. The rates, period and conditions may be prescribed by the Central Government. 3.78 Medicalbenefit : Payment for medical, surgical and obstetric treatment for and
- 171. attendance on insuredpersons, by the State Government or the Corporation. 3.79 Funeral expenses.: Payment to the family member or any other person who actually incurs The claims should be made within 3 months of the death of the insured person. Occupational Disease as an Employment injury : Contracting of any disease mentioned in the Third Schedule and in its Part A -without any period in that employment, Part B - for working more than 6 months in that employment, or Part C -for working such period as the Corporation specifies, Shall be deemed to be an "Employment injury arising out of and in the course of employment". Any question regarding permanent disablement or proportion of loss of earning capacity or any such assessment, shall be determined by a Medical Board. An appeal against the decision of the medical board may lie with the Medical Appeal Tribunal. Both the Board and the Tribunal can review their decisions if satisfied by fresh evidence. The corporation may, with the approval of the State Government, establish and maintain in the State hospitals, dispensaries, medical and surgical services for the benefit of the insured persons and their families. The right to receive any payment of any benefit is not transferable or assignable. Disablement benefit cannot be commuted for a lump sum amount. Sickness or disablement benefit for temporary disablement cannot be availed if the employee works on that day (of claim) or remains on leave or on a paid holiday or on strike. Recipient of sickness or disablement benefit will observe conditions to remain under medical treatment at a place provided under this Act, to carry out medical instructions, not to leave the area, to allow himself for medical examination and not to do anything which may retard chances of recovery. An insured person cannot get for the same period (a) both sickness and maternity benefit or (b) both sickness and temporary disablement benefit or (c) both maternity and temporary disablement benefit. When a person is entitled to more than one such benefits, he has to choose any one benefit. The corporation has right to recover where a principal employer fails or neglects to pay any contribution, or any amount for excessive sickness arised due to in sanitary working conditions or not observing any health regulations. If any person receives any benefit unlawfully, he shall be liable to repay to the corporation that amount. If any person dies, any cash benefit payable to him shall be paid to his nominee/representative upto and including the day of his death.
- 172. No employer canreduce wages or benefits payable by him under service conditions because of the benefits conferred by this Act. No employer can dismiss or punish employee during period of sickness, maternity, temporary disablement or certified illness etc. Notice of dismissal, discharge or reduction during such period shall be invalid or inoperative. A person who misuses the benefit given under this Act, will be disentitled by the Central Government after giving him an opportunity of being heard. Miscellaneous (Sec. 87 to 100) : The Government has power of exemptions. Rule making powers lies with the Central as well as the State Governments. The Corporation has power to make regulations. For their subjects see sections 95 to 97. THE EMPLOYEES' STATE INSURANCE (CENTRAL) RULES 1950: They came into force from 22-6-1950. The Chapter-6, sections 47 to 62 are important as they provide further details on the subject of provident fund, wage limit, rates of contribution and benefits. Their summary is as under: P.F.: The Corporation shall establish, maintain, and contribute to the "ESIC Provident Fund" for insured employees. It shall form a committee and regulations for its working. Contribution period and Benefit period : They are prescribed as under : Contribution Period Corresponding Benefit Period 1st April to 30th Sept. 1st January to 30th June of the year following 1st Oct. to 31st March of the year following 1st July to 31st December Incase of a person who becomes an employee for the first time, the first contribution period for him will begin from the date he enters into insurable employment in the contribution period current on that day (i.e. the date of employment) and his corresponding benefit period will begin on the expiry of nine months from the date of such employment. Wage Limit for Coverage : Up to Rs. 10000/ - p.m. w.e.f. 1-4-2006. Rates of Contribution : Employer's contribution 4.75% of the wages payable to an employee. Employee's contribution 1.75% of his wages (w.e.f. 11-1997). An employee whose average daily wage is upto Rs. 50/- is exempted from paying his contribution though the employer's contribution in respect of such employee, shall continue (News, 7-9-97). Standard benefit rate : As per Table, u/r 54. Revised with 18 entries w.e.f. 1-1-1997. Sickness benefit : It is available if the contribution is paid for 50% of days of the contribution period. For the first two days of sickness the benefit is not available. For maximum 91 days in any two consecutive period the benefit can be available. Payment rate
- 173. is the standardbenefit rate u/r 54. Maternity benefit: At least 70 days contribution during preceding two consecutive contribution periods make the insured women eligible for this benefit. For maximum 12 weeks the benefit is available. Medical proof is necessary. Payment rate is twice the 'standard benefit rate' u/r 54. Disablement benefit: It is available for the disablement period of more than 3 days (excluding the day of accident) and for the whole period of permanent disablement or for life. Daily rate of payment shall be 40% more than the standard benefit rate u/r 54, and this rate shall be called the "full rate". For temporary and permanent total disablement, full rate is available, but for permanent partial disablement from injury specified in Part II of the 2nd schedule, at such percentage of the full rate and for injury not specified in that schedule, at proportionate to the loss of earning capacity (assessed by the medical certificate) the benefit will be available. Dependants" benefit: To widow 3/5 of the full rate (till life or remarriage), to son 2/5 of the full rate (until he attains 18 years age), to unmarried daughter 2/5th of the full rate (until the age of 18 years or marriage whichever is earlier). If no widow or children, then, to a parent or grand parent for life 3/ 10 of the full rate, to any other male dependent till his age of 18 and to any other female dependent till the age of 18 or marriage, whichever is earlier or if widowed, until her age of,18 or remarriage whichever is earlier at 2/10 ofthe full rate. Total rate shall not exceed full rate and the amount shall be equally divided among the dependants. Funeral expenses: Rs. 2500/- from 1-10-2001. 1. The Employees' State Insurance (General) Regulations, 1950 : The corporation has made u/s 97, these regulations, w.e.f. 17-10-1950 to provide further details. Some summary is given below: Provisions of identity card, family identity care Inspector, Insurance Medical Officer, Insurance Number, local office, regional office, regional director local committees are explained. Registration of factories, establishments and families is required. Return of contributions, in Form No. 6, in 4 copies is to be sent to the ESI office Contributions should be paid within 21 days of the last day of the month in which it fall due. In case of permanent closure, it should be paid on the last. day of closure. For late payment, interest at 15% p.a is payable. In addition to this, damages are also payable as under: N o . Delay Period % P.A. damages 1 . Upto 2 months 3 2 . 2 to 4 months 10 3 4 to 6 months 15
- 174. . 4 . 6 monthsand above 25 Register of employees should be in Form-7. Benefits (Chapter 3, Regulation 44 to 95E) :For any benefit, proper claim form should be filledin Claim becomes due from the date of medical certificate and it shall be certified by the Local Office, which can ask further evidence also. Medical certificate from Insurance Medical Officer is necessary. Benefits (first payment) are payable as under N o . Ty pe To be paid within 1 . Sickness benefits 7 days 2 . Funeral expenses 15 days 3 . Maternity benefit 14 days 4 . Temporary disablement 30 days 5 . Permanent disablement 30 days 6 . Dependant’s benefit 90 days Disablement Benefit :An employee will inform employer about accident to him. Employer willrecord it in an Accident Book in Form No. 15 and will report to die Local Office in Form No. 16 within 24 hours. For occupational disease specified in 3rd schedule no such notice is necessary but information required by the Local Office shall be given. Employer shall arrange for the first aid. Dependants benefit :Death of an insured person is to be reported immediately to the LocalOffice and his body shall be disposed of 'after examination (and post-mortem if necessary) by Insurance Medical Officer or other Medical Officer. Death certificate in Form 17 shall be issued to the dependants. Claim for dependants' benefit will be submitted in Form 18 to the Local Office, with documents and proofs prescribed u/r 80. Maternity Benefit :An insured woman will give notice in Form 19 and pregnancy certificate inForm 20 to the Local Office. Other Forms 21, 22, 23 are also required as per Reg. 88. She may loose benefit if refuse for medical examination by a female doctor or midwife. Funeral expenses: Death certificate in Form 15 and claim Form 25-A are prescribed. Medical benefit :A person receiving disablement benefit can also get medical benefit. Thisbenefit is available after payment of contributions for 50% days of the contribution period and for a period of 3 months if he is continued in the service for 2 months or more.
- 175. Some 28 formshave been prescribed under these Regulations. For .figures of number of factories and employees covered and benefits given under the ES. Act see Table 5.13 and 5.14 of Chapter-5. Criticism : This ESI scheme logically and theoretically seems beneficial for well being of theworkers but in its practice of more than 45 years it has gained heavy criticism because of its 1. Poor administration. 2. Incapacity to provide speedy service to thousands of workers and their families. 2. Insufficient hospitals, dispensaries, doctors, facilities and staff. 3. Rude and rigid behaviour with workers who need love and affection. 4. Complexity of forms and procedure. 5. Hardship to workers in going to limited centres and at a longer distance. 6. Poor quality of medicines and treatment. 7. No real interest in worker's welfare 'and referring him here and there. 8. More stress in collecting money than 'disbursement of benefits to workers. 9. Profit making attitude instead of charitable. Because or above factors not only employers out employees and their trade unions have also opposed this scheme and resisted against its forceful application. Insured employees prefer to go to private doctors and hospitals for better treatment. They are loosing faith from ESI doctors, their treatment and medicines. Only poorer workers go there under compulsion. As per one news report of 25-8-1997, even after raising the eligibility wage limit from. Rs. 3500 to Rs. 6500 per month and similar increase in employers' contributions there is no improvement in ESI medical services. On the contrary the condition is deteriorated. Despite of increase in number of employees and income of the Scheme, strength of doctors is reduced. In 1995 there were 3160 doctors which reduced to 3076 in 1996. In 1991 there was, one doctor per 2127 members While in 1996 that proportion was one doctor per 2374 members! The Government gives subsidy also. Even then the service is not satisfactory. It is suggested in this report that the Government should give Health Insurance Policies to the members to make the Scheme more meaningful. In another press-note of Financial Express dated 4-9-97, it is confessed that many States are giving less importance to the Scheme and the Corporation has become a silent spectator and the quality of the Scheme has gone down. The Central Administration is unable to pay full attention and therefore it is, now, decided to establish State Corporations under the control of the Central ESI Corporation. Where ESI scheme is made applicable, a trend is noticed of increase in accidents. This may be due to a wrong approach of workers' to take benefit of accident leaves. This again adds to the loss of national production. ESI authorities and corporation has to find and apply remedial measures to above
- 176. problems. Expansion of infrastructure,HRD training to doctors and staff, loving and charitable attitude, less contribution and higher benefit utilising full income, better hospitals, nice dispensaries, good facilities and speedy service can certainly change its present scenario.
- 179. International Labour OrganizationStructure Cooperation between government and employers and workers organisations is important for working with ILO. The ILO accomplishes its work through three main bodies, which are as follows: 1. International Labour Conferences ( ILC ) : ILC is the Policy-making organ of the ILO it comprises of 4 representatives representing governments, employers and workers in the ratio 2:1:1. ILC holds its sessions once in a year Delegates to this session may be accompanied by advisory not exceeding two for each item on the agenda. Delegates have the right to choose the committee, they have wished to serve and once registered a member of a committee, they have the right to speak and to vote. Because of this voluntary selection of committee, the representation of groups on any particular committee may not be equal. Consequently, when votes are taken the voting of each group is ‘’weighted’’ so that the total voting power of each of the three groups is equal. Each committee elects its own officers –a chairperson and a worker and employers vice chairperson. Just as with the Conference as a whole government. Workers groups and employers groups within the committees hold their own separate meeting to discuss their views of the matters of agenda. Observer from trade union organisations with a special knowledge of the subject Participates in the worker’s group it has become the tradition that one such observer is elected secretary of the group and , is informally recognised as having a special position in the plenary sessions of the committee. These committees are: 1. The Credential Committee. 2. The Selection Committee. 3. The Resolution Committee. 4. A Committee for the application of Conventions and Recommendations; 5. The Drafting Committee. 6. The Committee on Standing Order. 7. The Finance Committee. Functions of ILC:
- 180. i. To formulateInternational Labour Standards. ii. To fix the amount of contribution by the member states. iii. To decide the expenditure budgeted estimate proposed by the Director-General and submitted to the Governing Body. iv. To make amendments to the constitution subject to subsequent ratification of the amendment by 2/3 member states including 5 of the 10 states of industrial importance. v. To consider the report of the director General giving labour problems and assists in their solution. vi. To appoint committees to deal with different matters doing each session. vii. To select once in 3 years members of the Governing Body. viii. To elect its President. ix. To seek an advisory opinion from the International Committee of justice. x. To confirm the powers, functions and procedure of Regional Conference. 2. Governing Body: It is the Principal organ of the ILO. It is ow political non-political parties body. It implements decisions of the ILC with the help of the International Labour Office , Out of the 56 members in it, 28 represent the governments, 14 employers and 14 labour India is one of the ten states of chief Industrial importance, The tenure of office of this body is 3 Years it meets several times a year to take decisions on the programmes of the ILO. Functions of Governing Body Functions of Governing Body are as follows: i. To coordinate work of the organisation, ii. To prepare agenda for each session and subject to the decision of the ILC to decide what subject should be included in the agenda of the ILC. iii. To appoint the Director General of the office. iv. To scrutinise the budget. v. To follow up the implementation of the conventions and recommendations adopted by the ILC by member states. vi. To fix the date, duration and agenda of the Regional conference. 3. International Labour Officer: This is the third major and important organ of the ILO. The Director- General of the ILO is the Chief Executive of the secretariat. He is appointed by the Governing Body. His tenure is for 10 years and his term may be extended by the Governing Body. Functions of International Labour Office:
- 181. i. To preparedocuments on the times of the agency for the conference. ii. To assist governments informing legislate on the basis of the decisions of the ILC. iii. To carry out its functions related to the observance of the conventions. iv. To bring out publications dealing with industrial labour problems of international interest. v. To collect and distribute information of international labour and social problems. Impact of ILO on Labour Welfare in India Labour class is defined one of the classes most vulnerable to exploitation if not the most. Most of the labour laws in India are pre-constitutional. The concept of Fundamental Rights was introduced by the Constitution. Although most of the pre- constitutional laws have been replaced or curtailed following the Doctrine of Eclipse and Doctrine of Severability, not a lot of changes had to be made to the labour laws that were well passed before the Constitution. The success of these labour laws must be attributed to the ILO, as the guidelines issued by the ILO were formed the principles on which laws were drawn. By observing the passage of Labour Laws in India ,through the various amendments, it is evident that the ILO did have a great impact on the Labour Laws in India. IOL CONVENTION AND RECOMMANDATION CONCERNING OCCUPATIONAL HEALTH AND SAFETY LIST OF IMPORTANT CONVENTION CONVENTION NO SUBJECT YEAR 45 UNDERGROUND WORK(WOMEN)CONVENTION 1935 77 MEDICAL EXAMINATION OF YOUNG PERSON (INDUSTIAL OCCUPATIONAL) 1946 78 MEDICAL EXAMINATION OF YOUNG PERSON (NON INDUSTIAL OCCUPATIONAL) 1946 115 RADIATION PROTECTION CONVENTION 1960 120 HYGINE CONVENTION 1964 124 MEDICAL EXAMINATION OF YOUNG PERSON (UNDERGROUND WORK ) 1965 130 MEDICAL CASE & SICKNESS BENEFIT CONVENTION 1969 139 OCCUPATIONAL CANCER CONVENTION 1974 148 WORKING ENVIRONMENT (HIV, NOICE, VIBRETION) 1977
- 182. 152 OCCUPATIONAL SAFETY& HEALTH CONVENTION (DOCK WORK) 1979 155 OCCUPATIONAL SAFETY & HEALTH CONVENTION 1981 161 OCCUPATINAL HEALTH SERVICE CONVENTION 1985 162 ASBESTOS CONVENTION 1986 167 SAFETY & HEALTH IN CONSTRUCTION CONVENTION 1988 170 CHEMICAL CONVENTION 1990 171 NIGHT WORK CONVENTION 1990 174 PREVENTION OG MAJOR INDUSTRIAL ACCIDENT 1993 176 SAFETY & HEALTH IN MINES 1995 184 SAFETY & HEALTH IN AGRICULTURE CONVENTION 2001 187 PROMOTIONAL FRAMEWORK FOR OCCUPATIONAL SAFETY & HEALTH CONVENTION 2006 LIST OF IMPORTANT RECOMMENDATION RECOMMENDATION NO SUBJECT YEAR 156 WORKING ENVIRONMENT (AIR POLLUTION, NOISE & VIBRATION ) 1977 164 OCCUPATIONAL SAFETY & HEALTH 1981 171 OCCUPATIONAL HEALTH SERVICE RECOMMENDATION 1985 172 ASBESTOS RECOMMENDATION 1986 175 SAFETY & HEALTH IN CONSTRUCTION 1988 177 CHEMICAL RECOMMENDATION 1990 178 NIGHT WORK RECOMMENDATION 1990 182 PREVENTION OF MAJOR INDUSTRIAL ACCIDENT 1993 183 SAFETY & HEALTH IN MINES 1995 192 SAFETY & HEALTH IN AGRICULTURE 2001 194 LIST OF OCCUPATIONAL DISEASE 197 PROMOTIONAL FRAMEWORK FOR OCCUPATIONAL SAFETY & HEALTH 2006
- 186. CHAPTER -1 MACHINEOPERATION AND GUARDING MACHINE GUARDING: - Machines are dangerous because they are designed to change the shape and form of materials which human strengthcannot do. Whenever man and machine meet, the possibili ty of accident is always there. Foran accident to take place of a machine the part of a person must be in the danger area and the dangerous part of machinery must make a motion. The aim of machine guarding is that these two things do not take place at the same time. In other words, a machinery guard is a barrier or device to prevent a person or his clothing coming in contact with the dangerous parts of machinery. Generally, it is aiding that 85% industrial accidents are due to human failure. So, on the face value we can say that all that needs to be done is to eliminate those unsafe acts. But human nature is unpredictable and we cannot rely upon, he skill and expertise of the operator working on a machine. Physical, mental and emotional variances cause different people to perform differently in the same environment, and the same individual acts differently at different times under the same set of conditions. SO, it is always better to eliminate unsafe conditions which are a positive permanent gain.
- 187. ERGONOMICSOFMACHINEGUARDING: Many a timeaccident had taken place on machines although the guard was there. This meant that the guards were not effective and wore not functioning for the purpose for which they were installed. There may be some fault in the design or operation. The following points should be considered i" the design of the guard: - It should provide positive protection and prevent all the access to the danger zone during operation. It is not enough for the guard to give only a signal or an alarm to warn. It should not cause discomfort or inconvenience to the operator. It should not unnecessarily interfere with production. It should work with minimum effort. It should be suitable for the job and the machine. It should not weaken the structure of the machine. This may arise when guards are not incorporated in the original design and are provided later on.
- 188. It should bedurable and resist normal wear and shock and should require minimum maintenance. It should not constitute a hazard by itself. Splinters, sharp corners, rough edges, traps between the guard and the moving part which it is guarding should be avoided. As the main function of the guard is to prevent a person coming in contact with moving parts of the machine, data based on human measurements is very important for proper design of the guards. A person can reach upwards, over, into, around and through. Upward reach A dangerous part which is beyond an upward reach of 8'6" is regarded as position ally safe in the absence of conditions to the contrary Reach over Carriers a) If the barrier is low, body can be bent and reach will be longer than the length of the arm. b) If the barrier is at armpit, reach is equal to length of the arm. c) If the barrier is above shoulder height, reach is equal, to length of the forearm. d) If the barrier is still higher, reach is equal to the length of the hand or fingers. Reach into pits Height of the- side of the hoppers etc. determines the extent of reach. Reach around Barriers Reach is interrupted by the elbow joint or by the wrist depending upon the- length of the side of the barrier and Position of the man in relation to the barrier. Reach into openings admitting fingers or hand a) No reach is possible through openings less than 1 cm x 1 cm. b) If opening admits one, two or three fingers, reach is restricted to maximum length of the largest finger.
- 189. c) If openingadmits four fingers, then size and shape of the opening will be an important factor in determining the extent of reach. d) If opening admits four fingers and the thumb, reach is limited by - i) thickness of the hand ii) thickness of the wrist iii) thickness of the arm at various points. If theopening is with parallel sides, maximum safe opening = in (6mm.) + 1/8 distance of the guard from danger point.The following table gives safe opening at various distances from danger point. Distance (in mm) Opening (in mm) 0 - 40 40 - 65 65 - 95 90 - 140 140 - 165 165 - 190 190 - 320 320 -400 400 - 450 450 - 800 6 10 12 15 20 22 30 40 50 55 Over800 150 maxes It must be borne in mind that actual physical check must be made to see that the opening is safe. The minimum distance of the guard from danger line for 6 mm deep opening should be 6 mm. In case of rolls instead of considering the point of contact of the rolls are danger line, a 10 mm. nip zone should be considered as danger line.
- 190. Other Devices Many atime a large number of machinery accidents can be avoided by the use of incidental safety devices. These devices arc- not guards but they help to do certain operations without any chance of part of the body coming in contact with the moving parts. Examples are: Use of tongs and vacuum feeding devices for power press. Striking gear for shifting bolts from fast to lose pulley and vice versa Non-repeat device on a power press which does not permit the second stroke even if the pedal is kept depressed. Emergency stops on machines. DANGEROUS PARTS OF MACHINES These can be divided into three broad groups: (1) Point-of-Operation. (2) Transmission machinery. (3) Other dangerous parts. These parts cause injury due to their rotary or reciprocating movement and their cutting and shearing action. Sometimes safety can be achieved by design and construction. The hazards can be completely eliminated or severity of injury can be reduced. In other cases, suitable guards can protect against direct contact with the moving parts, work in process and against any mechanical or human failure.
- 191. TYPES OF GUARDS:- Fixed Guard:One of the most effective method of machine guarding, to date has been to fix some kind of barrier around the dangerous area. A fixed guard provides the highest standard of protection and should be used as far as practicable where access to the danger area is not required during normal operation of the machinery. Interlocking Guards: When a process demands access to the danger are and fixed guard is impracticable the provision of interlocking guard should be considered. The interlocking system may be either mechanical or electrical f a combination of both the guard must safe guard the dangerous parts before the machine can be operated maintain the guarding till the dangerous parts have come to rest and only then the safe guard can be removed Automatic Guard: Where neither fixed nor interlocking guard is practicable, automatic guard can be used. This guard physically removes from the danger area, any body part of a person. This guard can be used only where there is adequate time for physical removal from the danger area to take place without introducing any further danger. Trip Guard: On machines which are normally in continuous motion where hands or other parts of a person have temporally to enter a space swept by the dangerous parts or where entanglement in an article or material being fed can occur, trip guard can effectively be used. The guard is so arranging that an approach by a person beyond a safe limit causes the guard to actuate the tripping mechanism to stop the machinery or reverse its motion. The tripping device may be a mechanical or photo-electric or an infra-red device. Two Hand Control: Where guarding is impracticable, two hand control offers a means of protection, as both the hands of the operator are kept engaged away from the danger area. If more than one person is to work on a machine, two hand control devices should be provided for each operator and unless all the operators operate their device together the machine should not start.
- 192. Fencing of Machinery(Guards) Every moving part of prime mover Every flywheel connected to prime mover Headrace & tailrace of every water wheel & water turbine Any part of stock-bar which project beyond the head stock of lathe Every part of an eclectic generator, a motor, or rotary converter Every part of transmission machinery Every dangerous part of any other machinery ---------------------------- shall be securely fenced by safeguards of substantial construction. Wood Working Machinery - (Wood Working Machinery means a circular saw, band saw, planning machine, chair mortising machine or vertical spindle moldings machine operating on wood or cork. Circular Saw means working in a bench which is moved towards the wood for cutting operation. Band Saw means a band saw, the cutting portion of which runs in vertical direction. Planning Machine means a machine for overhead planning or for thickening or for both operations). An efficient stopping and starting device shall be provided on every wood-working machine. Every circular saw shall be, fenced as follows: Behind and in direct line with the saw there shall be an arriving knife, which shall have smooth surface, shall be strong, rigid and easily adjustable. The distance between the front edge of the knife and the teeth of the saw shall not exceed 10mms. For a saw having dia. of <60cms, the knife shall extend upwards from the bench table to within 25mms. of the ton of the saw, for a saw having dia. of 60cms or over, shall extend upwards from the bench table to a height of at least 22.5 cms. The top of the saw shall be covered by a strong and easily adjustable guard, with a flange at the side of the saw-farthest from the fence. The part of the saw below the bench table shall be protected by two plates of metal one on each side of the saw. Such plate shall not be more than 15cms apart and shall extend from the axis of the saw outwards to a distance of not less than 5cms. beyond the teeth of the saw. Push Sticks - A push stick shall be provided for use at every circular saw and at every vertical spindle molding machine.
- 193. Vertical Spindle MoldingMachine - The cutter of every vertical spindle molding machine shall be guarded by the most efficient guard. Planning Machine - shall net be used for overhead planning unless it is fitted with a cylindrical cutter block very planning machine used for overhead planning shall be provided with a "bridge" guard capable of covering the length and breadth of the cutting slot in the bench. The feed roller shall be provided with efficient guard am Mortising Machine - The chain of every Chain Mortising Machine shall be provided with a guard which shall enclose the cutter. Rubber and Plastic Mills - (Rubber and Plastic Mills means machine with rollers used in breaking down, cracking, washing, grating, mixing, refining and warming of rubber and plastics. A calendar means machine with rolls used for fractioning, sheeting, coating and breading of rubber compounds and plastic or plastic compounds). Rubber and Plastic Mills shall be equipped with Hoppers so guarded that it is impossible to come into contact in any manner with the nip of rolls. Safety- trip rods shall extend across the entire length of the face of the rolls and shall be located not more than 170 cm above the floor or working level. Colander machines shall be equipped with Horizontal Safety- trip rods across both front and rear, which will when pushed or pulled operate instantly, to disconnect the power and apply the brakes or to reverse the roll Injunction MoldingMachine - An electrical interlock arrangement shall be provided so that the mould cannot be closed unless the front safety gate is fully closed and on opening the front safety gate, the molds will stop automatically Centrifugal Machines - (Centrifugal Machine includes centrifugal extractors, de extractors, separators and driers). Centrifugal Machines shall be provided with efficient interlocking devices that will physically prevent the lids from being opened while the rotating drums or baskets are in motion under power and would also prevent the starting of the drums or baskets under power while the lids are open. Centrifugal Machines shall not be operated at a speed in excess of the manufacture's rating.
- 194. All Centrifugal Machinesshall be provided with effective braking arrangement to bring cage, drum or basket to rest within short period of time after the power if. cut off. The cages, drums or baskets shall be thoroughly examined by a competent person regularity to check their balance. Sheared, Slitters and Guillotine Machines - (Shears, Slitters and Guillotine Machines means a machine, whether driven by power or otherwise, equipped with a straight blade operating vertically against a resisting edge and used for shearing metals or non-metallic substances). A barrier metal guard shall be provided at the front of the knife, fastened to the machine frame and shall be so fixed as would prevent any part of the operator's body to reach the descending blade from above, below or through the barrier guard or from the sides. At the back end of such machines, an inclined guard shall be provided over which the slit pieces would slide and be Elected at a safe distance in a manner as would prevent a person at the back from reaching the descending blade. Sitting Machines - (Slitter or Slitting Machine means a machine equipped with circular disc- type knives and used mg or cutting into metal or non-metallic substances or slitting them into narrow strips) Circular disc-type knives shall be provided with guards enclosing the knife edges. Index Cutters and Vertical Paper Slitters- (Index Cutters and Vertical Paper Slitters used for cutting strips from ends of books), shall be provided with fixed guards so arranged that the fingers of operators cannot come been the blades and the tables. Corner Cutters - (Corner Cutters used in the manufacture of paper boxes) shall be equipped with suitable guards tended to the machine in front of the knives and provided with slots or perforations to afford visibility of the oration Band Knives - Band wheels or band knives and all portion of the blades shall be completely enclosed with hinged is of sheet metal not less than 1mm in thickness.
- 195. Agitators and MixingMachines - (Agitators and Mixing Machines means a tank or other container equipped with power driven mixing arms, blades or paddle wheels fixed to revolving shafts or other simple mechanical devices for ending, stirring liquids with other liquids or with solid substances or combinations of these). When the top of an open agitator tank, beater tank, tank or paddle tank is less than 1m above the adjacent floor or working level, adequate standard railing shall be installed on all open sides. Agitator & mixing machines shall be provided with an efficient interlock arrangement for the lop lid, to prevent access to the agitating stirring or similar devices, while in motion and would prevent restart under power with the lid in open position. Openings at the top or sides of the containers vessels of the agitator and mixing machines provided for inspection & examinations shall be Divided with standard grill guards as would prevent access of any part of operator’s body coming in contact with agitating, stirring while in motion. When discharge holes, openings are provided at the bottom or at the sides of containers vessels of the agitator and mixing machines, they shall be so guarded as would prevent access of any part of operator’: body coming in contact with agitating, stirring while in motion inside the vessel. Leather. Plastic and Rubber Stripper Machines- tappers for trimming or punching tanned hides, plastic or rubber sheets in leather making, footwear manufacturing shall be provided with suitable devices which require simultaneous action of both the hands of the operator or an automatic device which will remove both the hands of the operator from the danger zone at every descent of the blade.punch or stripper cutter. All couplings with projecting bolt heads and similar projections shall be completely encased or effectively guarded as to prevent danger. Machines Dangerous parts Types of guards Textile machinery Blow room machines Main drive, beater cover, grid bars, dust chamber. Separate motors, belt shifting device, interlock guard, fixed fencing Lap M/c Lap forming rollers. Interlock guard Carding M/c Cylinder Interlock guard Speed frames headstock Interlock guard Calendaring Running rolls Nip guard
- 196. Cotton Ginning Line shaftto run the gins Line Shaft Wall or fencing with locking doors Wood working Machinery Circular Saws The Saw A riving knife of prescribed dimensions and setting. Adjustable top guards, two metal plates guards, push sticks. Band Saw Top & bottom pulleys and the blade Fixed guards Planning machine Cutting slot, freed roller Bridge guards (adjustable)- bridge guard above the cutter to reduce access to the cutter. The guard should be wider than the gap in that table, to prevent contact of hand with cutter. Rubber mills Rubber mill In-running rolls Height>96.5cm, a distance guard. Trip guard within 1.8m height Calendar machine In-running rolls Trip guard within 1.8m height, tight wire cable connected with it Other machines Pedestal grinder (Bench grinder) Grinder wheel Adjustable safety glass screen Power press(punching) continuous Point of operation- punch point Fixed mesh guard in front of punch point. Power press(punching) single stroke Punch point Interlock guard Hand operated press Punch point Sliding guard – if ram goes up guard also slides outside. Milling machine Point of operation Telescopic guard, two-piece barrier guard- guard is just front gate. Drilling machine Point of operation Telescopic guard for radial & heavy pedestal drilling m/c. Split cage type guard to give access to chuck. Adjustable guards attached to fixed part of the m/c. Sensitive trip bar- sensitive trip bar suspended closed to the drill switches off power supply and applies a brake if the trip bar is deflected. The sensitive trip bar
- 197. is telescopic sothat it can be adjusted to suit the length of the drill. Safety in the use of Machines: Boring Machines Hazards Guards spindle contact Sleeve guard Tool & chuck Telescopic drill guard Hair loose clothing Cage type guard Sweeping chips by hand Brush Belt pulleys, gears Fixed guards Rotating horizontal table Surrounding machine guard Milling machines Hazards Guards Revolving cutter Jaw type interlocked or adjustable guard or self-closing guard Removing chips by hand Brush magnetic sweep Failure to draw the job back to a safe distance while loading or un-loading Fixed guard Power drive belt pulleys, gears Fixed guards and start/stop switch within reach Planning machines Hazards Guards Bed traveling within 45cm of a fixed object Fixed guard. All gaps to be guarded fall from the table or bed Fixed or self-adjusting table guards Pulleys, belts, drives & reserving dogs Fixed guard and starting/stopping device Flying particles Goggles, aprons Shapers Hazards Guards Speed changing pulley belts and other drives Fixed or hinged guard Flying chips Goggles, aprons Flying jobs Clamping device Moving ram & tool Transparent shield for tool. A retriever to limit of the stroke of ram channel Reversing dogs Fixed guard
- 198. Grinding machines Hazards Guards Flyingparticles Goggles, aprons Dust generation Local exhaust ventilation Bursting of wheel Protection hood (steel guard) and protection flanges. Chucks or bands. Portable grinders Segment guard. Electrically earthed. Shock proof gloves Belt drive and other dangerous parts Fixed guard HAND TOOLS AND POWER TOOLS Main Causes of Tool Accident: Each year hand tools are round to be the source of about a percent of all accidents ported under the factories Act. In all branches of industry numerous hand tool and powered too! injuries are observed. Disabilities and injuries resulting from hand and powered tools include loss of eyes and vision, puncture wounds from flying chips, severed fingers, arteries etc. broken bones, contusion, infection from wound and numerous other type injuries. The proportion of permanent disability case from the use of hand tools is low as compared to such n many other activities like machine operation etc. flying particles from mushroomed heads, over tempered points may cause many serious accidents. Many fatalities result from the use of electric powered hand tools the minor tool Injuries in hand tool accident are too large i.e. the lost time due to injury is high enough and alarming. Therefore, hand tool injuries should be prevented and it is always profitable. Different types of hand tools are used in different -try, mainly in metal working industries and wood working trades. But some tools are common to all industries and woodworking traders. But some tools are common to all industries. Hand tools are also used in maintenance and repair work, construction, logging and lumbering. Certain special tools are also used for special purpose, it is mainly the responsibility of the supervisory staff to keep the tools in safe working condition, to check the unsafe methods of use of tools, to select the right tool for the right job and making the working mass aware of reducing the injuries. The main causes of the tool accident (hand tool or powered tool) may be summarized as: 1. Wrong selection of tools 2. Improper use 3. Unsafe condition (Using Defective Tools) Due to lack of Knowledge and lack of supervision. 4. Improper Storage/Stacking I 5. Improper Carrying. 6. No ear thing of electric tools.
- 199. Control 1. Proper Supervision 2.Proper selection of tool (Proper tool and its material too) 3. Proper use (at right place in right way). 4. Safe working condition (Proper maintenance and repairing and supply). 5. Selection of right person (Trained person / Skilled person) For Proper job). 6. Proper storage, carrying and repair 7. Centralized control. Safety practice. 1 Always use the proper personal protective equipment: Goggles for eyes, gloves for hands, safety helmet for head and safety shoes for your legs. 2 Select the right tool for the job: Check unsafe practices - striking handed surface with hardened head tool using a wrench as hammer, a file to be used as a pry etc. knife used as a screw driver, pipe used on wrenches leverage etc. 3 Keep tools in good condition: Use of cracked or worn jaws of wrench, screw driver without proper head, mushroomed head hammer or chisel, hammer with broken handle, dull saws etc. 4 Use tools correctly: The common causes are: Screwdriver applied to job held in the hand. Knives pulled towards your body. Hammer striking hardened tool. Placing the fingers or thumb close to the bade when starting it's cut. Pliers and wire cutters cutting a line or repairing files used without handles. Hitting a file with a hammer. 5 Keep tools in a safe place: Main cause are: Falling from overhead. Unprotected sharpened adages of knives, chisels etc. keeping the sharp adages in pocket or tools box exposed. Safety program or control of accidents: The safety programs should be followed as: a) Proper the job training to workers for the selection of tight tool for each job and ensure the availability of the right tool. b) Regular and periodical inspection of the tools for their safe working condition should be ensured. c) Proper repair and maintenance should be done for regular supply of the required tools. d) Proper training to the supervisory staff and workers regarding correct use of the tools a vital factor for job safety. e) Check out list and record should be maintained for the control of the use and supply of the tools. f) Provision should be made for the proper storage of the tools in the storehouse. tool, kits and the toolbox. g) Provision of supply and use of personal protective equipment should be done, h) Proper advance planning should be done to maintain all the above requirements. Centralized Control: 1. Tool-room control: All tools should be issued from the tool - room and returned to it periodically for inspection as repair the tool - room should have its own repair shop. The tools which cannot be repaired in the tool room may be sent to other section for repairing and
- 200. brought back tothe tool - room. The supervisor or the foreman should take care of the repair and maintenance of the tools issued from the tool - room. 2. Centralized: tool control other than tool - room assures uniform inspection and maintenance 0. tools by trained employee’s Central storage facilities will also assure more positive control than scattered storage. 3. Toolboxes: These are of two types, stationary and portable. The stationary toolboxes of bigger size are called tool chests. Thesecontain a number of drawers for different type of tools. The portable or mobile tool cabinets are convenient to be carried to any spot and provide a number of tools at the spot. 4. Carrying tools: should never car^ tools in the pocket is very risky and s oud be restrained. In the case of transportation of tools those should be enclosed in strong box or leather bags for the safety of the worker handling them the sharp- edged tools may be carried only in a toolbox, coat or carrying belt. Tool pouch etc. Purchase Storage and Supply of tools: In every industry, the purchase section or department has to play significant role for timely and methodically purchasing of the required tools. The basis of the purchase should be, the proper planning, requirement and supply from the source. The factor o efficiency and safety has also to be looked into. The planning department forwards the note on which purchase department makes the purchase and the tools are stored in the store department. The purchasing and storages should be supervised by a man having sufficient knowledge regarding the tools and their usage and who can foresee the application of them in the shops. He is charged with the responsibility for ordering suitable tools for the shops and his request to the purchasing agent should specify the kind of tool to be ordered, and if necessary, the catalog number. This gives a greater assurance of the safety of design, construction and application. Inspection and Maintenance of tools: Inspection, maintenance and repairing is regular requirement for the working of tools. Metal tools break during their normal use to the detectable cause overheating or under heating of the forging. Improper tempering, cracks from the improper for forging, failure to relieve stress during forging, improper quenching, incorrect angle of cutting edge, or material of poor quality etc. defects of these types will be found in tools of inferior quality and construction, which because of breakage and failure are more expensive in the long run.therefore, it pays to purchase the tools of best quality. The tool room attendant should be qualified by training and experience to accept the tools for further use. The used up or defective tools should be returned to the storage to be issued for further use. Efficient tool control requires periodical inspection of all the tool operations. Responsibility such inspection should be borne by the departmental head. He should also ensure that sufficient numbers of tools are available in stock. The inspection should cover the housekeeping in the tool supply room, tool maintenance service number of tools in the inventory handling routine and condition of the tools. Hand tool receiving the heaviest wear such as chisels, punches, wrenches, hammers, star drills and black smith' s tools require frequent maintenance or regular basis. Proper maintenance and repair of tools require adequate facilities like - work benches vises, safety goggles, repair and sharpening tools and good lighting. Specially trained and skilled persons should be engaged for such work. Tempering of tools:
- 201. Hammer struck andstriking tools (Chisels, stamps, punches, cutters, hammers, sledges and rock drills) should be made of carefully selected steel and heat - treated so that they are hard enough to withstand blows Bout mushrooming excessively and yet not be so hard fiat they chip. For safety it is better that shock tools some which can be dressed frequently, be a little soft rather ‘. nan too hard, because a chip may fly from an excessively tool without warming when the tool is struck with a harmer or sledge. Tempering of tools is metallurgical process require vary special skill. It is a process of heat - treatment and depends upon the % of carbon present in the I. For alloy steel tools the process of heat - treatment or tempering is quite different than the low - carbon mild " tools. Therefore, before tampering the exact analysis of the tool and its method of heat - treatment should be ascertained. Safe-ending of tools:Hammer - struck tools, such as chisels, rock drills, flatters, wedges, punches, cold cutters and number dies, should have heads properly hardened by qualified person. The hazards of burned heads can be used by safe - ending of tools. This can be quickly and economically achieved by grinding or flame - cutting a shoulder recess about 1/8-inch-wide by V* inch deep into the tool head and then bronze welding it. The proper bore metal for bronze welding is 1600 f to 1700 f. the correct temperature is in directed temperature by a bright red color when the tool is looked at through dark - glasses in the light of any acetylene flame. Short section of tight fitting rubber hose can also be set with the striking ends of hammer - struck tools to keep chips off from flying and protect the hand too. Dressing of tools: Shock, cutting and pointed tool require regular maintenance of their edges or striking faces. Once the cutting or striking faces have been properly hardened and tempered, only an emery wheel, grind stone, file or oil stone need be used to keep the head in shape and the edges clean and sharp. Proper precaution should be taken before grinding hardened tools. They should not be ground until after they have been drawn or tempered the grinding should be done in the specialized way with the proper recommendation of grinding wheel. Each cutting edge should have correct angle according to its use and be finished off with a file. Re - Dressing requires the following – 1. Rigidly support the tool being dressed. 2. Use a hand file or whetstone, never a grinding wheel. 3. Restore the original contour of the cutting edge by filling. Cold Chisel: Cold chisels are hardened on the cutting edge. Dressing may be done with a hand file or whetstone restoring to original shape or to an include angle of 70. Other commonly used metal working chisels are Round Nose, Diamond Point and cope. Dressing instructions are same as for flat cold chisels except the bevel angles are as shown. Hot Chisel - Same as cold chisels. Punches: The working end of pin and rivet punches and blacksmith's punches should be observed flat and square with the axis of the tool. The point of center punches should be redressed to an include angle of 60 while prick: bunches to an angle of 30. Handles: The tool handles should be of the best straight-grained material. Fitting of handles is very important. Poorly fitted handles make it difficult for the workers to control the tool.
- 202. Wooden handles ofhand tools used for striking such as hammer, and sledges. Should be of preferably hickory ash or maple neatly finished. Alternate materials like fiberglass or steel with a rubber sleeve may be used. Loose wooden handle in sledges, axes, hammers etc. created hazard. Use and shrinkage made it loose after a considerable time. Therefore, repairing and replacement becomes necessary. After the handle is firmly fitted into the head eye, wedging according to the original pattern makes the tool firm and ready for reuse. Use of Hand Tools - Common Purpose: Th2 use of hand tools in unsafe way is source of injury. Injury results because of the assumption "anybody knows how" to use common hand tools. Therefore, every job programme sheet should include the type, specification and the proper way of using the tool for a particular operation on the specified machine. The persons should be thoroughly trained for the job operation and may be specialized for a job. The trained or d persons should only be engaged for a job. Workers should positively use the personal protective equipment like googles and helmets to protect their faces from flying chips and objects due to working of hand tools. Safe use of some of the common tools – Screw Driver: Should never be used with punches, wedges, pinch bars, etc. w driver tip should be selected to fit the screw. A sharp square edges bit will not slip. While putting in a screw. A sharp square edges bit will not slip. While putting in a screw, the work should be held in vise or laid to a flat surface, electrical work, the screwdriver must be insulated. Hammer - Safety tips for hammers in use - 1. Safety goggles should be worn. 2. Hammer blow should strike squarely to the striking surface. 3. When striking another tool like chisel punch, wedge etc., the diameter of the striking face of the hammer should be 3/8" (9mm) larger than the head of the tool. 4. Use a hammer of suitable size and weight.' 5. Never strike a hammer by another hammer. 6. Never use a hammer with loosened handle. 7. Discard a hammer if its striking face is crack, have dents and mushroomed. Redressing of a hammer is generally not recommended. Type of hammers – Ball pen hammer- used for rewetting, shaping and straightening unhardened metal sheet. Nail hammer - Wood working and nails, Sledge hammer- Sledging operation. Hand drilling hammer- Chisels, punches, star drills, hardened nails Bricklayer's hammer - Brick work Punches:- Punches are of various types - square, round, hexagonal, octagonal etc. these are used for making the metal. driving and removing pins and rivets and align the holes. Punch should not be used for a mushroomed face or dull and deformed face. Dull bent and crack punches should be discarded. Repressing to original size is recommended.
- 203. Metal Cutting Tools:Chisel, Hack saws, Files, Tap, Die, Stamp. Chisel – Cold Chisel - Used for cutting, shaping and removing metal, softer than that of chisel like cast iron, wrought n, steel, bronze and copper 70 to 60 angle of chisel edge. Types and Use: i. Flat cold chisel is mostly used for cutting, shearing and chipping. For ordinary use 3/4 * width chisel with 11b hammer should be used. ii. Diamond point chisel cuts v – grove and interior angles. iii. Cape chisel is used for cutting key – ways, slots, or square corners. iv. Round nose chisel is used for cutting rounded or semi – circular groves. Chisel should be discarded if it is bent, cracked, or chipped. The cutting edge should be redressed to the original contour when grinding a chisel, the cutting edge should not be pressed hard against the wheel because otherwise it will be tempered due to the heat generated due to grinding action. To avoid it, the chisel should be immersed in cold water frequently while grinding. Hack saws: Hacksaws should be tightened to the frame to avoid breaking and buckling. It should not be tightened too much to break of the pins to support the blade. Blade should have a forward tooth.14 – teeth blade should be used for soft metal cutting.18 – teeth blade should be used for cutting steel, iron pipe, hard metal and general purpose.24 – teeth for drill rods, sheet metal, copper, brass, tubing, 32 – teeth for thin sheet metal, tubing. For thin metals at least 2 teeth must be in contact. Force should be applied in the forward stroke with a speed 40/60-es/ minute. Files - Selection of right kind of file for the right job should be done to prevent injury and long life. A file should not be used without a handle otherwise it will damage and puncture the palm. The file should not be cleaned by striking against vice or any hard surface but a file - cleaning card should be used. File should never be hammered otherwise hard material will chip and fly to cause injury. For working, the job should be held firmly on vice or clamp and the stroke of the file be made gently in the forward direction only. Wood cutting tools: Wood chisels, saws, Axes and hatchets. Wood chisel - Wood working chisel with wood handle but designed to be struck by wood or plastic metal, the handle should be protected by a metal or leather band. Heavy duty chisels made of solid metal handle may be struck by metal or steel hammer. The finish cuts to be done by hand strokes only. The job must be held firmly in a wire or damped properly. The chisel should never be used as pry or wedge. Other use the tool should be kept in rack or tool bench. Saws - Selection of the proper type for proper job is a vital factor. For fast cross cutwork on green - wood a coaxes (4 to 5 points per inch) should be used. For smooth dry wood cutting a (8 to 10 points per inch) fine saw should be used. No. of points per inch is stamped on the blade. Never drop a saw otherwise the blade may break or get loose. Use of Safety goggle is a must.
- 204. Material Handling Tools: Crowbars- Crow bar of proper size with kind of bar for the job should be used. The crow bar of proper size with kind bar for the job should be used. The crow bar should have a proper point or toe of such shape that it will grip the object to be moved and a heel to act as a pivot. The handle may be made as long as feasible but not too long. Hooks - Hand hooks for handling of material should be kept sharp so that they will not slip when applied to box or other objects. The handle should be of proper size and shape to suit the hands. The hook tip and handle should lie in the same plane to give true action to the hook. Shovels: Shovels edges should be kept trimmed and handles should be checked for sprinters. The wearing of safety. shoes be checked for sprinters. The wearing of safety shoes is a must. The worker should carry the load his legs before striking with a shovel. Dipping of the edge in water time to time keeps the sticky material away off the edge. When not in use. They are to be kept in racks lying horizontally. Torsion Tools - Types: Open --end wrenches, combination wrenches, box and socket wrenches adjustable wrenches, pip wrenches, wrenches, tongs, pliers etc. the worker should be alert and skillful while using such tools. The possibility of slipping of the wrench or the job being free or losing the balance or his body while in action are various causes of the injury. The use must take care of al! possible factors regarding the safe condition of the tool and his own safe way of using the same. The correct size wrench should be selected for a job and never a wrench of different size be used for the job by grinding its grip to make the size. Open - end wrench - Have strong jaws and are fit for medium duty turning. If not fitted properly to the job, they slip and hence should not be used. Combination - wrench: Have at one end open and other end box type. These are hardier for use. Box and Socket Wrench- Are used where a heavy pull is necessary with safety in the view. Box and socket wrenches completely encircle the nut. Belt or fitting and grip it at all comers. There are no chances of slipping the box socket wrenches. These are generally of the type - single hex, double hex or Double Square as required for different job heads. Special heavy- duty wrenches are available with handle of three feet for the job. Where possible penetrating oil should be used for loosening. The socket should be kept clean of dirt. A common cause of socket and box wrench failure is 'Cocking' is a situation on which the tool cannot fit squarely on the job but fits at an angle only, concentrates the strain on smaller area and hence failure. Toque Wrenches - Toque are used where the toque has been specified for the job. The toque wrench should be. used carefully and calibrated according to the job. The torque, or twisting force, exerted on a nut or bolt is directly proportioned to the length of the wrench handle and the pulling force exerted on it. Adjustable Wrenches: Are generally use for light duty work or when the proper size fixing wrenches not available. The wrench should be pulled and never pushed. The movable jaws are weaker than the fixed jaws and hence it should be set tight by hands only.
- 205. Pipe wrenches -workers on overhead jobs have been injured due to slipping of pipe wrenches on pipes. Pipe wrenches both, clean to prevent their slipping. The adjusting nut of the wrench should be inspected frequently. Using a wrench of wrong length is inviting accident wrench too - small handle does not give proper grip or leverage. Too lightly handle may break the work or strip suddenly. Pipe wrench should never be used on nuts or bolts, the corners of which will break the teeth of the wrench. It should not be used on vales or small brass, copper or other soft fittings, which may be crushed or bent. A wrench should not be struck by a hammer. Pipe Tongs: Are used for fitting of pipes. They should only be used when the pipes are placed in line for fitting purpose. The ends of the tongs can be upended to give clearance for user's hands. Often the user’s hands are pinched when the tong is close. . Pliers - Pliers are meant for gripping and cutting operations. They are not recommended as a substitute for wrenches because their jaws are flexible and frequently slip when used for this work. Pliers also tend to around the corner of bolts and nuts and leave a few works thus make it difficult to be used by wrench. The pliers for electrical work must be insulated the cushion grips on handles are primarily for comfort hence it must be ensured that the same is an insulator before it is used for electrical work. Pullers - are the only quick, safe and easy way to pull a gear, wheel pulley or bearing from a shaft. The jaw capacity of the puller should such that it presses tightly against the part being pulled. Shock looks - i he pliers use for electrical work, as tools are shock tools. If the insulation is not of exact material it is pot shock - proof. Care is to be taken before its use so that injuries do not happen for this cause. Non - spark tools - Non - ferrous toots reduce the hazard from sparking out do not eliminate it. They therefore require regular inspection before each use to be certain that they have not picked up foreign particles that could produce friction - spark. These tools are made up of non - ferrous materials such beryllium copper alloy etc. these are used for flammable gases, highly volatile liquids and other explosive substances stored or used. Portable Power Tools:Portable power tools can be divided into five groups. 1. Electric 2. Pneumatic. 3. Gasoline. 4. Hydraulic. 5. Powder Actuated (Explosive) The tools like saws, drills and grinders are common to the first three groups. Hydraulic tools are used mainly for compression work. Powder - actuated tools are used exclusively for penetration work. Cutting and compression. Hazards - A portable power - too! presents similar hazards as a stationery machine of same kind, in addition to the risk of handling. Bums, cuts and strains are the main injuries.
- 206. Source - thesource of injury is Electrical shock Particles in the eye Fire Fails Explosion of vapours or gases Falling of tools. Safety Tips 1. Source of power should be disconnected before any accessories are changed. 2. Before any use / work the guard should be placed in proper position. 3. The tool should not be left in overhead position. It will cause an injury if the cord or hose is pulled. 4. The cord or hose should not be kept lying on the floor they will create a tripping hazard. They should be kept suspended over aisles or work areas. 5. Where it is not possible to keep the cord or hose suspended they should be covered with wooden planks so that they are protected from the human contact. 6. while in suspension cord or hose should not disturb the operator's way. 7. The cord should never be hanged sharp edge and should be kept away from oil, hot surfaces and chemicals. 8. Power - driven tools while in use should be covered properly otherwise thy create hazards if come in contact with the human body easily. 9. They should be stored properly and never be left encored on the ground. Selection of tools: Selection of a power tool replacing the hand tool for the same job will increase the degree of hazard. The hazard will be electrical or mechanical in place of manual. Therefore, the safe design (safe condition) proper training (safe use) should be ensured before any power - tools brought into use. Complete information the job should be made available so that the tool selected should be most appropriate. The tool selected for intermittent use or light work are called "home owners’ grade" and those for heavy decay are called "industrial duty", provision of tool - proof training for the proper selection of tool is of. Inspection and Repair: Periodic inspection is essential for the maintenance of power tools. A schedule be maintained, defective tool should be repaired or replaced. Electrical tools should be thoroughly checked visually and also "knock inspection should be carried out at specified intervals. A colored tag can be attached to the tool last ted. The inspection should be done by a skilled and expert person who knows all the checking procedures. 3€-r training arrangement should be done for now - how in detail. The responsibility to carry out inspection and 1 follow up actions should be maintained by an authorized person. Make - shift arrangement must be avoided. No airing should be done without proper authorization. Cleaning of the power tools should be done with a mended non - flammable and non - solvent. Air-drying should be used in place of blowing with compressed Inspection Checklist General: Low voltage or battery powered equipment used in tanks and wet areas? Tools well maintained? Motors in good condition? Approved tools used in explosive atmosphere? left where they cannot fall? CORDS insulation and plugs unbroken?
- 207. was protected againsttrack and oil Cords not in aisles? GROUNDING Ground wire fastener in safe condition? 3-w ire plug extension cord (if a 3 - wire tool) Ground wire used? Defects or minor shocks reported? Ground fault circuit interruption used? GUARDING used on grinders and saws? Movable guards operate freely Eye |or face protection worn? Brief Description of Tools Electric Tools - are of two types - (1) Battery powered. (2) Electric powered. Battery powered is the safest tool as they do not head any extension cord and produce no risk of shock. These two are themain hazards. Other electric tools have the main hazard of shock. The types of injuries are electric flash, minor shock causing a fall and major shock may cause a death. Factors of safety: are insulating platforms, rubber mate and Rubber gloves. 1. when the work is done in wet areas like, tanks, boilers etc. 2. Low voltage to the tune of 6,12, 24 or 32 volts through 3. Double insulated tools (symbol) protect human body from all type of shock hazards 4. Grounding of portable electric tools and the proper use of grounding fault circuit interrupters provide the most convenient safeguarding. 5. Use of P.P.E. like goggles, Apron, hand gloves, helmet etc. Types - Electric drills., electric saws, grinding wheels, sanders. powders tools - types - Air hose, Air power grinders, or pneumatic Impact tools. lose - Pressure should not exceed 30 atmospheres for the cleaning purpose, it should be kept suspended in and work areas. Proper housing arrangement. Should be providing. Safety check valve may be provided for pressure to be released.
- 208. CHAPTER 2:MATERIAL HANDLINGAND STORAGE Manual Material Handling: KINETICS OF MANUAL HANDLING: Proper Lifting Methods. No single technique for preventing injury during lifting and material handling has been discovered despite numerous research efforts. The best prevention strategy is to ensure workstations are properly designed, loads are manageable and weight distribution, the frequency and duration of lifting are not excessively stressful, and workers can demonstrate knowledge of proper techniques for material handling. There are three basic methods of lifting, that is, straight back Each has advantages and limitations: 4.6.1. The kinetic method is the most widely accepted and taught because it provides more stability for the worker while reducing load on the back muscles and intervertebral disks. Instructions and diagram on how to lift properly follow: 4.6.1.1. Before an object is lifted, it should be inspected to make certain no grease or slippery substance will cause the object to slip. Also inspect the objects for slivers, sharp edges, and rough or slippery surfaces before attempting to lift. 4.6.1.2. Position feet correctly. Place far enough apart for balance with one foot to the rear of the object and the other foot slightly ahead of the other and to the side of the object. 4.6.1.3. Crouch close to the load. Crouching is preferred to squatting. St minimize strain on the back muscles. 4.6.1.4. Always keep the back as straight as possible. It may not be possible to keep the back in the vertical plane but avoid arching the back. Bend from the hips and not from the middle of the back. 4.6.1.5. Pick up materials with a full palm grip. Do not attempt to pick up items using a fingertip grip. Gloves (Leather or Leather sharp or burred edges or splintered surfaces. 4.6.1.6. With the arms, slide the object towards the body putting it in motion (kinetic energy). At the same time, lift the object with the legs and bring the back to a vertical position. Keep the object close to the body; avoid twisting while lifting. CHAPTER 2:MATERIAL HANDLING AND STORAGE KINETICS OF MANUAL HANDLING: . No single technique for preventing injury during lifting and material handling has been discovered despite numerous research efforts. The best prevention strategy is to ensure workstations are properly designed, loads are manageable and weight distribution, the frequency and duration of lifting are not excessively stressful, and workers can demonstrate knowledge of proper techniques for material handling. There are three basic methods of lifting, that is, straight back-bent knees, free style, and kinetic. Each has advantages and limitations: 4.6.1. The kinetic method is the most widely accepted and taught because it provides more stability for the worker while reducing load on the back muscles and intervertebral disks. nstructions and diagram on how to lift properly follow: 4.6.1.1. Before an object is lifted, it should be inspected to make certain no grease or slippery substance will cause the object to slip. Also inspect the objects for slivers, sharp edges, and rough or slippery surfaces before attempting to lift. . Position feet correctly. Place far enough apart for balance with one foot to the rear of object and the other foot slightly ahead of the other and to the side of the object. 4.6.1.3. Crouch close to the load. Crouching is preferred to squatting. Stay close to the load to minimize strain on the back muscles. 4.6.1.4. Always keep the back as straight as possible. It may not be possible to keep the back the vertical plane but avoid arching the back. Bend from the hips and not from the middle of 4.6.1.5. Pick up materials with a full palm grip. Do not attempt to pick up items using a or Leather-palmed) shall be worn when lifting objects which have burred edges or splintered surfaces. With the arms, slide the object towards the body putting it in motion (kinetic energy). the same time, lift the object with the legs and bring the back to a vertical position. Keep the object close to the body; avoid twisting while lifting. CHAPTER 2:MATERIAL HANDLING AND STORAGE . No single technique for preventing injury during lifting and material handling has been discovered despite numerous research efforts. The best prevention strategy is to ensure workstations are properly designed, loads are manageable in both size and weight distribution, the frequency and duration of lifting are not excessively stressful, and workers can demonstrate knowledge of proper techniques for material handling. There ent knees, free style, and kinetic. 4.6.1. The kinetic method is the most widely accepted and taught because it provides more stability for the worker while reducing load on the back muscles and intervertebral disks. 4.6.1.1. Before an object is lifted, it should be inspected to make certain no grease or slippery substance will cause the object to slip. Also inspect the objects for slivers, sharp edges, and . Position feet correctly. Place far enough apart for balance with one foot to the rear of object and the other foot slightly ahead of the other and to the side of the object. ay close to the load to 4.6.1.4. Always keep the back as straight as possible. It may not be possible to keep the back the vertical plane but avoid arching the back. Bend from the hips and not from the middle of 4.6.1.5. Pick up materials with a full palm grip. Do not attempt to pick up items using a palmed) shall be worn when lifting objects which have With the arms, slide the object towards the body putting it in motion (kinetic energy). the same time, lift the object with the legs and bring the back to a vertical position. Keep the
- 209. 4.6.2. Setting theObject Down. Use the same motion as when lifting, but reverse it to set an object down. Lower the load by bending the legs and crouching with the back straight. Take care when releasing the load to prevent injury to fingers, hands, or feet. 4.6.3. Team Lifting. When its required to move heavy or unusual shaped items manually, always seek and obtain assistance When it is not practical to use mechanical equipment assign additional workers to the task. When two or more people are required to move or carry an object, adjust the load so each person carries an equal part. If possible use workers similar in size and train them in team-lifting. Workers need to understand that if one worker lifts too soon, shifts the load, or lowers improperly, that person or their partner(s) may be overloaded and strained. Test lifts should be made before proceeding. The key to lifts using two or more personnel is to make every move in unison. Assign one person to give orders to ensure the necessary coordination for movement. The supervisor and workers are responsible for assessing all available methods to safely handle materials described above and using mechanical assistance whenever possible. 4.7. Carrying Methods. Acceptable carrying methods differ, based upon the type of material, distance, and number of workers. Workers should be instructed during initial training in each procedure--for example, neck, shoulder, side, tray, two-person, and under-arm carry methods, etc. Points to remember: 4.7.1. Use appropriate PPE as determined for each task, such as gloves, to protect the hands and protective footwear to protect the feet. 4.7.2. Keep fingers away from pinch and shear points. 4.7.3. Do not carry a load that obstructs the view of the direction of travel. Make sure that the path of travel is clear. 4.7.4. Do not turn at the waist to change direction or to put an object down. Turn the whole body and crouch down to lower the object. 4.8. Carrying Items Up or Down Stairways: 4.8.1. Adhere to the guidance provided by the supervisor. 4.8.2. Try to reduce the bulk or size of the object carried to allow for maximum visibility. 4.8.3. Use assistance when required and available. 4.8.4. Use mechanical material handling equipment whenever loads are too heavy or bulky to be lifted or carried efficiently or safely by hand. Forklifts, hand trucks, rollers, conveyors, or cranes (when properly used) simplify materials handling and greatly reduce the hazards of handling supplies and equipment. Maximum load that could be carried: There is no legal maximum weight to lift at work. There are, however, guidelines which set out the recommended safe maximum weight for lifting at work. Manual Handling Guidelines set out recommended safe lifting limits for men and women. The recommended maximum weight limit should be adjusted depending on how the load is being lifted, how close to the body the weight is held, and how high or how low the weight is lifted.
- 210. The guidelines suggestthat the maximum weight men should lift at work is 25kg. This relates to loads held close to the body at around waist height. The recommended maximum weight is reduced to 5kg for loads being held at arm’s length or above shoulder height. Maximum weight guidelines recommend lower weights for women. The suggested maximum weight for women is 16kg for loads held at waist height. Lifting a weight below the maximum limit does not always make the load ‘safe’ The weight of the load is not the only factor to be considered. There are a number of factors to consider when assessing whether a load is ‘safe’ for an employee to lift at work. The guidelines assume that the manual handling and lifting is taking place in reasonable working conditions. It is also assumed that the load is easy to hold and easily grasped with both hands. The guidance is also based on the assumption that the weight is being lifted by a reasonably fit, well-trained individual. The weight of a load may need to be reduced below the maximum guideline weights for various factors These factors include: any lifting which involves twisting or bending if the manual handling is being carried out in a confined space or if the lifting activity is being repeated. There are therefore a number of factors to assess when considering whether the load a person lifts at work is ‘safe’.
- 211. Employers should carryout a manual handling risk assessment to assess any manual handling or lifting that an employee is required to do as part of their work Material Handling That Stacks Up & Down to Safety Requirements Improper stacking and storage can result in injuries to workers and damage to costly materials. Make sure your material handlers stack up when it comes to safety. Although OSHA does not provide much specific direction concerning safe stacking and storage, 29 CFR 1910.176(b) of the material handling standard does generally require secure workplace storage of materials. The regulation states: “Storage of material shall not create a hazard. Bags, containers, bundles, etc., stored in tiers shall be stacked, blocked, interlocked and limited in height so that they are stable and secure against sliding or collapse.” General safe stacking and storage rules with which employees who handle materials should be familiar include: Ensure that stacks are stable and self-supporting. Observe height limitations when stacking materials. Allow sufficient clearance around stacks for safe handling and easy access. Make sure there is sufficient clearance between stacks and lights, heating pipes, and sprinkler heads. Make sure stacks don’t block emergency exits, emergency equipment, or fire alarms. When stacking boxes, employees should: Place boxes on a pallet for stability and to make them easy to move. Interlock boxes to make a more stable stack. Band boxed materials or secure them with cross-ties or shrink wrap. A good rule of thumb for ensuring a stable stack is to observe a height to base ratio that does not exceed 3:1 (or 4:1 at most if the stack is effectively interlocked and there is a good grip between the contacting surfaces). When stacking bags, sacks, and baled and bundled materials, workers should: Stack bags and bundles in interlocking rows to keep them secure. Stack bagged material by stepping back the layers and cross-keying the bags at least every 10 layers.
- 212. Store baledpaper and rags inside a building no closer than 18 inches to the walls, partitions, or sprinkler heads. When stacking pipes, poles, and bars, employees should: Not store pipes, poles, and bars in racks that face main aisles to avoid creating a hazard to passersby when removing supplies. Stack and block pipes and poles as well as structural steel, bar stock, and other cylindrical materials to prevent spreading or tilting unless they are in racks. When stacking barrels and drums, workers should: Stack drums, barrels, and kegs symmetrically. Chock the bottom tiers of drums, barrels, and kegs to keep them from rolling if stored on their sides. Place planks, sheets of plywood dunnage, or pallets between each tier of drums, barrels, and kegs to make a firm, flat stacking surface when stacking on end. When stacking lumber, employees should: Stack lumber no more than 16 feet high if it is handled manually, and no more than 20 feet if using a forklift. Remove all nails from used lumber before stacking. Stack and level lumber on solidly supported bracing. LAYOUT CONDITION FOR SAFETY IN STORAGE: General principle of plant layout: Plant layout is often a compromise between a number of factors such as: The need to keep distances for transfer of materials between plant/storage units to a minimum to reduce costs and risks; The geographical limitations of the site; Interaction with existing or planned facilities on site such as existing roadways, drainage and utilities routings; Interaction with other plants on site; The need for plant operability and maintainability; The need to locate hazardous materials facilities as far as possible from site boundaries and people living in the local neighborhood; The need to prevent confinement where release of flammable substances may occur; The need to provide access for emergency services; The need to provide emergency escape routes for on-site personnel; The need to provide acceptable working conditions for operators. The most important factors of plant layout as far as safety aspects are concerned are those to: Prevent, limit and/or mitigate escalation of adjacent events (domino); Ensure safety within on-site occupied buildings;
- 213. Control accessof unauthorized personnel; Facilitate access for emergency services. In determining plant layout designers should consider the factors in outlined in the following sections. Inherent safety The major principle in Inherent Safety is to remove the hazard altogether. The best method to achieve this is to reduce the inventory of hazardous substances such that a major hazard is no longer presented. However, this is not often readily achievable and by definition no COMAH facility will have done so. Other possible methods to achieve an Inherently Safer design are: Intensification to reduce inventories; Substitution of hazardous substances by less hazardous alternatives; Attenuation to reduce hazardous process conditions i.e. temperature, pressure; Simpler systems/processes to reduce potential loss of containment or possibility of errors causing a hazardous event; Fail-safe design e.g. valve position on failure. Plant layout considerations to achieve Inherent Safety are mainly those concerned with domino effects (see below). Domino effects Hazard assessment of site layout is critical to ensure consequences of loss of containment and chances of escalation are minimised. Domino may be by fire, explosion (pressure wave and missiles) or toxic gas cloud causing loss of control of operations in another location. Explosion Explosion propagation may be directly by pressure waves or indirectly by missiles. As for fires, inherently safe methods that should be considered are: arranging separation distances such that damage to adjacent plants will not occur even in the worst case; provision of barriers e.g. blast walls, location in strong buildings; protecting plant against damage e.g. provision of thicker walls on vessels; directing explosion relief vents away from vulnerable areas e.g. other plants or buildings, roadways near site boundaries. However, the latter may not provide practical solutions, particularly against missiles, and risk analysis may be required to prove adequate safety. Toxic gas releases Toxic gas releases may cause domino effects by rendering adjacent plants inoperable and injuring operators. Prevention/mitigation of such effects may be affected by provision of automatic control systems using inherently safer principles and a suitable control room (see section below on Occupied Buildings).
- 214. Reduction of consequencesof event on and off Site In addition to the measures described in the sections above, Plant Layout design techniques applicable to the reduction of the risks from release of flammable or toxic materials include: Locating all high-volume storage of flammable / toxic material well outside process areas; Locating hazardous plant away from main roadways through the site; Fitting remote-actuated isolation valves where high inventories of hazardous materials may be released into vulnerable areas; Provision of ditches, dykes, embankments, sloping terrain to contain and control releases and limit the safety and environmental effects; Siting of plants within buildings as secondary containment; Siting of plants in the open air to ensure rapid dispersion of minor releases of flammable gases and vapours and thus prevent concentrations building up which may lead to flash fires and explosions; Hazardous area classification for flammable gases, vapours and dusts to designate areas where ignition sources should be eliminated. Risk management techniques should be used to identify control measures that can be adopted to reduce the consequences of on or off-site events. See references cited in further reading material. Positioning of occupied buildings The distance between occupied buildings and plant buildings will be governed by the need to reduce the dangers of explosion, fire and toxicity. In particular, evacuation routes should not be blocked by poor plant layout, and personnel with more general site responsibilities should usually be housed in buildings sited in a non-hazard area near the main entrance. Consideration should be given to siting of occupied buildings outside the main fence. In all cases occupied buildings should not be sited downwind of hazardous plant areas. Further guidance is available in standard references. Aggregation / trapping of flammable vapors To avoid aggregation and trapping of flammable / toxic vapours which could lead to a hazardous event, buildings should be designed so that all parts of the building are well ventilated by natural or forced ventilation. Flammable storages should be sited in the open air so that minor leaks or thermal outbreathing can be dissipated by natural ventilation. Maintenance procedures should include the displacement of vapours from hazardous areas before work begins (see Technical Measures Document on Permit to Work Systems). Hazards and Human Factors: • Strains, sprains, hernias, fractures, bruises, and lacerations may result from poor manual material handling and lifting practices. • Lifting, carrying, dropping, and lowering are the common physical acts responsible for injuries. • Many strains are the direct result of improper lifting techniques, lifting with no assistance, or failure to use required and available manual material handling equipment.
- 215. Minimizing Manual MaterialHandling Hazards: Engineering Controls. A preferred method of minimizing the risk of manual lifting is the use of engineering controls such as employing mechanical assists to decrease the force, the repetition, distance of travel, and frequency of the manual handling activities. Some examples might include employing scissor tables, elevators, conveyors, and gravity chutes. Administrative Controls. Job rotation schedules and mandatory work-rest cycles can be useful to reduce mishap potential, but do not eliminate the hazard and are not as reliable as engineering controls. Work Design Principles. Conduct a job safety analysis to identify potential hazards, and when practical, arrange tasks and select workstations using the following principles: 1. Place objects to be lifted at the approximate height of the knuckles when the arms dangle at side of the body. 2. Limit stack height to shoulder level. If items must be stacked higher, provide step-up access to eliminate lifting above shoulder level. 3. Use grips, handles, and other devices to provide better control of items. 4. Slide materials instead of lifting, whenever possible. 5. Use gravity assist in moving materials. 6. Ensure adequate maneuvering space to eliminate the need to twist the body. 7. Consider team lifting when items are known to weigh more than 25 pounds. Manual Material Handling Equipment. This equipment will be used whenever loads are too heavy or bulky to be lifted or carried efficiently or safely by hand. Hand trucks, dollies, two- wheeled hand trucks and wheelbarrows (when properly used) simplify materials handling and greatly reduce the hazards of handling supplies and equipment. 1. Hand Trucks, Dollies and Wheelbarrows. Hand trucks, dollies, wheel barrows or other manual devices shall be used to lift and (or) carry bulky or heavy items whenever possible. Tip the load to be lifted forward slightly so the tongue of the truck goes under the load. Make sure the tongue of the truck is all the way under the load prior to movement. Keep the center of gravity of the load as low as possible. Place heavy objects on the bottom of the load. Keep feet clear of the wheels. The center of gravity of the load on both the hand truck and wheelbarrow will be kept as low as possible. The weight should be forward so it will be carried by the axle, not the handles. If loaded correctly, the hand truck should carry the load—the operator need only balance and push. Place the load so it will not slip, shift, or fall. Load only to a height that will allow a clear view ahead. For added safety, strap or chain bulky or dangerous cargo (such as cylinders or drums) to the hand truck’s frame. Avoid walking backward with a hand truck if possible. This eliminates the need for a worker to look over their shoulder to see clearly. Never brake a hand truck by putting your foot on its wheel; keep your feet clear of the wheels at all times. When going down an incline, keep the hand truck ahead of you. When going up, pull the hand truck behind you. Move the truck at a safe speed. Do not run. Keep the truck constantly under control. Secure and store unused trucks in a designated area where they don't create a hazard or traffic obstruction. When a hand truck is loaded in a horizontal position, proper lifting procedures will be used to
- 216. prevent operator injury. 1.The same basic principles listed in paragraphs through shall apply to dollies and wheelbarrows. Two-wheeled hand trucks and wheelbarrows are designed in a variety of shapes and sizes for both general and special purposes. Preference will be given to procuring hand trucks and wheelbarrows equipped with knuckle guards. 2. Multi-Wheel Trucks. As with two-wheeled equipment, multi-wheeled trucks and dollies vary greatly in design and use. Most mishaps occur due to improper parking causing the worker to fall over the equipment or improper loading of material which causes the cart to tip. Extra emphasis will be placed on worker training in these two areas, along with frequent observation of work practices to immediately correct unsafe acts. In addition: 1. When loading, arrange the cargo so items won’t fall. 2. If the truck has no drawbar, push it. Keep your hands behind the cart. 3. If the truck has a drawbar, pull it, so you’ll be able to see better. Stand to one side, to keep the truck from running onto your ankles. 4. If there are floor markings, stay within their boundaries. 5. When storing the truck, lock or block its wheels. 6. Don’t misuse the truck. 7. Don’t ride on a truck designed for a walking operator. 8. Don’t carry other people. 9. Don’t carry more than the truck’s maximum load capacity. 10. Ensure the weight of the truck, plus its load, is less than maximum posted floor loads. 11. Make sure you have enough clearance in aisles and other tight areas. 12. Remember that the inertia, or momentum, of a truck can make it hard to change its speed or direction. 13. Watch out for pedestrians--always give them the right-of-way. 14. Don’t block aisles, doorways, or material another worker may need. 3. Lever-Operated Hoists: 1. Acquisition. Lever-operated hoists shall meet the requirements and specifications of recognized industry standards. Capacity of all lever-operated devices shall be permanently and conspicuously marked in an easily visible place on the hoist. Only ratchet and pawl and load brake hoists, which include a means to prevent a suspended load from self-lowering, will be procured. Lowering under load shall be by operation of the hoist lever. Inspections. Daily or prior to each use, lever-operated hoists shall be inspected for: Loose or worn parts, nuts, bolts, etc.; Cracked or broken welds or parts; Deformed or damaged hooks Bent or deformed pawls. 4. Annual inspection shall include: 1. Complete inspection of all wire rope, chain, and fittings or attachments. 2. Inspection of brakes, pawls, or other holding features. 3. Inspection of the chain length. Chains that have elongated more than one fourth of an inch in 12 inches shall be removed from service.
- 217. 4. Identification Tags.Identification tags shall be attached to all hoists and shall include the following information: date of inspection; date of proof test; capacity of hoist; and identification number of hoists. 5. Maintenance and Testing: 1. All new hoists will have the manufacturer’s certification indicating that all proof-testing has been accomplished. All hoists which have had load-suspension parts altered, replaced, or repaired will be proof-tested before use. These tests will be performed at no less than 100 percent or more than 125 percent of the rated capacity. Underhung hoists that are not an integral part of a supporting structure for lateral movement, such as an overhead crane, must have manufacturer’s certification indicating the proof test was accomplished with a test load of at least 125% of rated capacity) Reference ANSI/ASME B30.16). A record of all tests will be maintained by the user. 2. Maintenance and lubrication will be performed according to the manufacturer’s instruction. 6. Safe Operations: 1. Lever-operated hoists shall only be used in a direct pull. Where indirect pulls are permitted by design of the hoist, a sheave or pulley of adequate size shall be used. 2. Hoist cable, rope, and chain shall not be wrapped around the load. Use only slings or other approved lifting devices. 3. Positive action safety latches shall be installed on all hooks. 4. Hooks shall not be point loaded unless designed for this purpose. All loads shall be seated in the saddle of the hook. 5. Extensions to levers (cheater bars or pipes) shall not be used to increase leverage. Extendible levers designed and permanently installed by the manufacturer are authorized. 6. Manually operated lever hoists shall only be operated by personnel familiar with the use of the equipment. Operator qualifications will be as determined by the facility and (or) shop supervisor or designated representative. 7. The rated load shall not be exceeded except for authorized proof tests. 8. Hoists shall be attached to well defined dead-end points capable of withstanding the intended load. NOTE: Lifeline attach points shall not be used for hoists. 9. Inspection of Materials. Prior to movement, material will be examined for sharp edges, protruding points, and weak places. When defects cannot be corrected, additional steps will be taken to protect the worker. This should be accomplished by isolating the unsafe condition, for example, using an enclosed cart when moving sheet metal scraps. Personal Protective Equipment (PPE). Supervisors will conduct a JSA to evaluate each manual material handling task and identify the need for PPE such as safety-toed shoes, gloves, and eye protection. The EH&S Department is available to assist in this evaluation process. Protective footwear shall be provided and worn when there is a reasonable possibility of sustaining foot injuries due to heavy or sharp objects and electrical and (or) static electricity considerations. Personnel will wear leather or leather-palmed gloves when manually handling objects that have sharp or burred edges or splintered surfaces.
- 218. Personnel will wearappropriate ear protection when working in or visiting hazardous noise areas. Personnel will carry tools that have sharp edges in protective holders. Personnel will wear appropriate protective clothing when transporting, delivering, or working with hazardous materials. Material handlers will not wear finger rings, jewelry (which may include watches), or loose clothing and will keep long hair completely covered when around moving conveyor belts, open rotating shafts, or other moving parts of machinery. Personnel will wear goggles and (or) safety glasses with side shields and gloves when cutting strapping. Personnel will stand clear so cut strapping does not contact them. A board or other hold-down device may be used to prevent the strapping from flying out from the material when cut. Inspection and Maintenance of Manual Handling Equipment (MHE): Manual MHE, such as hand trucks, wheelbarrows, dollies, pallet jacks and similar unpowered equipment, will be checked visually before use to assure equipment is in operable condition. This equipment will also be maintained and inspected in accordance with the manufacturer’s instructions. Any repairs required will be accomplished prior to use of the equipment. Other Safety Requirements: 1. Stack all materials neatly, arrange them in an orderly manner. Limit the stack height to minimize the possibility for the materials to fall or collapse. 2. Remove, repair, or replace defective or broken strapping on material. 3. Except when using approved chutes, do not throw materials from elevated places. Carry or lower them. 4. If materials handling equipment (MHE) is not available and drums must be manually moved; roll drums by pushing with the hands, not the feet. Ensure a minimum of two workers set the drum upright. 5. Place broken glass in a sturdy container or enclose the broken glass in cardboard or protective shield if disposal includes placing glass in a plastic bag. This should eliminate broken glass protruding from bags and prevent injury to personnel who handle the bags. 6. Do not run when carrying materials. 7. Practice good housekeeping when unpacking materials. Discard banding, packing materials, and empty cartons properly and do not allow these materials to accumulate in work areas. Composition of the flooring The flooring is constructed on the substrate, which normally consists of a sub-base of agglomerated material, firmly compacted to withstand the load. This layer consists of any type of material, either natural or filler. A concrete slab designed to support the pressure is placed onto the sub-base.
- 219. Concrete slabs havehigh compressive strength yet little tensile strength. During their curing process, the concrete contracts but the conglomerated sub-base does not. These contractions produce tensions in the slab, which can lead to accidental breakage and warping. To minimize these problems, one must ensure that the surface of the substrate onto which the slab is placed is completely flat and smooth. Once this point has been checked, a type of membrane or film is placed between the sub-base and the substrate to reduce the friction between the two. During the curing process, this film allows the slab to move independently and acts as a barrier against humidity, which is required to limit the loss of water in the concrete and achieve better curing. Another measure to relieve the problem of potential breakage and very frequent warping consists of installing a light metal reinforcing mesh that remains close to the surface. This is a very common practice that allows for the construction of larger slabs with fewer expansion joints. Reinforcement can also be provided using steel bars, which increase the resistance of the cured layer despite the inevitable contractions and slippage suffered by the concrete during the process. Whether or not this reinforcement is included, it is inevitable that cracks will appear in the cured slabs, even if the greatest possible care has been taken in their construction. If these cracks are incidental and random, the impossibility of carrying out the appropriate filling due to their irregular shape invariably causes problems in terms of load fluctuations. Cracking is often induced so that these openings appear in specific places that can be observed and controlled. This is done by sawing the slab along a given strip, cutting to a depth of between one-quarter and one-third of the layer's thickness. In this way, the breakage takes place in these positions as opposed to others, and can be easily filled following a simple and clean process.
- 220. Strength, porosity, bondingand durability of floorings In addition to the construction characteristics mentioned earlier, warehouse floors must also have other features that make them particularly suitable for their intended use. Thus, they must be resistant to abrasion, an issue addressed in the UNE 41008 standard, which establishes a scale known as the MOHS that goes from 0 to 10. They must also withstand compression, and be able to support over 7,112 psi in general areas. Depending on the devices used, they may be required to support up to 11,378 psi on the routes used for the movement of the devices. In terms of requirements for flexural resistance, these tend to be around 2,133 psi to 3,556 psi. The floor must also be resistant to the effects of elements such as oil, grease, and hydrocarbons. While these materials are not stored in the installation, they are used for the forklifts and there will inevitably be stains on the floor. Allowable porosity must be very low (below 3%). The flooring must form a monolith together with the support base to prevent slippage and downward movements that cause bumps on the surface. Finally, the floor must be durable and resistant to wear and tear, although it is inevitable that over time ruts will form from the constant repetitive movements of the wheels of devices along the same routes and given their tremendous weight. These ruts can become very deep and cause misalignments in the facility, with the resulting implicit risks. Using a company that specializes in flooring for narrow aisle forklifts is, undoubtedly, the best way to ensure a perfect and longest-lasting surface. Skimping in this respect can seriously compromise the entire facility. A very expensive project can be ruined due to savings in one area that appears less important, but which in practice is crucial. Devising a warehouse's layout is the first step in designing an installation. While this may seem like a simple issue, in practice it is difficult to figure out. In this article, it outlines the main factors that need consideration in the design process. As well, it shows an example of a warehouse layout distributed into six differentiated areas, including AS/RS systems. Generally speaking, warehouse designers have to work with a space in which certain factors limit the surface area available. This is why the layout has to be carefully planned. When deciding on the internal and external layout of a warehouse, there are three possible scenarios that could necessitate a different assignment of space: the installation of new warehouses, the extension of existing facilities and the reorganization of those currently operating (even though the last of these options does not involve making extremely important decisions that will affect the development of the business over the medium- to long-term). Nonetheless, despite the specific circumstances, the general layout of a facility must cover all these needs: Making the most of the available space Reducing the handling of goods to a minimum
- 221. Providing easyaccess to the stored product Having the highest rotation ratio possible Offering maximum flexibility in the positioning of products Controlling the amounts stored To achieve these objectives, the first step is to create a warehouse layout, where the design of the warehouse is represented in the form of a plan. First and foremost, the created layout must respect the basic rules of good storage mentioned above and avoid areas and points of congestion, facilitate maintenance tasks and establish the resources required to obtain the greatest possible workflows, with the associated reduction in runtimes. The following areas must be perfectly defined when designing a layout: A. Loading and unloading areas B. Reception area C. Storage area D. Picking area E. Dispatch area An example of a layout that includes all of these areas is shown below:
- 222. Mechanical material handling: LiftingMachineries: I. Transport Equipment. Equipment used to move material from one location to another (e.g., between workplaces, between a loading dock and a storage area, etc.). The major subcategories of transport equipment are conveyors, cranes, and industrial trucks. Material can also be transported manually using no equipment. II. Positioning Equipment. Equipment used to handle material at a single location (e.g., to feed and/or manipulate materials so that are in the correct position for subsequent handling, machining, transport, or storage). Unlike transport equipment, positioning equipment is usually used for handling at a single workplace. Material can also be positioned manually using no equipment. III. Unit Load Formation Equipment. Equipment used to restrict materials so that they maintain their integrity when handled a single load during transport and for storage. If materials are self-restraining (e.g., a single part or interlocking parts), then they can be formed into a unit load with no equipment. IV. Storage Equipment. Equipment used for holding or buffering materials over a period of time. Some storage equipment may include the transport of materials (e.g., the S/R machines of an AS/RS, or storage carousels). If materials are block stacked directly on the floor, then no storage equipment is required. V. Identification and Control Equipment. Equipment used to collect and communicate the information that is used to coordinate the flow of materials within a facility and between a facility and its suppliers and customers. The identification of materials and associated control can be performed manually with no specialized equipment. A. Conveyors: 1. Chute conveyor 2. Wheel conveyor 3. Roller conveyor 4. Chain conveyor 5. Slat conveyor 6. Flat belt conveyor 7. Magnetic belt conveyor 8. Troughed belt conveyor 9. Bucket conveyor 10. Vibrating conveyor 11. Screw conveyor 12. Pneumatic conveyor 13. Vertical conveyor 14. Cart-on-track conveyor 15. Tow conveyor 16. Trolley conveyor 17. Power-and-free conveyor 18. Monorail 19. Sortation conveyor B. Cranes: 1. Jib crane 2. Bridge crane 3. Gantry crane 4. Stacker crane C. Industrial Trucks: 1. Hand truck 2. Pallet jack 3. Walkie stacker 4. Pallet truck 5. Platform truck 6. Counterbalanced lift truck 7. Narrow-aisle straddle truck 8. Narrow-aisle reach truck 9. Turret truck 10. Order picker 11. side loader 12. Tractor-trailer 13. Personnel and burden carrier 14. Automatic guided vehicle
- 223. Lifts and hoists: Usedfor vertical translation (i.e., lifting and lowering) of loads Frequently attached to cranes and monorails to provide vertical translation capability Can be operated manually, electrically, or pneumatically Uses chain or wire rope as its lifting medium Hoists are categorized into duty classes: H1 infrequent, standby duty use (1 or 2 lifts per month); H2—light duty (avg. 75 start/stops per hour); H3— medium (max. 250 start/stops per hour); H4—heavy, and H5—severe duty Signaling: • The "crane operator" is responsible for operating the crane correctly and safely. be at least 18 years of age and hold a valid crane operation certificate; be familiar with hand signals for communication. The "slinger" is responsible for attaching and detaching the load to and from the crane. He shall: – have received appropriate training on general safe lifting operations; selecting lifting gears suitable for the loads; movement of the crane safely. • The "signaler" is responsible for relay He shall: – have received appropriate training on general safe lifting operations; direct the movement of the crane and loads. Used for vertical translation (i.e., lifting and lowering) of loads Frequently attached to cranes and monorails to provide vertical translation capability Can be operated manually, electrically, or pneumatically Uses chain or wire rope as its lifting medium Hoists are categorized into duty classes: H1 duty use (1 or 2 lifts per month); light duty (avg. 75 start/stops per hour); medium (max. 250 start/stops per hour); • The "crane operator" is responsible for operating the crane correctly and safely. be at least 18 years of age and hold a valid crane operation certificate; – be physically fit; be familiar with hand signals for communication. The "slinger" is responsible for attaching and detaching the load to and from the crane. He have received appropriate training on general safe lifting operations; selecting lifting gears suitable for the loads; – liaise with the operator and direct the movement of the crane safely. • The "signaler" is responsible for relaying the signal from the slinger to the crane operator. have received appropriate training on general safe lifting operations; direct the movement of the crane and loads. Frequently attached to cranes and monorails to provide vertical translation capability Can be Uses chain or wire rope as its lifting medium Hoists are categorized into duty classes: H1— • The "crane operator" is responsible for operating the crane correctly and safely. He shall: – be physically fit; – The "slinger" is responsible for attaching and detaching the load to and from the crane. He have received appropriate training on general safe lifting operations; – be capable of liaise with the operator and direct the ing the signal from the slinger to the crane operator. have received appropriate training on general safe lifting operations; – be able to
- 224. Industrial machinery: Machinery –refers to lifting appliances and all lifting gears. The lifting appliance includes a crab, winch, teagle, pulley block, gin wheel, crane, sheerleg, excavator, pile driver, pile extractor, dragline, aerial rope way, aerial cableway transporter or overhead runway, etc. Industrial lifting trucks: Industrial lift trucks are powered mobile plant designed to move goods, materials or equipment. They are equipped with an elevating load carriage and for normal use, are equipped with a load-holding attachment. There are different types of powered industrial lift trucks including ride-on forklift trucks, pedestrian-operated trucks, straddle carriers and reach trucks. Mobile cranes, earthmoving machinery and manually-powered lift trucks like pallet lifters are not industrial lift trucks. For the purposes of this Guide, reach stackers, multi-purpose tool carriers and telehandlers are not industrial lift trucks. What is a forklift truck? A forklift truck is a powered industrial lift truck equipped with lifting media made up of a mast and elevating load carriage with a pair of fork arms or other arms that can be raised 900 mm or more off the ground. A pedestrian-operated lift truck or a manually powered pallet truck is not a forklift truck. Forklift trucks are the most commonly used industrial lift truck. How can industrial lift truck risks be managed? Use the following steps to ensure, so far as is reasonably practicable, that workers and other people are not exposed to health and safety risks: 1. Find out what could cause harm. The following can help you identify potential hazards: „ Observe the workplace to identify areas where industrial lift trucks operate and how they interact with other vehicles, pedestrians and fixed structures like storage racks. „ Visually inspect the industrial lift truck.
- 225. „ Ask yourworkers, pedestrians and visiting delivery drivers about any problems they encounter at your workplace when interacting with industrial lift trucks–consider operation, inspection, maintenance, repair, transport and storage requirements. „ Review your incident and injury records including near misses. 2. Assess the risk if necessary. In many cases the risks and related control measures will be well known. In other cases, you may need to carry out a risk assessment to identify the likelihood of somebody being harmed by the hazard and how serious the harm could be. Most incidents involving industrial lift trucks are from: „ the industrial lift truck overturning or the operator being ejected „ collisions with pedestrians or other vehicles working in the same area „ loading and unloading e.g. loads falling on operators or workers, and „ mechanical failure of pressurized systems (e.g. hydraulic) that may release fluids that pose a risk. People who work with or near industrial lift trucks are most at risk. Customers and visitors may also be at risk. A risk assessment can help you determine what action you should take to control the risk and how urgently the action needs to be taken. 3. Act to control the risk. The WHS laws require a business or undertaking do all that is reasonably practicable to eliminate or minimize risks. The ways of controlling risks are ranked from the highest level of protection and reliability to the lowest. This ranking is known as the hierarchy of risk control. You must work through this hierarchy to manage risks. The first thing to consider is whether hazards can be completely removed from the workplace. For example, risks can be eliminated by changing the workplace so materials are delivered directly to the location where they are stored so there is no need to use an industrial lift truck. If it is not reasonably practicable to completely eliminate the risk then consider one or more of the following options in the order they appear below to minimize risks, so far as is reasonably practicable: „ substituting the hazard for something safer e.g. use a manually-powered lift truck or pedestrian-operated lift truck instead of a ride-on forklift truck „ isolating the hazard from people e.g. by installing physical barriers that separate people from operating industrial lift trucks „ using engineering controls e.g. using a falling object protective structure (FOPS) or a roll over protective structure (ROPS), or a combination of both. If after implementing the above control measures a risk still remains, consider the following controls in the order below to minimize the remaining risk, so far as is reasonably practicable: „ using administrative controls e.g. schedule delivery times to avoid or reduce the need for pedestrians and vehicles to interact, or „ using personal protective equipment (PPE) e.g. high visibility clothing and eye protection. #1 Identify hazards #2 Assess risks #3 Control risks GENERAL GUIDE FOR INDUSTRIAL LIFT TRUCKS:
- 226. A combination ofthe controls set out above may be used if a single control is not enough to minimize the risks. You need to consider all possible control measures and decide about which are reasonably practicable for your workplace. Deciding what is reasonably practicable includes the availability and suitability of control measures, with a preference for using substitution, isolation or engineering controls to minimize risks before using administrative controls or PPE. Cost may also be relevant, but you can only consider this after all other factors have been considered. Check your control measures regularly to ensure they are working as planned. 4. Check Your Control Measure: Control measures need to be regularly reviewed to make sure they remain effective, taking into consideration any changes, the nature and duration of work and that the system is working as planned. Further information on the risk management process is in the Code of Practice: How to manage work health and safety risks. More information on managing the risks of plant is in the Code of Practice: Managing risks of plant in the workplace Choosing an industrial lift truck: Before you choose an industrial lift truck you should discuss your workplace needs with suppliers and identify industrial lift trucks that are most suited to the workplace and the work it will be used for. For example, a pedestrian operated industrial lift truck may be more suitable to minimize traffic movement risks in a small, busy workplace than a ride-on industrial lift truck. A second-hand industrial lift truck is more likely to have outdated or missing safety features. Suppliers of a second-hand lift truck must do what is reasonably practicable to supply equipment that is safe to use at work. Some of the things to look for when choosing an industrial lift truck are: „ operator protective devices e.g. ROPS and FOPS „ integrated guarding e.g. for engine and battery compartments „ safe entry and exit e.g. enough steps and handholds „ low noise and vibration e.g. through a sprung and adjustable seat „ a fork load back-rest high enough to prevent the load or part of the load falling back onto the operator „ good visibility e.g. adjustable rear vision mirrors of enough size „ operator activated warning device (e.g. a horn) „ flow restrictors or similar, fitted to hydraulic lines to prevent free fall in the event of hydraulic hose failure e.g. when lifting people in a work box „ emission control systems or forklifts that do not produce emissions e.g. if the industrial lift truck will be working in a poorly ventilated area e.g. cold store, and „ flame and static proofing e.g. if the industrial lift truck will be working in or near areas containing flammable or combustible atmospheres or materials. Lifting Tackles: Lifting gears play an important part in the lifting operation. Their function is to tie the objects tightly and hang them on the crane. There is a great variety of lifting gears. If there is insufficient knowledge or a wrong choice is made, lifting may fail and accidents may result. All lifting gears shall be tested by qualified examiners and suitably marked with a Safe Working Load (SWL).
- 227. Wire rope slings: Wire rope consists of individual wires laid into a number of strands, which are then wrapped around a central core. Different number of wires in the strands and various methods of arrangement may affect the characteristics of the wire rope sling. The wire rope shall be equipped with a thimble and with pressed metal sleeve and marked with a Safe Working Load (SWL) Inspection points: • The wire rope sling shall not be used and shall be disposed if they are: Points for attention: • Use only suitable wire rope slings. • Never use damaged wire rope slings. • During lifting, the Safe Working Load must not be exceeded. • Regular inspections shall be conducted • Sudden elevation is not allowed • If more than one wire rope sling is used in lifting, pay attention to the angle between the slings.
- 228. Wire rope slings- cable clip The cable clip shall be properly installed according to the following points: • The wire rope sling is equipped with thimble. • There is a minimum of 3 cable clips. • The direction of instal • The distance between the cable clips shall be the same. Wire rope slings - cable clip The cable clip shall be properly installed according to the following points: • The wire rope sling is equipped with thimble. • There is a minimum of 3 cable clips. • The direction of installation shall be correct. • The distance between the cable clips shall be the same. cable clip The cable clip shall be properly installed according to the following points: • The wire rope sling is equipped with thimble. • There is a minimum of 3 cable clips. • The direction of installation shall be correct. • The distance between the cable clips shall be the same. cable clip The cable clip shall be properly installed according to the following points: • The wire rope sling is equipped with thimble. • There is a minimum of 3 cable clips. • The direction of installation shall be correct. • The distance between the cable clips shall be the same. The cable clip shall be properly installed according to the following points: The cable clip shall be properly installed according to the following points:
- 229. Chain slings Rigging equipmentfor material handling: Rigging equipment inspections (By a Competent Person – Prior to use on each shift – As necessary during its use to ensure that it is safe – Defective rigging equipment removed from service Not be loaded in excess of its recommended safe working load Custom design grabs, hooks, clamps, or other lifting accessor modular panels, prefabricated structures and similar materials Marked to indicate the safe working loads Be proof-tested prior to use to 125 percent of their rated load Alloy steel chains Welded alloy steel chain slings – Permanently affixed durable identification stating Size Grade Rated capacity Sling manufacturer Alloy steel chains Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, other such attachments, shall not be used Inspections – Frequent Visual examination by the user Periodic – Complete link by link inspection of the entire sling and all attachments. Rigging equipment for material handling: Rigging equipment inspections (By a Competent Person) Prior to use on each shift As necessary during its use to ensure that it is safe Defective rigging equipment removed from service Not be loaded in excess of its recommended safe working load Custom design grabs, hooks, clamps, or other lifting accessories, for such units as modular panels, prefabricated structures and similar materials Marked to indicate the safe working loads tested prior to use to 125 percent of their rated load Alloy steel chains alloy steel chain slings Permanently affixed durable identification stating Rated capacity Sling manufacturer Alloy steel chains Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, other such attachments, shall not be used Visual examination by the user Complete link by link inspection of the entire sling and all attachments. ies, for such units as tested prior to use to 125 percent of their rated load Job or shop hooks and links, or makeshift fasteners, formed from bolts, rods, etc., or Complete link by link inspection of the entire sling and all attachments.
- 230. – Documented CPinspections made & based on – Frequency of sling use; – Severity of service conditions; – Nature of lifts being made; and – Experience gained on the service life of slings used in similar circumstances. Such inspections at least once a year Documented & available Shackles: Hook rings are divided into two main ca type shackle. Both are available with screw pins or round pins. Points for attention: • Never replace the shackle pin with a bolt. • Ensure the pin is totally locked. • Do not use screw pin shackles if the pin can roll and unscrew. • During lifting, shackles shall not lean to one side. Hook rings are divided into two main categories: Chain ("D" type) shackle and anchor (bow) type shackle. Both are available with screw pins or round pins. • Shackle pins must always be attached to the hook. • Washers may be used to center the shackle. Eye bolts Eye bolts are mainly classified into plain (shoulder less) eye bolts and shoulder type eye bolts. • The bolt length shall be 1-1.5 times the diameter of the bolt and totally drilled on the load. • The bolt hole shall fit into the bolt CP inspections made & based on Frequency of sling use; Severity of service conditions; Nature of lifts being made; and Experience gained on the service life of slings used in similar circumstances. Such inspections at least once a year Documented & available Hook rings are divided into two main categories: Chain ("D" type) shackle and anchor (bow) type shackle. Both are available with screw pins or round pins. • Never replace the shackle pin with a bolt. • Ensure the pin is totally locked. • Do not use screw pin shackles if the pin can roll and unscrew. • During lifting, shackles shall not lean to one side. Hook rings are divided into two main categories: Chain ("D" type) shackle and anchor (bow) type shackle. Both are available with • Shackle pins must always be attached to the hook. • Washers may be used to center the shackle. Eye bolts are mainly classified into plain (shoulder less) eye bolts and shoulder type eye 1.5 times the diameter of the bolt and totally drilled on the load. • The bolt hole shall fit into the bolt Experience gained on the service life of slings used in similar circumstances. tegories: Chain ("D" type) shackle and anchor (bow) • During lifting, shackles shall not lean to one side. Hook rings are divided into two main categories: Chain ("D" type) shackle and anchor (bow) type shackle. Both are available with Eye bolts are mainly classified into plain (shoulder less) eye bolts and shoulder type eye 1.5 times the diameter of the bolt and totally drilled on the load.
- 231. Safety points: • Thehook shall not be directly fixed on to the eye bolt. • Plain eye bolts only apply to the • The angle of lifting of shoulder eye bolts shall not be less than 45 • Washers may be used to ensure that the shoulder is firmly in contact with the surface. • Never use a sling through a pair of eye bolts. Conveyors Belt: 1. Chute conveyor 2. Wheel conveyor 3. Roller conveyor 4. Chain conveyor 5. Slat conveyor 6. Flat belt conveyor 7. Magnetic belt conveyor 8. Troughed belt conveyor 9. Bucket conveyor 10. Vibrating conveyor 11. Screw conveyor 12. Pneumatic conveyor 13. Vertical conveyor 14. Cart-on-track conveyor 15. Tow conveyor 16. Trolley conveyor 17. Power free conveyor 18. Monorail 19. Sortation conveyor Conveyors are used: • When material is to be moved frequently between specific points • To move materials over a fixe • When there is a sufficient flow volume to justify the fixed conveyor investment Conveyors can be classified in different ways: • Type of product being handled: unit load or bulk load • Location of the conveyor: in • The hook shall not be directly fixed on to the eye bolt. • Plain eye bolts only apply to the vertical lifting. • The angle of lifting of shoulder eye bolts shall not be less than 45o. • Washers may be used to ensure that the shoulder is firmly in contact with the surface. • Never use a sling through a pair of eye bolts. conveyor 2. Wheel conveyor 3. Roller conveyor 4. Chain conveyor 5. Slat conveyor 6. Flat belt conveyor 7. Magnetic belt conveyor 8. Troughed belt conveyor 9. Bucket conveyor 10. Vibrating conveyor 11. Screw conveyor 12. Pneumatic conveyor 13. Vertical track conveyor 15. Tow conveyor 16. Trolley conveyor 17. Power free conveyor 18. Monorail 19. Sortation conveyor • When material is to be moved frequently between specific points • To move materials over a fixed path • When there is a sufficient flow volume to justify the fixed conveyor investment Conveyors can be classified in different ways: • Type of product being handled: unit load or bulk load • Location of the conveyor: in-floor, on-floor, or overhead • Washers may be used to ensure that the shoulder is firmly in contact with the surface. conveyor 2. Wheel conveyor 3. Roller conveyor 4. Chain conveyor 5. Slat conveyor 6. Flat belt conveyor 7. Magnetic belt conveyor 8. Troughed belt conveyor 9. Bucket conveyor 10. Vibrating conveyor 11. Screw conveyor 12. Pneumatic conveyor 13. Vertical track conveyor 15. Tow conveyor 16. Trolley conveyor 17. Power-and- • When there is a sufficient flow volume to justify the fixed conveyor investment Conveyors
- 232. • Whether loadscan accumulate on the conveyor or no accumulation is possible 1. Chute conveyor Unit/Bulk + On-Floor + Accumulate Inexpensive Used to link two handling devices Used to provide accumulation in shipping areas Used to convey items between floors Difficult to control position of the items 2. Wheel conveyor Unit + On-Floor + Accumulate Uses a series of skate wheels mounted on a shaft (or axle) Spacing of the wheels is dependent on the load being transported Slope for gravity movement depends on load weight More economical than the roller conveyor For light-duty applications Flexible, expandable mobile versions available 3. Roller conveyor Unit + On-Floor + Accumulate May be powered (or live) or nonpowered (or gravity) Materials must have a rigid riding surface Minimum of three rollers must support smallest loads at all times Tapered rollers on curves used to maintain load orientation Parallel roller configuration can be used as a (roller) pallet conveyor (more flexible than a chain pallet conveyor because rollers can be used to accommodate are greater variation of pallet widths) 4./ Chain conveyor Unit + In-/On-Floor + No Accumulation Uses one or more endless chains on which loads are carried directly Parallel chain configuration used as (chain) pallet conveyor or as a pop-up device for sortation (see Sortation conveyor: Pop-up devices) Vertical chain conveyor used for continuous high-frequency vertical transfers, where material on horizontal platforms attached to chain link (cf. vertical conveyor used for low-frequency intermittent transfers) 5. Slat conveyor Unit + In-/On-Floor + No Accumulation Uses discretely spaced slats connected to a chain Unit being transported retains its position (like a belt conveyor) Orientation and placement of the load is controlled Used for heavy loads or loads that might damage a belt Bottling and canning plants use flat chain or slat conveyors because of wet conditions, temperature, and cleanliness requirements.
- 233. Safe Workload Limit: SafeWorking Load (SWL) sometimes stated as the Normal Working Load (NWL) is the maximum safe force that a piece of lifting equipment, lifting device or accessory can exert to lift, suspend, or lower, a given mass without fear of breaking. Usually marked on the equipment by the manufacturer. It is a calculation of the Minimum Breaking Strength (MBS)aka Minimum Breaking Load (MBL) divided by its risk factor, usually ten to one (10:1 or 1/10) for lifting equipment although depending on the application. SWL can also apply to other lifting devices or components of lifting devices, such as a line, rope or crane. The SWL is also sometimes referred to as Normal Working Load or Working Load Limit. It is the mass that lifting equipment can safely hold without fear of breaking. The SWL or NWL is often a fifth of the Minimum Breaking Strength of the cable, although sometimes other fractions are used, depending on the manufacturer. The manufacturer's recommended maximum weight load for a line, rope, crane or any other lifting device or component of a lifting device. The SWL is determined by dividing the minimum breaking strength (MBS) of a component by a safety factor assigned to that type and use of equipment. The safety factor generally ranges from 4 to 6 unless a failure of the equipment could pose a risk to life; in that instance the safety factor would be a 10. For example, if a line has an MBS of 1,000 pounds and a safety factor of 5, then the SWL would be 200 pounds. 1000 / 5 = 200. Also called working load limit (WLL). Making the Calculations To calculate the SWL, you need to know the diameter of the cable or rope. While you may find this on the packaging, you can also calculate it manually by measuring it yourself. Ensure that you enclose all of the strands of rope when measuring the diameter, and measure from the top of one strand to the top of the strand which is directly opposite. If you’re worried about the accuracy of your measurements, conduct your measurements three times at different places on the cable, and use the average of your three measurements as the diameter of the rope. Once you know the diameter of the rope, you can apply it to the formula, which is SWL = D2 x 8. D represents the diameter of the rope in inches. If you’re working with a 1.5-inch diameter cable, for example, then the formula would be SWL = 1.52 x 8 or SWL = 2.25 x 8. This calculation means the SWL of a 1.5-inch diameter rope is 18 tons.
- 234. In Health andSafety, it is expected that all manufacturers of a lifting equipment and lifting accessories should specify the safe working load of that equipment/accessory to prevent overload. Overload of an equipment can result to accidental release of the load which could cause serious injury or death. To ensure safe lifting, risk assessment must be carried out for all lifting exercises. One of the things to consider during the risk assessment is the lifting machinery, lifting accessories and the load. This consideration will guide on the choice of the best lifting machinery and accessories for a successful completion of the task. Any machinery that do not have its safe working load conspicuously stamped on the body of the equipment should not be used for lifting based on assumption. If need arise to make use of the equipment, the manufacturer of the lifting equipment or the lifting accessories should be contacted in order to ascertain the capacity of the equipment or accessories before use. SWL Chart: Taking Precautions Take note that most manufacturers will provide you with the SWL for their rope or cable under specific conditions. It’s important to use the SWL the manufacturer gives you. If you’re working with old rope or rope that is worn down, you may want to reduce the SWL of the rope by as much as half, based on the condition of the rope. You can also use the manufacturer’s Breaking Strength of the rope if it is available. Safe System of Work for Inspection, Thorough Examination and Testing 28 8.1 A safe system of work should be developed to ensure the safety of personnel engaged in the job in addition to carrying out of a good quality and accurate inspection, examination or test. Legally, every employer must ensure the safety and health at work of all his employees. He should provide and maintain a safe system of work that is safe and without risk to health. The safe system of work should be worked out under the advice of a registered safety officer. The system should include the following main ingredients:
- 235. • site conditions; •weather conditions; • test weights; • procedure and safety precautions; • prevention from swinging or wheeling outwards of loads; • competence of operator engaged in examination or testing; Site Conditions When a lifting appliance or lifting gear is to be examined or tested in a site or inside a workshop, due consideration should be given to the condition of the site or premises where examinations or tests are to be conducted. Whenever possible, the lifting appliance or lifting gear should be examined and tested in open area or workshop where no other work activities are carried out concurrently. The ground or structure for support the lifting appliance should be well consolidated, structurally stable and capable of withstanding the loads that would be applied to it. Care should be taken to ensure that there are no hidden hazards in the vicinity such as cable ducts, drains, pipes, back-fill areas, cellars or other underground weakness when testing of a lifting appliance is conducted. Lifting appliances should not be examined or tested in the vicinity of overhead power lines. In general, brick or masonry work, metal or bamboo scaffolding, or temporary structure or working platforms should not be used as a test site during the proof load test. The site where the test is conducted should be of sufficient area and have unrestricted overhead clearance to allow the unobstructed movement of the lifting appliance and load throughout all its appropriate test movements. It should also keep in mind to ensure all personnel not involved in the test be kept away from the test area. Particular care should be taken when a mobile crane or a tower crane is tested near a public area, highway, or occupied buildings. Appropriate time and date should be arranged with all relevant parties to keep away traffic and pedestrians during the test. Weather Conditions: If the test site is situated in an open area, examinations or tests should not be carried out in adverse weather condition. Gusting wind may introduce an additional adverse effect on the safe handling of the load and the safe operation of the lifting appliance. Accident may happen to the personnel involved in the examination or test as rainy weather may increase the slipperiness of the frame structure of the lifting appliance on which they may walk. Suitable safety precautions should be devised if examinations and tests in such weather condition could not be avoided. Test Weights The test weights used should comply with the following requirements: • weights of proven accuracy within +/- 1.0%, • weights proven on a weighbridge, the weighbridge has been calibrated within the last 12 months, and • weights suspended from a calibrated weighing device, the weighing device has been calibrated within the last 12 months. The suspended test weights should be kept as close to the ground as possible, such as in the range of 100mm to 200mm above ground. Safety precautions should be taken to ensure the
- 236. work safety ofthe personnel involved in the proof load test if the test weights are required to be hoisted or travelling along a path. Test weights should be made up of concrete/metal blocks/plates, preferably with markings to show their actual weights. Under no circumstances, should reinforcement bars, wooden planks or life load be used as test weights. Procedure and Safety Precautions A proper procedure should be worked out to clearly define the sequence and the responsibility of each personnel engaged in the inspection, examination or test of a lifting appliance or lifting gear. It should set out which tests to be carried out first and what follows a non-destructive test. It is important to note down all safety precautions from relevant codes of practice, national/international standards and the manufacturer's operation and maintenance manual, and if appropriate, incorporate them into the safe system of work. The proper procedure and safety precautions for manually handling heavy test weights, equipment and lifting tackles should be laid down. If it involves working at height, relevant safety measures to prevent fall of persons should be adopted, including the provision of safe access and egress, proper working platforms and personal protective equipment such as independent life lines and safety harnesses, etc. A briefing session to explain and highlight the procedure and precautions should be conducted to ensure that every personnel is fully familiar with this topic. Prevention from Swinging or Wheeling outwards of Loads When a lifting appliance operates with various SWLs at different working radii, adequate precautions should be exercised during the proof load test to prevent the load from swinging or wheeling outwards in order not to overload the lifting appliance. In case of a horizontal jib crane with trolley, suitable device should be fitted at the maximum radius of the jib, e.g. clamps to prevent the trolley from moving beyond this point. Competence of Operator Engaged in Examination or Testing The safe system of work should specify the competence of the operator who is engaged in the functional test or proof load test. The operator should be familiar with the characteristics of the lifting appliance, the safety precautions in handling overloading and the limitation of the lifting appliance in the brake test, functional test and proof load test. He should be able to put the lifting appliance under control at any time during the examination and testing work. The operator should hold a relevant certificate, if required under the law, to qualify him in operating the lifting appliance. He should fully understand all signals given by the competent examiner to operate the lifting appliance smoothly and accurately Duties and Responsibilities of Competent persons: Personnel related to the lifting operation include "competent examiner", "competent person", "crane operator", "slinger", "signaler" and others working nearby. • The "competent examiner" is responsible for regular examinations of the lifting appliances or lifting gears. He shall be: – appointed by the employer or the owner of the lifting appliances/lifting gears; – a registered professional engineer within a relevant discipline; – properly trained with relevant practical experience.
- 237. • The "competentperson" is responsible for regular inspections of lifting appliances or lifting gears. He shall be: – appointed by the employer or the owner of the lifting appliances/lifting gears; – properly trained with relevant practical experience. • The "crane operator" is responsible for operating the crane correctly and safely. He shall: – be at least 18 years of age and hold a valid crane operation certificate; – be physically fit; – be familiar with hand signals for communication. Mechanical handling of materials facilitates quickening of the process and is economical on large-scale deployment, hazards of mechanical handling are different than the hazards due to manual handling. The hazards due to Mechanical handling are: Traumatic injuries due to falling objects. Equipment failure. Improper guarding. Unsafe operations involving ropes, slings, hoists, cranes and powered industrial trucks. Mechanical handling is done by means of EOT Cranes, gantry cranes, mobile crane, jib cranes, fork lifts and chain pulley blocks. For lifting the materials, manila ropes, wire ropes and chain slings are used.
- 238. CHAPTER 3: PLANT LAYOUT DESIGNAND HOUSEKEEPING Plant layout will be based on factors like: • New site development or addition to previously developed site. • Type and quantity of products to be produced, • Possible future expansion, • Operational convenience and accessibility, • Type of process and product control, • Economic distribution of utilities and services, • Type of building and building code requirements, • Guidelines related to health and safety, • Waste-disposable problems, • Space available and space requirement, • Auxiliary equipment, and • Roads and railroad. General: • Size, shape, location, construction, and layout of buildings and other facilities should permit the most • efficient utilization of materials, processes, and methods. • Some materials and processes may favor gravity How and the construction of a multistory building, for example, in the case of mills for one treatment. In processes, where material charging is to be done through trolleys or drums, which are required to be carried from one floor to other, elevators may be provided, to avoid accidents in lifting them. Location of Buildings and Structures: • The segregation of raw materials storage, processing buildings, and storage for finished products warrants thorough study in laying out a plant to minimize fire and explosion hazards. • Storage of volatile flammable liquids in an area apart from processing buildings reduces the fire hazards. In the event of fire, control is more easily achieved. • Analytical laboratories should be in a safe area, but otherwise as close as possible to the plants served. So, should workshops and general stores. The stores also require ready access for stores materials. • Ample space should be provided between segregated units, from such flame sources as boilers, and from shops, streets, and adjoining property. The codes of local, state
- 239. and central authoritiesshould be followed in planning the location of the units of a plant. • Many plants use and store flammable liquids having flash points below 93°C. Plans and layouts in such plants should conform strictly to specifications for handling and storing flammable liquids stipulated by Department of Explosives. • In large petrochemicals complex/refineries, multi-fire station locations for a minimum distance from all plants should be considered. • Standards for tanks include type and thickness of material, provisions for relieving excessive internal pressure, grounding, insulation, piping, and other appurtenances, and similar details (see IS 2825). • The distance between occupied buildings and plant buildings will be governed by the need to reduce the dangers of explosion, fire and toxicity. • In particular, evacuation routes should not be blocked by poor plant layout. • Administration buildings should be situated in safe area on the public side of the security point. The main office block should always be near the main entrance and other administration buildings should be near this entrance if possible. • Other buildings such as medical centers, canteens, etc., should be in a safe area and the latter should have ready access for food supplies. Control facilities: • The control building should protect its occupants against the hazards of fire, explosion and toxic release. • The control building should be situated on the edge of the plant to allow an escape route. • Recommended minimum distances between the plant and the control building tend to lie in the range 20 - 30 m. • It should not be so near the plant that its occupants are at once put at risk by serious leak of flammable, toxic, or corrosive materials. • minimum area to probable centers of explosion, with a strong construction, constructed in ductile materials (Ductile material include steel and reinforced concreter). • The control room should not be used as a center to control emergencies, nor it should be used as an emergency assembly point. There should be a separate emergency control center for controlling the incident by the incident controller, having necessary arrangements for positive pressure inside. • Water drift from cooling towers can cause corrosion of plants, air intake towers, increase vibration in centrifugal air compressors, so the towers should be sited to minimize this. Escape: • A minimum of two escape routes should be provided for any workspace, except where the fire risk is very small.
- 240. • No workplaceshould be more than 12-45 m, depending on degree of risk, from an exit, and a dead end should not exceed 8 m. • Escape routes across open mesh areas should have solid flooring. • Escape stairways should be in straight flights preferably be on the outside of buildings. Fixed ladders may be used for escape from structures if the number of people does not exceed 10. • The escape times of personnel should be estimated, paying particular attention to people on tall items such as distillation columns or cranes. Fire Fighting: • This is provided by the suggested plot size of 100 m × 200 m with approaches preferably on all four sides and by spacing between plots and buildings of 15 m. • Some basic principles are that it should be possible to gel fire-fighting equipment sufficiently close the site of the fire. • Hydrant points should be positioned so that hoses can reach any fire on the plot. Hydrant spacing of 48 in, 65 m, and 95 m are suitable for high, medium, and low risk plots, respectively. • Plants over 18 m high should be provided with dry riser mains and those over 60 m high or of high risk should be equipped with wet riser mams. • The inlets on the ground floor to dry riser mains and the outlets on all floors to both types of mains should be accessible. Flow Sheet: • A detailed flow sheet is a useful guide in the layout of plant, particularly those using dangerous and harmful materials and complicated processes. • The nature of the materials and processes in each manufacturing stage can be studied and provision made to eliminate or control hazards. • A comprehensive risk assessment study can be done which is based on consequence analysis and engineering judgment can lead to a set of conclusion and risk mitigation to arrive at a safe process flow sheet (HAZOP). • Auto-Cad computer applications can be used to plan the layout and flow sheet. A typical flow sheet and layout:
- 241. Layout of Equipment: •Now-a-days, computer aided design (CAD) method are widely used. One type of Code gives visualization of the layout, 2D or in 3D forms. Typically, such CAD packages not only give 3D display, but hold a large amount of information about the plant such as coordinates of the main items and branches, the piping routes, the materials list etc. • By using the three-dimensional method (3D) model of the space occupied by each item of equipment, congested areas can be anticipated and avoided. These pile-up areas mean frequent handling of materials, many unnecessary movements, and result in bad housekeeping, which, may be in itself a prolific source of accidents. • This 3D envelope should include space for: • Operations access, • Maintenance access, and • Piping connections. • Additional Facilities • Smoking room should be provided in process plants where smoking is prohibited. • Greater use should be made of mechanical handling devices, such as conveyors, bucket elevators, etc. in order to reduce transport by rail and road to an optimum extent. • Sectionalizing arrangement should be made in electrical supply line to equipment. • Planning and erection of equipment should take into consideration facilities for repairs and preventive maintenance work. • Equipment layout/installation should also consider the case of removal of the equipment (by cranes), especially when located on higher floors. • As far as possible, bridging of the platforms of adjacent columns (distillation, scrubbers, evaporators, etc.) should be done, for ease of operation especially during shutdown and start up. HOUSEKEEPING: Good housekeeping is the foundation of a safe, healthy and pleasant workplace. It is essential that all areas be kept clean, orderly, and with all necessary things in the proper places. Employees should be aware of hazards arising from poor housekeeping. Good housekeeping improves safety, efficiency and quality at the same time. Plus, bonus, it’s easier to find things!
- 242. Housekeeping Guidelines: Keepwork areas neat and clean. Place tools, equipment and supplies in their correct places. Keep stairways and other walkways free of debris, hoses and other obstructions. Put trash in approved containers. Remove protruding objects such as nails, spikes, wire or other sharp points. Keep workbenches and stations free from items that are not being used or worked on at present. Place oily rags in the metal containers provided. Paper cups, plates, and lunch debris, including trash must be thrown in the appropriate trashcans. To avoid skin irritations, wash frequently, using soap and water. Wear gloves when handling substances that may cause irritation. Cigarette butts belong in containers provided. Employee’s Housekeeping Responsibility: Good housekeeping is a team effort and a team is made up of individuals. The individual employee’s responsibility, is as follows: To keep work areas clean, neat, tidy and free from excessive material at all times. To work areas, clean during the shift. To constantly put trash in the proper trash bins, scrap in the scrap bins and recyclable materials in the designated bins with lids. To keep the floors free from excessive material. To ensure that aisles and walkways are clear, unobstructed and in good order. To ensure that materials are stacked correctly and safely in the correct places. To do an informal housekeeping inspection of the area on a daily basis and to rectify housekeeping hazards. To monitor that no items are stacked in no stacking areas such as under fire equipment and electrical switchgear. Report faded housekeeping notices and signs. Always return tools to their correct place after use. Ensure that spill and other tripping slipping hazards are cleaned up or fixed. Golden Housekeeping Rules: If you remove something, replace it. If you unlock it, lock it. If you open it, close it.
- 243. If youswitched it on, did you switch it off? If you break it, fix it, if you borrowed it, look after it, if you use it, look after it as if it were yours. If it is not yours, ask permission first, if you have not been trained to do it, don’t do it, do not interfere if it does not concern you. If you spill it, wipe it up. If you mess up, clean up, if you remove, replace. To get others to follow, set the example. You are the champion of good housekeeping. Teach others that neatness is an important part of maintaining a safe environment. Safety and Good Housekeeping: Effective housekeeping results in: reduced handling to ease the flow of materials fewer tripping and slipping incidents in clutter-free and spill-free work areas decreased fire hazards lower worker exposures to hazardous products (e.g. dusts, vapours) better control of tools and materials, including inventory and supplies more efficient equipment clean-up and maintenance better hygienic conditions leading to improved health more effective use of space reduced property damage by improving preventive maintenance less janitorial work improved morale improved productivity (tools and materials will be easy to find) Plan for a good housekeeping program? A good housekeeping program plans and manages the orderly storage and movement of materials from point of entry to exit. It includes a material flow plan to ensure minimal handling. The plan also makes sure that work areas are not used as storage areas by having workers move materials to and from work areas as needed. Part of the plan could include investing in extra bins and more frequent disposal. The costs of this investment could be offset by the elimination of repeated handling of the same material and more effective use of the workers' time. Often, ineffective or insufficient storage planning results in materials being handled many times and being stored in hazardous ways. Knowing the workplace layout and the movement of materials throughout it will help when planning work procedures. Worker training is an essential part of any good housekeeping program. Workers need to know how to work safely with the products they use. They also need to know how to protect
- 244. other workers suchas by posting signs (e.g., "Wet - Slippery Floor") and reporting any unusual conditions. Housekeeping order is "maintained" not "achieved." Cleaning and organization must be done regularly, not just at the end of the shift. Integrating housekeeping into jobs can help ensure this is done. A good housekeeping program identifies and assigns responsibilities for the following: clean up during the shift day-to-day cleanup waste disposal removal of unused materials inspection to ensure cleanup is complete Do not forget out-of-the-way places such as shelves, basements, sheds, and boiler rooms that would otherwise be overlooked. The final step to any housekeeping program is inspection. It is the only way to check for deficiencies in the program so that changes can be made. Examples of checklists include inspecting offices and manufacturing facilities. Effects of poor housekeeping: Some people can’t stand a mess, while others leave an evidence trail of poor housekeeping everywhere they go. But in the workplace, bad housekeeping can have consequences that go far beyond creating an image of a sloppily run, unprofessional operation. WHAT’S THE DANGER? Poor housekeeping causes a wide range of injuries and fatalities, ranging from painful slips, trips and falls, to workers being unable to evacuate burning buildings because of blocked fire exits, to dust explosions that can claim multiple lives in an instant. Example: The lead singer and guitarist of a popular band was participating in a game show in Japan when he fell head-first from a slippery and wet stage to the floor below. He suffered severe brain injuries and died several days later. And dust explosions, many of which are linked to poor housekeeping, have claimed more than 100 workers’ lives and injured about 600 others across the US since the early 1980s, according to the US Chemical Safety and Hazard Investigation Board. HOW TO PROTECT YOURSELF The possibilities for injury or death in a cluttered workplace are many. Workers can slip on spilled material that hasn’t been cleaned up, trip over debris on a floor, hurt themselves while walking past heavy or sharp objects that are protruding from shelves or be struck by unsecured items that shift and fall from racking.
- 245. If sawdust, sugaror other material is left to accumulate on surfaces and it comes in contact with an ignition source, it can cause a deadly explosion and fire. It is neither safe nor practical for you to sweep dust off a beam high in the air in your workplace. If you are concerned about a build-up of combustible dust and the potential for an explosion, talk to your supervisor. As a worker, there’s plenty you can do on the ground to keep yourself and your co-workers safe. While it can be annoying to see someone create a mess such as a spill and walk away from it, ignoring that mess yourself is wrong because it puts everyone in danger. The few seconds it takes to mop up a coffee spill on the floor or sweep up some wood chips and sawdust can make a huge difference to the safety of your workplace. But if you don’t know what the spilled material is, talk to your supervisor before attempting to clean it up. Disposal of Scrap and other Trade waste: Material intended for reuse and storage at Physical Plant may only be accepted by the Central Stores Manager of Physical Plant. A superintendent or Assistant Director must request the item(s) be stored and that person shall be the responsible manager assigned to that material and/or equipment. The Stores Manager will create and maintain a record of these items deemed "Special Inventory" which shall list the following minimum information: Description of the item, quantity, original location obtained (IE Simpkins Hall), location stored (North Shed, South Bay #1), date stored, superintendent or assistant director requesting storage (the responsible manager), description of how item would be reused. Generally, historical building components may be stored indefinitely at Physical Plant. Items which are scavenged for use on existing operating obsolete equipment may be kept as long as that equipment is still in use, but must be properly disposed of when the obsolete equipment is no longer in use or is scheduled for imminent replacement. Non-historical distinctive fixtures from restrooms, lighting, or other building components which are no longer available may be kept as long as those fixtures are still being used in a campus building. Most other building materials shall be reused in less than 12 months. Exceptions include new or almost new building materials salvaged or not used on renovation or construction projects. These items as well as other new or almost new building materials being stored at Physical Plant should not be included in the inventory described here. However, the physical limits for storage of surplus materials such as lumber, plywood, piping, masonry, and electrical supplies shall be specifically defined by the Stores Manager. Surplus materials shall not exceed the assigned storage space allocated for them by the Store Manager.
- 246. The Physical Plantwill not store used building materials for use by residence hall students or student clubs to be used for the purpose of modifying their residence hall rooms or any other part of a residence hall, or for any other building type project, or for sandwich signs. This prohibition includes but is not limited to, plywood, framing lumber, concrete masonry, paint, etc. No less than once every 24 months the Stores Manager shall require all responsible managers authorized storage to reaffirm that material or equipment they have entered into this special inventory shall remain in storage. Responsible managers shall notify the Stores Manager when an item located in storage that is included in the special inventory has been removed for reuse, salvage to the State, or disposed. Service request manifest procedures described in this policy shall also be used for removal of inventoried storage. The Stores Manager shall use these manifests to update the special inventory report. Every effort will be made by responsible managers and the Stores Manager to limit storage of items designated for reuse, as well as to provide for the expeditious turnover of items stored for reuse. Decisions to store any such items shall consider the cost of storage relative to the true value of the item being stored and the benefits of its reuse. While reuse can be a desirable sustainable initiative, there is a cost associated with storage to include loss of valuable space, risk of shrinkage, breakage, obsolescence, and the cost of continuous management of the special inventory. All superintendents and managers shall prepare a written report of items covered by this directive which are currently stored or proposed to be stored in other remote campus locations. This does not include short term storage of construction materials or equipment being installed on a project. The report shall generally describe the items being stored, quantities, and location by building and room number. Remote storage that is intended to avoid the purpose of this directive is deemed inappropriate. Long term remote storage is discouraged and shall be carefully considered by a responsible manager for cost versus benefit as well as risks associated with long term remote storage. The responsible manager is accountable for security, proper controls, and safety of any remote storage that is associated with their functions. WHAT IS COLOUR CODED CLEANING? It was in the late 1990s that The British Institute of Cleaning Science (BICSc) first began to develop a universal colour code which would be recommended for use for the cleaning industry. BICSc believes all materials within a hospital janitorial cupboard should be colour coded including; cloths, mops, buckets, aprons, and gloves. Over the years the BICSc has reviewed its recommendations to align with those from organizations such as the National Patient Safety Agency. COLOUR CODED CLEANING EXPLAINED
- 247. Colour coded cleaningis the process of designating colour to cleaning equipment in certain areas of a venue, reducing the spread of germs across areas and increasing hygiene throughout a business or home. The four main colour used and to separate out areas such as bars, public areas, kitchen & food preparation areas and washrooms, are red, blue, green and yellow. From 1 January 2006, a number of new food and hygiene legislations were applied to the UK. As good practice, the Food Standards Agency suggested that separate cleaning equipment such as cloths, sponges and mops, should be used in areas where ready-to-eat foods are stored, handled and prepared. Colour coding is used throughout a variety of industries and trades where health and safety are paramount, in particular catering and healthcare as cross contamination will lead to illness. The cleaning equipment colour are representative to their area of use. For example, you would not want to clean the floors of a kitchen with a mop that has been previously used to clean the bathroom floors. Colour coding can be broken down into 4 areas: Public areas – such as lobbies, receptions and hallways Washroom and toilets – this can include shower rooms and bathrooms Restaurant and bar – including dining areas and cafe lounge spaces Kitchen and food preparation areas – any kitchen, food station or area where food is kept and/or prepared For this system to work, you will need to assign a different mop (and other cleaning equipment) to each area, with a colour handle, head or bristles to make it easily identifiable. This hygienic cleaning system can be applied to any cleaning equipment that is used in each area; from mops and brushes to cloths and gloves. Three Colour Coded Items You Should Have So what items are colour coded to help you keep your business as hygienic as possible? The list is extensive, but here's the top three that we think every business should have as a priority: Mops Mop Buckets Dustpan and Brushes
- 248. With these threeitems you should be able to ensure the hygiene of your premises never slips. Extras such as cleaning cloths and cleaning buckets should also be considered for a thorough and strict colour coded cleaning environment. WHERE IS COLOUR CODING USED AND WHO USES IT? The colour coordination of cleaning products can vary from business to business and the system you choose is entirely up to you. However, the above guide is the most broadly accepted system that most catering establishment adhere to. The colour you assign to each area is your choice, so long as your staff members are trained on the system you choose. There are, however, laws and regulations for healthcare establishment that must be followed to ensure patient care. As businesses must now conform to the Environmental Health Officer (EHO), the use of colour coded cleaning equipment is particularly useful and has been widely adopted by the catering industry, as well as offices, factories and the retail sector. The EHO handle complaints about food quality, hygiene and safety issues and make sure that people’s living and working surroundings are safe, healthy and hygienic. Choosing to employ a colour system in your workplace can make cleaning easy, efficient and in turn, increase general hygiene and cleanliness. WHY IS COLOUR CODING SO USEFUL? Using a single mop to clean every floor in a restaurant, for example, can spread bacteria from
- 249. the washrooms andtoilets to kitchen and food preparation areas. This carries with it an inherent risk of cross contamination and consequently, illness. Applying a colour coded system to segregate sensitive areas from one-another is the most efficient and effective way of reducing the risk of cross contamination. 5s System: What Is 5S? 5S is a systematic form of visual management utilizing everything from floor tape to operations manuals. It is not just about cleanliness or organization; it is also about maximizing efficiency and profit. 5S is a framework that emphasizes the use of a specific mindset and tools to create efficiency and value. It involves observing, analysing, collaborating, and searching for waste and also involves the practice of removing waste. 5S includes five terms that all start with the letter "S." What Does 5S Stand For? 5S, sometimes referred to as 5s or Five S, refers to five Japanese terms used to describe the steps of the 5S system of visual management. Each term starts with an S. In Japanese, the five S's are Seiri, Seiton, Seiso, Seiketsu, and Shitsuke. In English, the five S's are translated as Sort, Set in Order, Shine, Standardize, and Sustain. There are five key practices involved in 5S. They are as follows: Japanese Term American Term Definition Seiri Sort Sort through materials, keeping only the essential items needed to complete tasks. (This action involves going through all the contents of a workspace to determine which are needed and which can be removed. Everything that is not used to complete a work process should leave the work area.)
- 250. Seiton Set inOrder Ensure that all items are organized and each item has a designated place. Organize all the items left in the workplace in a logical way so they make tasks easier for workers to complete. This often involves placing items in ergonomic locations where people will not need to bend or make extra movements to reach them. Seiso Shine Proactive efforts to keep workplace areas clean and orderly to ensure purpose- driven work. This means cleaning and maintaining the newly organized workspace. It can involve routine tasks such as mopping, dusting, etc. or performing maintenance on machinery, tools, and other equipment. Seiketsu Standardize Create a set of standards for both organization and processes. In essence, this is where you take the first three S's and make rules for how and when these tasks will be performed. These standards can involve schedules, charts, lists, etc. Shitsuke Sustain Sustain new practices and conduct audits to maintain discipline. This means the previous four S's must be continued over time. This is achieved by developing a sense of self-discipline in employees who will participate in 5S SAFETY CHECK-LIST FOR NEW MACHINERY 1. Operation manual. 2. Safety manual. 3. Safe operating procedure. 4. Safety instructions.
- 251. 5. Start-up &shut-down procedure. 6. Trouble shooting guide. 7. Doe’s & don’ts. 8. Encasing or effective guards to: Set screw, bolt or key on revolving shaft Spindle, wheel or pinion Spur, worn and other toothed or friction gearing (while in motion). 9. Any projection that creates hazardous condition. 10. Inbuilt safety: Trips. Interlocks. Auto controls. 11. Maintenance manual (procedure & schedule). 12. Details of spares(availability). 13. After sale-service. Machinery Purchasing Safety Checklist 1. New equipment – 2. general • Do our intended manufacturers/suppliers have a good reputation within the industry? ......................................................................................................... • Can the manufacturers/suppliers give us contact details of other users of their equipment? ................................................................................................... • Does the new machinery come with a CE mark? .................................................. • Does the new machinery have a “Certificate of Conformity”? ............................... • Is full installation data provided? ........................................................................... • Are full operating instructions provided? ............................................................... • Can the manufacturer/supplier provide full safety information for the machine, e.g. a description of all risks associated with its use? ................ • Can the manufacturer/supplier arrange safety and general training for our employees? ........................................................................................................... • Does the manufacturer/supplier offer a maintenance contract? ............................ • Have we made an allowance in our budget for unexpected “extras” e.g. removal and safe disposal of the old equipment? .......................................... • Will the manufacturer/supplier take our old equipment in part exchange? ............ • Does the manufacturer/supplier offer a range of accessories designed to be used with the machinery, e.g. noise reduction devices? .................................. • Do we have noise reduction devices fitted to our existing equipment? ................. • If so, can it be used on the new equipment that we’re proposing to buy? ............. 3. Used equipment – general
- 252. • Does thesupplier of used machinery have a good reputation in the business? .............................................................................................................. • Can the manufacturer/supplier give us contact details of other users of their used equipment? .......................................................................................... • Are the original manufacturers of the machinery still in business? .......................... • If not, are spare parts still available for the machines, (possibly from an independent supplier)? ......................................................................................... • Are the prices of spares for used machines significantly lower than for its new equivalent? .................................................................................................... • Can full safety information be provided? ............................................................... • Is full installation data provided? ........................................................................... • Are full operating instructions provided? ............................................................... • If the used machinery has been totally refurbished and modified in some way, does it have a CE mark? .............................................................................. • Is the purchase price significantly less than its new equivalent? ........................... • Will the supplier take our old machinery in part-exchange? .................................. • Do we have noise reduction devices fitted to our existing machinery? ................. • If so, can it be used on the equipment we’re planning to buy? .............................. • Have we made an allowance in our budget for unexpected “extras” e.g. removal and safe disposal of the old equipment? .......................................... • Does the supplier offer a maintenance contract on its used machines? ............... • If so, does it charge more for contracts on used machines? ................................. 4. Sound and vibration levels • Has the machine been designed to minimize the noise and vibration levels produced? ............................................................................................................. • Does the supplier specify the sound levels in the machine’s specification? .......... • Does the sound level value exceed 85dBA? ......................................................... • If applicable, are there any accessories available to reduce the sound level produced by the machinery? ................................................................................. • If applicable, are there any accessories available to reduce vibration? ................ • Can we afford these accessories within our budget? ............................................ • If applicable, have we allowed for the cost of having sound level measurements carried out? .................................................................................. This checklist has been completed to the best of my knowledge. Signed: .............................................. Date: .................................................................. Note: This checklist is to be retained on file for at least three years.
- 253. Electrical Hazards atWorkplace: Places of work generally have power nominally supplied at 230 volt (single phase) and 400 volts (3 phase) although some larger workplaces will receive electricity at a higher supply voltage. The information below relates to workplaces using 230 and 400-volt supplies. The main hazards with electricity are: contact with live parts causing shock and burns faults which could cause fires; fire or explosion where electricity could be the source of ignition in a potentially flammable or explosive atmosphere, e.g. in a spray paint booth. (this is dealt with in more detail in our ATEX Section The risk of injury from electricity is strongly linked to where and how it is used and there is greater risk in wet and/or damp conditions. Basics of Contact with Electricity It is the level of voltage the body is exposed to and the resistance to flow of electrical current offered by the body that determines the impact of exposure to electricity. The following factors determine the severity of the effect electric shock has on your body: The level of voltage The amount of body resistance you have to the current flow The path the current takes through your body The length of time the current flows through your body If a worker has come into contact with electricity the worker may not be able to remove themselves from the electrical source. The human body is a good conductor of electricity. If you touch a person while they are in contact with the electrical source, the electricity will flow through your body causing electrical shock. Firstly, attempt to turn off the source of the electricity (disconnect). If the electrical source cannot readily and safely be turned off, use a non-conducting object, such as a fibreglass object or a wooden pole, to remove the person from the electrical source. Safe limits of amperages, voltages: There are many dangers associated with electricity. An accidental shock can cause severe burns, damage to internal organs, and even death. Interestingly, while most people think of electricity in terms of voltage, the most dangerous aspect of electrical shock is the amperage, not the voltage. Voltage vs. Amperage Voltage and amperage are two measures of electrical current, or flow of electrons. Voltage is a measure of the pressure that allows electrons to flow, while amperage is a measure of the volume of electrons. An electrical current at
- 254. 1,000 volts isno deadlier than a current at 100 volts, but tiny changes in amperage can mean the difference between life and death when a person receives an electrical shock. Effects of Amperage on Electrical Shock Different amounts of amperage affect the human body in different ways. The following list explains some of the most common effects of electrical shock at various amperage levels. To understand the amounts involved, a milliampere (mA) is one-thousandth of an ampere or amp. A standard household circuit that supplies your outlets and switches carries 15 or 20 amps (15,000 or 20,000 mA). 1-10 mA Little or no electrical shock is felt. 10-20 mA Painful shock, but muscle control is not lost. 20-75 mA Serious shock, including a painful jolt and loss of muscle control; victim cannot let go of wire or another source of shock. 75-100 mA Ventricular fibrillation (uncoordinated twitching of ventricles) of the heart can occur. 100-200 mA Ventricular fibrillation occurs, often resulting in death. Over 200 mA Severe burns and severe muscle contractions occur. Internal organs can be damaged. The heart can stop due to chest muscles applying pressure to the heart, but this clamping effect can prevent ventricular fibrillation, greatly improving the chances of survival if the victim is removed from the electrical circuit. This gives you an idea of just how much danger there is in the home wiring system we take for granted, where wires carry 15,000 or 20,000 mA. Staying Safe The best way to prevent electrical shock is to follow standard safety procedures for all electrical work. Here are some of the most important basic safety rules: Shut off the power. Always turn off the power to a circuit or device that you will be working on. The most reliable way to shut off the power is to switch off the breaker for the circuit in the home's service panel (breaker box). Test for power. After turning off a circuit's breaker, check the wiring or devices you will be working on with a non-contact voltage tester to confirm the power is off. This is the only way to be sure you turned off the correct circuit.
- 255. Use insulatedladders. Never use an aluminum ladder for electrical work. Always use an insulated fiberglass ladder to keep you safe. Stay dry. Avoid wet areas when working around electricity. If you are outdoors in damp or wet conditions, wear rubber boots and gloves to reduce the chance of getting shocked. Plug power tools and appliances into a GFCI (ground-fault circuit-interrupter) outlet or GFCI extension cord. Dry your hands before grabbing any cord. Post warnings. If you are working on the service panel or a circuit, place a warning label on the face of the panel to warn others not to turn on any circuits. Before turning the power back on, make sure no one else is in contact with the circuit. Capacity and protection of conductor: The purpose of overcurrent protection for conductors is to open the electric circuit if the current reaches a value that will cause an excessive or dangerous temperature in the conductor or conductor insulation. A grounded conductor is protected from overcurrent if a protective device of a suitable rating or setting is in each ungrounded conductor of the same circuit. Overcurrent protection of conductors. Each conductor must be protected in accordance with its current carrying capacity, except a conductor for the following circuits which must meet the following listed subparts of this chapter: (1) Propulsion circuits (2) Steering circuits (3) Motor circuits (4) Flexible cord and fixture wire for lighting circuits (5) Switchboard circuits (c)Fuses and circuit breakers. (1) This rating must not be larger than 150 percent of the current- carrying capacity of the conductor; and (2) The effect of temperature on the operation of fuses and thermally controlled circuit breakers must be taken into consideration. (d)Parallel overcurrent protective devices. An overcurrent protective device must not be connected in parallel with another overcurrent protective device. (e)Thermal devices. No thermal cut out, thermal relay, or other device not designed to open a short circuit may be used for protection of a conductor against overcurrent due to a short circuit or ground, except in a motor circuit
- 256. (f)Ungrounded conductors. Afuse or overcurrent trip unit of a circuit breaker must be in each ungrounded conductor. A branch switch or circuit breaker must open all conductors of the circuit, except grounded conductors. (g)Grounded conductor. An overcurrent device must not be in a permanently grounded conductor, Means of cutting off power: In electrical distribution, a fuse cutout or cut-out fuse is a combination of a fuse and a switch, used in primary overhead feeder lines and taps to protect distribution transformers from current surges and overloads. An overcurrent caused by a fault in the transformer or customer circuit will cause the fuse to melt, disconnecting the transformer from the line. It can also be opened manually by utility linemenstanding on the ground and using a long insulating stick called a "hot stick" No load protection: here are occasions when the water pump runs idle when there is no water in the sump/underground tank or the treadmill machine is left on, unintentionally. In such cases, motors of these electrical machines run unnecessarily. Running these for a long time may lead to burnout. Such situations can be addressed by using this no-load and overload protector circuit. It can switch off the appliance in case of overload. The author’s prototype is shown in Fig. 1.
- 257. Earth Fault Protection Earthfault is the unintended fault between the live conductor and the earth. It also occurs, because of the insulation breakdown. When the fault occurs, the short-circuit currents flow through the system, and this current is returned through the earth or any electrical equipment. This fault current damaged the equipment of the power system and also interrupted the continuity of the supply. The earth fault can be dispersed by using the restricted earth fault protection scheme. The earth fault protection scheme consists the earth fault relay, which gives the tripping command to the circuit breaker and hence restricted the fault current. The earth fault relay is placed in the residual part of the current transformers shown in the figure below. This relay protects the delta or unearthed star winding of the power transformer against the fault current. The connection of earth fault relay with the star or delta winding of the transformer is shown in the figure below.
- 258. The current transformersare placed on both sides of the protective zone. The secondary terminal of the current transformer is connected in parallel with the relay. The output of the current transformer is equal to the zero sequence current flows in the line. The zero-sequence current is absent for the external fault and for the internal fault it becomes twice the value of fault current Earthing Standards: Electrical Earthing or Grounding System for buildings to be carried out all in accordance with the international standards in conjunction with the local authority requirements and recommendations. Earthing standards and methods are highly depending on the nature of the utilities and equipment installed / used at the premises. Simple earthing system we provide to the domestic connections while complex systems are being used in the power stations and industries. Medium and large-scale building projects require simple system for residential areas and rest requires medium complex system. In most cases earthing integrates with lightning protection system and low current systems. Following are the most recommended and used standards across the world: IEC 60364-1 and 60364-4-41: Electrical Installations in Buildings. BS 7671 Requirements for Electrical Installations (lEE Wiring Regulations 16th Edition). Comply with BS 6651 (Protection of Structures against Lightning) when interconnecting with lightning protection system.
- 259. ANSI / IEEE/ std 80: IEEE Guide for Safety in AC Substation Grounding. ANSI / IEEE / Std 81: IEEE Guide for Measuring Earth Resistivity, Ground Impedance, and Earth Surface Potential of a Grounding System. BS 7430: Code of Practice for Earthing. DIN VDE 0141: Earthing Systems for Power Installations with Rated Voltages above 1 kV. BS EN 1360I Copper and copper alloys. Copper rod, bar and wire for general electrical purposes. BS 1433: Specification for copper for electrical purposes. Rod and bars. BS EN 1057: Copper and copper alloys. Seamless round tubes for water and gas in sanitary and heating applications. BS EN 12449: Copper and copper alloys. Seamless round tubes for general purposes. BS EN 12451: Copper and copper alloys. Seamless, round tubes for heat exchangers. BS 7668: Specification for weldable structural steels. Hot finished structural hollow sections in weather resistant steels. BS 6360: Specification for conductors in insulated cables and cords. BS EN 10029: Specification for tolerances on dimensions, shape and mass for hot rolled steel plates 3 mm thick or above. BS EN 10113-1: Hot-rolled products in weldable fine grain structural steels. Delivery conditions for thermo-mechanical rolled steels. BS EN 10113-2: I: Hot-rolled products in weldable fine grain structural steels. Delivery conditions for normalized/normalized rolled steels. BS EN 10113-3: Hot-rolled products in weldable fine grain structural steels. Delivery conditions for thermo-mechanical rolled sheets. BS EN 10155: structural steels with improved atmospheric corrosion resistance. Technical delivery conditions.
- 260. BS EN 10210-1:Hot finished structural hollow sections of non-alloy and fine grain structural steels. Technical delivery requirements. BS EN 10137-1: Plates and wide flats made of high yield strength structural steels in the quenched and tempered or precipitation hardened conditions. General delivery conditions. BS EN 10137-2: Plates and wide flats made of high yield strength structural steels in the quenched and tempered or precipitation hardened conditions. Delivery conditions for quenched and tempered steels. BS EN 10137-3: Plates and wide flats made of high yield strength structural steels in the quenched and tempered or precipitation hardened condition. Delivery conditions for precipitation hardened steels. BS EN 10025: Hot rolled products of non-alloy structural steels. Technical delivery conditions. BS 7655-1-5: Specification for insulating and sheathing materials for cables. Elastomeric insulating compounds. Flame retardant composites. BS 7655-0: Specification for insulating and sheathing materials for cables. General introduction. BS 6004: Electric cables. PVC insulated, non-armoured cables for voltages up to and including 450/750 V, for electric power, lighting and internal wiring. ISO 630: Structural steels. IEC 60502-1: Extruded solid dielectric insulated power cables for rated voltages from I kV to 30 kV. Voltage fluctuations Most of us are familiar with the odd flickering light in the living room. This flickering is the direct result of voltage fluctuations in the grid. Generally, these fluctuations do not present any real nuisance because your distribution system operator has specific and multiple safety measures in place. For example, heavy-duty installations will not be connected to the low-voltage grid. Unplanned and unintended interruptions in the mains power supply are quite rare, although they sadly can never be completely ruled out. Their causes may vary:
- 261. short circuits:e.g. due to a broken cable that was ripped up during excavation works overload: e.g. as a result of a lightning strike voltage spikes: e.g. as a result of the sudden wide-scale installation of solar panel Possible voltage fluctuation effects on electrical devices Your home is connected to the low-voltage grid, which delivers power at a voltage of 230 volts. To prevent electrical appliances from getting damaged or breaking down altogether, standards exist which set limits on the maximum deviation from this mains voltage. In turn, electrical appliances need to be designed in such a way that they operate properly within these limits. An appliance built to operate at 230 V will serve its maximum lifetime at this voltage. If the voltage is too low, the amperage increases, which may result in the components melting down or causing the appliance to malfunction. If the voltage is too high, this will cause appliances to run ‘too fast and too high’ which will shorten their service life. Leads, cables, cords and power lines are not at risk. Hazards arising out of 'borrowed' neutrals • Neutrals are grounded but carry current under load. • The source of neutral current cannot always be identified. • Breaking a neutral under load could create a shock hazard. • Individuals contacting a lifted neutral potentially provide an alternate path to ground. • A broken neutral or lifted neutral could result in a shock or an arc. • A neutral was misidentified and inadvertently opened creating an arc (ORPS EM-SR- WSRC-FTANK-2005-0009) • A circuit was moved to a different distribution panel, but the neutral was spliced in the original panel (ORPS EM-RL-PHMC-PFP-2005-0011) • An electrician received a shock after lifting a neutral from its bus bar. The neutral received its power through an emergency light that received power from another distribution panel. (ORPS SC-PNSO-PNNL=PNNLBOPER-2005-0018)
- 262. Electrical Protective Device Adevice used to protect equipment,machinery,components and devices,in electrical and electronic circuit, against short circuit, over current and earth fault, is called as protective devices. Necessity of Protective Devices Protective devices are necessary to protect electrical appliance or equipment against a) Short Circuit b) Abnormal variations in the supply voltage c) Overloading of equipment d) To protect operator against accidental contact with the faulty equipment, falling which the operator may get a severe shock. Types of Protective Device Different types of the protective device that are commonly used in electrical and electronic circuit 1.Fuse Wire or Fuse 2.MCB – Miniature circuit breaker 3.ELCB – Earth Leakage Circuit Breaker 4.ELCB & MCB 5.Earthing or Grounding Hazardous Area Classification for Flammable Gases and Vapours Area classification may be carried out by direct analogy with typical installations described in established codes, or by more quantitative methods that require a more detailed knowledge of the plant. The starting point is to identify sources of release of flammable gas or vapour. These may arise from constant activities; from time to time in normal operation; or as the result of some unplanned event. In addition, inside process equipment may be a hazardous area, if both gas/vapour and air are present, though there is no actual release. Catastrophic failures, such as vessel or line rupture are not considered by an area classification study. A hazard identification process such as a Preliminary Hazard Analysis (PHA) or a Hazard and Operability Study (HAZOP) should consider these abnormal events. The most commonly used standard in the UK for determining area extent and classification is BS EN 60079 part 101, which has broad applicability. The current version makes clear the direct link between the amounts of flammable vapour that may be released, the ventilation at that location, and the zone number. It contains a simplistic calculation relating the size of zone to a rate of release of gas or vapour, but it is not helpful for liquid releases, where the rate of vaporisation controls the size of the hazardous area. Other sources of advice, which describe more sophisticated approaches, are the Institute of Petroleum Model Code of Practice (Area Classification Code for Petroleum Installations, 2002), and the Institution of Gas Engineers Safety Recommendations SR25, (2001). The IP code is for use by refinery and petrochemical type operations. The IGE code addresses specifically transmission, distribution and storage facilities for natural gas, rather than gas utilisation plant, but some of the information will be relevant to larger scale users.
- 263. Zoning Hazardous areas aredefined in DSEAR as "any place in which an explosive atmosphere may occur in quantities such as to require special precautions to protect the safety of workers". In this context, 'special precautions' is best taken as relating to the construction, installation and use of apparatus, as given in BS EN 60079 -101. Area classification is a method of analysing and classifying the environment where explosive gas atmospheres may occur. The main purpose is to facilitate the proper selection and installation of apparatus to be used safely in that environment, considering the properties of the flammable materials that will be present. DSEAR specifically extends the original scope of this analysis, to consider non-electrical sources of ignition, and mobile equipment that creates an ignition risk. Hazardous areas are classified into zones based on an assessment of the frequency of the occurrence and duration of an explosive gas atmosphere, as follows: Zone 0: An area in which an explosive gas atmosphere is present continuously or for long periods; Zone 1: An area in which an explosive gas atmosphere is likely to occur in normal operation; Zone 2: An area in which an explosive gas atmosphere is not likely to occur in normal operation and, if it occurs, will only exist for a short time. Various sources have tried to place time limits on to these zones, but none have been officially adopted. The most common values used are: Zone 0: Explosive atmosphere for more than 1000h/yrs. Zone 1: Explosive atmosphere for more than 10, but less than 1000 h/yrs. Zone 2: Explosive atmosphere for less than 10h/yrs., but still sufficiently likely as to require controls over ignition sources. Where people wish to quantify the zone definitions, these values are the most appropriate, but for the majority of situations a purely qualitative approach is adequate. When the hazardous areas of a plant have been classified, the remainder will be defined as non- hazardous, sometimes referred to as 'safe areas'. The zone definitions take no account of the consequences of a release. If this aspect is important, it may be addressed by upgrading the specification of equipment or controls over activities allowed within the zone. The alternative of specifying the extent of zones more conservatively is not generally recommended, as it leads to more difficulties with equipment selection, and illogicality’s in respect of control over health effects from vapours assumed to be present. Where occupiers choose to define extensive areas as Zone 1, the practical consequences could usefully be discussed during site inspection. As an example: A proposal was made to zone an aircraft hangar as Zone 1, although the use of fuels handled above their flash point would be a rare event. It proved difficult to obtain a floor-cleaning machine certified for Zone 1 areas, though the floor needed sweeping regularly. The option of writing out an exception to normal instructions to allow a non-Ex-protected machine to be used regularly is not recommended. Instead, a more realistic assessment of the zones is needed, and special instructions issued for the rare event of using more volatile fuels. A hazardous area extent and classification study involves due consideration and documentation of the following: The flammable materials that may be present; The physical properties and characteristics of each of the flammable materials; The source of potential releases and how they can form explosive atmospheres; Prevailing operating temperatures and pressures; Presence, degree and availability of ventilation (forced and natural); Dispersion of released vapours to below flammable limits; The probability of each release scenario.
- 264. These factors enableappropriate selection of zone type and zone extent, and also of equipment. The IP code gives a methodology for estimating release rates from small diameter holes with pressurised sources, and shows how both the buoyancy and momentum of the release influence the extent of a zone. It tabulates values for an LPG mixture, gasoline, natural gas, and refinery hydrogen for pressures up to 100barg. Similarly, the IGE code gives a methodology for natural gas, relating the leak rate to the hole-size and the operating pressure. The tables of dispersion distances to the zone boundary address in the main quite large diameter deliberate vents. There is in practice little overlap between the codes. The results of this work should be documented in Hazardous Area Classification data sheets, supported by appropriate reference drawings showing the extent of the zones around (including above and below where appropriate) the plant item. The NFPA way What follows is a brief, nine-step outline of NFPA practices. The actual practices and associated references should be consulted when performing any EAC. To determine an electrical area classification: 1. Assemble pertinent information, including: codes, standards, practices, and reference; process and operating descriptions; process flow diagrams and material and heat balance chart; piping and instrumentation diagrams; equipment arrangement drawings and plot plans; and commissioning, testing, operating, and safety procedures. 2. List all flammable and combustible materials and their pertinent properties, such as ignition temperatures and flash points. 3. Confirm the need for classification by assessing the likelihood of the presence of flammable and combustible materials. 4. Locate material release sources, such as open process points, control valves, pump seals, drains, metering points, sampling points, and vents. See NFPA 497 and 499 for additional guidance in identifying sources. As a practical matter, areas with large quantities of process equipment and piping that handle flammable/combustible materials can, as an area, be considered a release source. 5. Determine an area’s Class and Group from the chemicals present. 6. Determine the degree of hazard (Division 1 or Division 2) by assessing the probability of presence. 7. Determine the extent (or distance from the source) of hazardous areas by reviewing the plant’s equipment layout drawings. 8. Consider using recognizable boundaries (walls, floors, ceilings, and column lines) to delineate Classified Areas. This approach will greatly simplify both design and installation. 9. Prepare the recommended documentation for the EAC project team to review and approve.
- 265. Selection of Equipment DSEARsets out the link between zones, and the equipment that may be installed in that zone. This applies to new or newly modified installations. The equipment categories are defined by the ATEX equipment directive, set out in UK law as the Equipment and Protective Systems for Use in Potentially Explosive Atmospheres Regulations 1996. Standards set out different protection concepts, with further subdivisions for some types of equipment according to gas group and temperature classification. Most of the electrical standards have been developed over many years and are now set at international level, while standards for non-electrical equipment are only just becoming available from CEN. The DSEAR ACOP describes the provisions concerning existing equipment. There are different technical means (protection concepts) of building equipment to the different categories. These, the standard current in mid-2003, and the letter giving the type of protection are listed below. Zone 0 Zone 1 Zone 2 Category 1 Category 2 Category 3 'ia' intrinsically safe EN 50020, 2002 'd' - Flameproof enclosure EN 50018 2000 Electrical Type 'n' - EN 50021 1999 Non-electrical EN 13463-1, 2001 Ex s - Special protection if specifically certified for Zone 0 'p' - Pressurised EN 50016 2002 'q' - Powder filling EN 50017, 1998 'o' - Oil immersion EN 50015, 1998 'e' - Increased safety EN 50019, 2000 'ib' - Intrinsic safety EN 50020, 2002 'm' - Encapsulation EN 50028, 1987 's' - Special protection Correct selection of electrical equipment for hazardous areas requires the following information: Classification of the hazardous area (as in zones shown in the table above); Temperature class or ignition temperature of the gas or vapour involved according to the table below:
- 266. Temperature Classification Maximum Surface Temperature, °C IgnitionTemperature of gas or vapour, °C T1 450 >450 T2 300 >300 T3 200 >200 T4 135 >135 T5 100 >100 T6 85 >85 If several different flammable materials may be present within a particular area, the material that gives the highest classification dictates the overall area classification. The IP code considers specifically the issue of hydrogen containing process streams as commonly found on refinery plants. Consideration should be shown for flammable material that may be generated due to interaction between chemical species. STATIC ELECTRICITY: We take electricity for granted: it's easy to forget that homes, offices, and factories have been powered in this clean and convenient way only since the end of the 19th century—which, in the broader run of human history, is no time at all. It was during the 19th century that pioneers such as Alessandro Volta, Michael Faraday, Joseph Henry, and Thomas Edison figured out the secrets of electricity, how to produce it, and how to make it do useful things. Before that, electricity was largely a curiosity: it was very interesting for scientists to study and play with, but there wasn't much else they could do with it. In those days, people cooked and heated their homes using wood or coal stoves and lit their rooms with candles or oil lamps; there were no such things as radios or TVs, much less cell phones or computers. The "modern electricity" that powers everything from the phone in your pocket to the subway you ride to school or work is what we call current electricity (or electric current). It's energy that travels down a metal wire from the place where it's produced (anything from a gigantic power plant to a tiny battery) to the thing it powers (often an electric motor, heating element, or lamp). Current electricity is always on the move, carrying energy from one place to another.
- 267. Before the 19thcentury, the only kind of electricity people really knew about or tried to use was static electricity. The ancient Greeks understood that things could be given a static electric "charge" (a build-up of static) simply by rubbing them, but they had no idea that the same energy could be used to generate light or power machines. One of the people who helped to make the connection between static and current electricity was American statesman, publisher, and scientist Benjamin Franklin. In 1752, when Franklin tried to figure out the mysteries of electricity, he famously did so by flying a kite in a thunderstorm to catch himself some electrical energy (an extremely dangerous thing to do). A lightning bolt zapped down the kite to the ground and, had Franklin not been insulated, he might well have been killed. Franklin realized that static electricity, accumulating in the sky, became current electricity when a lightning bolt carried it down to the surface of the Earth. It was through research such as this that he developed one of his most famous inventions, the lightning rod (lightning conductor). Franklin's work paved the way for the electrical revolution of the 19th century—and the world really changed when people such as Volta and Faraday, building on Franklin's discoveries, learned how to produce electricity at will and make it do useful things. USE OF STATIC ELECTRICITY: Now static electricity is all very interesting, but what possible use is it? You can't make toast from a lightning bolt and you can't charge your cell phone simply by rubbing its case on your pullover. You might think static is one of those fascinating but ultimately quite useless bits of science that has no practical applications—but you'd be wrong: static electricity is used in all kinds of everyday technology!
- 268. Laser printers andphotocopiers use static electricity to build up ink on a drum and transfer it to paper. Crop spraying also relies on static electricity to help herbicides stick to the foliage of plants and distribute themselves evenly over the leaves. Factory paint-spraying robots use a similar trick to ensure that paint droplets are attracted to metal car bodies and not the machinery around them. In many power plants and chemical factories, static electricity is used in smokestacks to scrub away pollution (read more in our article on electrostatic smoke precipitators). Of course, static electricity has its drawbacks too. It can cause sparks and explosions in fuel depots and stray static is a real nuisance if you're working with electronic components. That's why engineers and chemists have developed all kinds of anti-static technologies (from simple wires to ingenious, slightly conducting paints and coatings) that prevent static build up in sensitive places. While you're reading these words, you can be sure that someone, somewhere is trying to find a new way to harness static electricity or a better way to stop it causing problems. Static electricity may be stationary, but it's never standing still! HAZARDS OF ELECTROSTATIC ELECTRICITY: Electrostatic charging can occur when solids or liquids move relative to the plant they are contained in or charged by induction. Electrostatic charging therefore occurs frequently in industrial process plant. If charge is allowed to accumulate and discharge, an electrostatic hazard may arise. A static related incident can cause a serious fire or explosion. These incidents can cause significant loss of life and plant followed by legal action and associated bad publicity. Any process plant that handles or processes flammable liquids, dusts, gases or vapours is at risk from electrostatic induced ignition. Static electricity is an imbalance of electric charges within or on the surface of a material. The charge remains until it is able to move away by means of an electric current or electrical discharge. Static electricity is electricity that does not flow in a current. Static electricity generated by rubbing two nonmagnetic objects together. The friction between the two objects generates attraction because the substance with an excess of electrons transfers them to the positively-charged substance. Usually, substances that don’t conduct current electricity
- 269. (insulators) are goodat holding a charge. These substances may include rubber, plastic, glass or pitch. The electrons that are transferred are stored on the surface of an object. Static electricity presents fire and explosion hazards during the handling of petroleum and tanker operations. Certain operations can give rise to accumulations of electric charge which may be released suddenly in electrostatic discharges with sufficient energy to ignite flammable hydrocarbon gas/air n-fixtures; there is, of course, no risk of ignition unless a flammable mixture is present. There are three basic stages leading up to a potential static hazard: 1. Charge separation, 2. Charge accumulation and 3. Electrostatic discharge. All three of these stages are necessary for an electrostatic ignition Lightning Arrestors: lightning arrester is a device used on electrical power systems and telecommunications systems to protect the insulation and conductors of the system from the damaging effects of lightning. The typical lightning arrester has a high-voltage terminal and a ground terminal In a direct hit, the electrical charge strikes the person first. Splash hits occur when lightning jumps to a person (lower resistance path) from a nearby object that has more resistance, striking the person on its way to the ground. In ground strikes, the bolt lands near the person and is conducted by a connection to the ground (usually the feet), due to the voltage gradient in the earth. This can still cause substantial injury. lightening stroke- discharge of lightning between a cloud and the earth, esp. one that causes damage (veterinary science) sudden death due to being struck by lightning, esp. of cattle, horses or sheep A Lightning Protection System (LPS) is designed to protect a structure or building and contents from damage caused by the intensely high voltage currents of a lightning strike (often exceeding a 1,000,000,000 Volt Amps). Lightning protection systems act like a Faraday Cage for buildings. Protecting the building and its contents from external electric fields by migrating that energy around the cage instead of through its contents. A Faraday cage or Faraday shield is an enclosure formed by conductive material or by a mesh of such material, used to block electric fields. Faraday cages are named after the English scientist Michael Faraday, who invented them in 1836.
- 270. With a lightningprotection system, lightning rods or air terminals are strategically sited on a structure to increase the chances of intercepting a lightning strike before it hits the property being protected. The highly conductive lightning rods of a lightning protection system are normally made of copper or aluminium and are designed to emit positive streamers into the air instead of the structure they are protecting. These positive streamers from the rods intercept the negative leaders of a lightning strike drawing the high voltage currents safely into the lightning protection system and away from the building’s structure. A lightning protection system significantly increases a building safekeeping from the damage caused by lightning and not its probability of being struck. Facts about Lightning: • A strike can average 100 million volts of electricity • Current of up to 100,000 amperes • Can generate 54,000o F • Lightning strikes somewhere on the Earth every second • Kills 100 US residents per year • Lightning can strike ground up to ten miles from a storm (Lightning out of the blue) • There is an average of 2-3 miles between strikes • So how can we tell how far away lightning has struck? Use the Five Second Rule: • Light travels at about 186,291 miles/second • Sound travels at only 1,088 feet/second • You will see the flash of lightning almost immediately • 5280/1088= 4.9 • About 5 seconds for sound to travel 1 mile Types of Lightning Arrester Rod gap arrester Sphere gap arrester Horn gap arrester Multi gap arrester Electrolyte type arrester Metal-oxide lightning arrester Maintenance of Lightning Arrester Cleaning the outside of the arrester housing. The line should be de-energized before handling the arrester. The earth connection should be checked periodically. To record the readings of the surge counter. The line lead is securely fastened to the line conductor and arrester. The ground lead is securely fastened to the arrester terminal and ground.
- 271. Stepped Leader Streamers Effectof lightning strike The effects of lightning are those of a high-strength impulse current that propagates initially in a gaseous environment (the atmosphere), and then in a solid, more or less conductive medium (the ground): visual effects (flash): caused by the Townsend avalanche mechanism acoustic effects: caused by the propagation of a shock wave (rise in pressure) originating in the discharge path; this effect is perceptible up to a range of around 10 km thermal effect: heat generated by the Joule effect in the ionized channel electrodynamic effects: these are the mechanical forces applied to the conductors placed in a magnetic field created by the high voltage circulation. They may result in deformations electrochemical effects: these relatively minor effects are consisting in the form of electrolytic decomposition in accordance with Faraday’s law –– induction effects: in a varying electromagnetic field, each conductor becomes the seat of an induced current effects on a living being (human or animal): the passage of a transient current of a certain r.m.s value is sufficient to incur risks of electrocution by heart attack or respiratory failure, together with the risk of burns. Lightning causes two major types of accidents: accidents caused by a direct stroke when the lightning strikes a building or a specific zone. This can cause considerable damage, usually by fire. In order to prevent any risk of accident, lightning air terminals should be used
- 272. accidents causedindirectly, as when the lightning strikes or causes power surges in power cables or transmission links. Hence the need to protect with SPD the equipment at risk against the surge voltage and indirect currents generated. Direct effects Thermal effects: These effects are linked to the amount of charge associated with lightning strikes. They result in fusion points melting holes of varying sizes at the point of impact of materials with high resistivity. For material which is a poor conduc energy is released in the form of heat. The heating of water vapour contained in the material results in very high abrupt localized pressure which may cause it to explode. Effects due to the initiation: In the event of a lightning st ground potential of the installation will occur depending on the grounding network and soil resistivity. Potential differences will also be created between various metal elements. Hence the need to pay particular attentio structures adjoining the conductors. accidents caused indirectly, as when the lightning strikes or causes power surges in power cables or transmission links. Hence the need to protect with SPD the equipment at risk against the surge voltage and indirect currents generated. : These effects are linked to the amount of charge associated with lightning strikes. They result in fusion points melting holes of varying sizes at the point of impact of materials with high resistivity. For material which is a poor conductor, a large amount of energy is released in the form of heat. The heating of water vapour contained in the material results in very high abrupt localized pressure which may cause it to explode. : In the event of a lightning strike a substantial increase in the ground potential of the installation will occur depending on the grounding network and soil resistivity. Potential differences will also be created between various metal elements. Hence the need to pay particular attention when installing earth rods and inter-connection of metal structures adjoining the conductors. accidents caused indirectly, as when the lightning strikes or causes power surges in Hence the need to protect with SPD the equipment at risk against the surge voltage and : These effects are linked to the amount of charge associated with lightning strikes. They result in fusion points melting holes of varying sizes at the point of impact of tor, a large amount of energy is released in the form of heat. The heating of water vapour contained in the material results in very high abrupt localized pressure which may cause it to explode. rike a substantial increase in the ground potential of the installation will occur depending on the grounding network and soil resistivity. Potential differences will also be created between various metal elements. Hence connection of metal
- 273. Acoustic effects -thunder: Thunder is due to the sudden increase in pressure (2 to 3 atmospheres) of the discharge channel developed by the electrodynamic fo lightning flash. The duration of a thunder clap depends on the length of the ionized channel. For high frequencies, propagation of the spectral components released by the shock wave is perpendicular to the channel. For low frequencies, prop different forms of rumbling or claps heard by an observer according to the distance and orientation of the successive channels used by the lightning flash. Luminous effects: A lightning strike nearby violently sensitiz The eye is dazzled and vision is lost for several long seconds. Electrodynamic effects: Electrodynamic effects between conductors and other parts occur due to large magnetic field of the lightning forces, both attractive and repulsive, that are all the stronger when the conductors are close together or the current is high. Electrochemical effects: The fleeting nature of lightning impacts (compared to stray g currents) mean that these effects are highly negligible and without influence on earth rods : Thunder is due to the sudden increase in pressure (2 to 3 atmospheres) of the discharge channel developed by the electrodynamic fo lightning flash. The duration of a thunder clap depends on the length of the ionized channel. For high frequencies, propagation of the spectral components released by the shock wave is perpendicular to the channel. For low frequencies, propagation is omnidirectional; hence the different forms of rumbling or claps heard by an observer according to the distance and orientation of the successive channels used by the lightning flash. : A lightning strike nearby violently sensitizes the retina of an observer. The eye is dazzled and vision is lost for several long seconds. : Electrodynamic effects between conductors and other parts occur due to large magnetic field of the lightning current. This results in substantial mechanical forces, both attractive and repulsive, that are all the stronger when the conductors are close together or the current is high. : The fleeting nature of lightning impacts (compared to stray g currents) mean that these effects are highly negligible and without influence on earth rods : Thunder is due to the sudden increase in pressure (2 to 3 atmospheres) of the discharge channel developed by the electrodynamic forces during the lightning flash. The duration of a thunder clap depends on the length of the ionized channel. For high frequencies, propagation of the spectral components released by the shock wave is agation is omnidirectional; hence the different forms of rumbling or claps heard by an observer according to the distance and es the retina of an observer. : Electrodynamic effects between conductors and other parts occur This results in substantial mechanical forces, both attractive and repulsive, that are all the stronger when the conductors are close : The fleeting nature of lightning impacts (compared to stray ground currents) mean that these effects are highly negligible and without influence on earth rods
- 274. CHAPTER 5:SAFETY INENGINEERING INDUSTRIES AUTOMOBILE INDUSTRY This is a part of an engineering industry and carries out various processes like casting, forging, machining, electroplating, painting, assembly, testing etc. the safety measures include: 1. Noise and vibration control 2. Dust, fumes and gas pollution control by exhaust ventilations 3. High temperature control near furnaces by insulating material or heat - reflective surfaces to heat source 4. Heat protective clothing, eye and face protection 5. Mechanical lifting 6. Guarding of drilling, reaming, grinding milling machines, power presses, conveyor belt etc.Machine tools with splash guard 7. Barrier creams and oil - resistant aprons 8. Welding and soldering precautions 9. Electroplating baths with special lip ventilation and anti - farming surface tension agents 10. Solvent and spray fumes controls with special booths in painting requiring worker outside are safer. 11. Driers with exhaust ventilation 12. Controls for chemicals which are toxic, flammable and explosive 13. Electrical safety 14. Precautions against silicosis, solvent poisoning, lead poisoning, skin diseases, X-rays for non - distractive testing etc. FOUNDARY OPERATION: Casting of various shapes and sizes are formed in foundry by melting and pouring the molten metal in molds. Foundries will normally have a Core Room, Molding Section, Melting & Pouring Section and Fettling Section besides service departments including Pattern Shop, Stores and Maintenance Department. Foundry operations, machines and equipment used, hazards inherent in foundry operations including health hazards, methods of safe guarding against these hazards, safe practices & procedures in foundry operations and general preventive measures are discussed department- wise in the paragraphs below. CORE ROOM A) Operations: Sand is received in bags or loose, drying of sand in sand drier, feeding of sand to core sand mixer through the skip hoist, sieving of sand for some cores, mixing of sand in core mixer, after mixing prepared sand is taken in a trolley bucket for supply to core making machined Cores are made by: Blowing - First the sand is blown in the core box, then the core is drawn in a drawer (plate) on rollover, the core along with the plate is then put on oven for baking.
- 275. Jolting - sandis manually put in the core boxes which are mounted on the machines. Jolting of core box is done on machine table itself. Hot and shell core Making - sand is supplied by a trolley bucket to the machine hopper by a hoist. Sometime the sand is wet and sometime dry but mixed with resins. Box is automatically heated up to& desired temperature. Hand- some cores are made by hand i.e. putting the sand in core fixtures manually Small parts of cores are at times assembled/joined Handling of Core Boxes, Core Plates & Cores. Manual loading of cores in core baking ovens, unloading after baking. Painting of some cores, drying of assembled cores in hot room with portable gas burners. Assembly of a few cores on core assembly fixture. Cleaning of core boxes. Cutting of reinforcement wires. Prepared cores are passed on to molding section.] B) Machine Used: Sand driver, Core Sand Mixers, Core Making Machines, Molding Machines for heavy cores, Hettinger’s Hot & Shell Core making machine, Core Ovens C) Hazards in Core Room: 1) Filling or collapsing of stacked sand bags, if not stacked properly or when wet sand bags become dry. 2) Drying of sand in drier will give out smoke, it should be exhausted out through an outlet or chimney. Chain drive of the driver to the enclosed. 3) All the pits and openings to be fenced (skip hoist, area below sand mixer platform). Overhead platforms and steps to be provided side rails, toe guards (sand mixer platform and approach to core making machines, core oven platforms), fixed ladders for reaching heights. 4) Sand mixer platform and steps to be kept clear of sand accumulation. 5) Interlocking arrangements should be made for sand mixer hood or cover. Inspection windows to be provided for sampling of sand. Samples to be taken by wooden spoons and not by hand (this is a common unsafe practice causing injuries) 6) Sufficient space and arrangements for fencing around rollover type core making machines to prevent accidental hit to persons working nearby while the machine is rolling over. 7) All V-Belt drives and chain drives to be guarded with fixed guards. 8) Possibility of fingers getting caught or pressed in between the core plate and squeeze plate while making core on machine. Job Safety Training. 9) Back Fire hazard while lighting kerosene burner of sand drier and kerosene core baking oven. Kerosene fired oven have not pilot arrangements. Piece of cloth or cotton waste soaked in kerosene is tied to one end of a long stick and lighted. Kerosene and air are slowly released and is lighted with the stick. If Kerosene and air is not slowly released there will be a back fire. Similarly, the lighting device should not be allowed to go off. Otherwise the kerosene and air will get accumulated and later on while lighting there may be an explosion. To overcome this a gas burner should be provided for lighting the ovens. Job Safety Training to the operator's. 10) While loading and unloading cores on core baking oven hazard of cores falling down. Employees will be exposed to heat, smoke & fumes, inform red rays and falling of hot
- 276. sand on head.While handling core boxes, core plates & cores fall on feet & toes. Training in safe methods of handling to the employees, asbestos hand gloves or aluminized hand gloves for handling hot cores, light green goggles, fume mask, caps and safety shoes to be used. 11) Outlet & exhaust arrangements to be provided for smoke and fumes generated in core baking ovens. 12) Heating of core with portable gas burners to be done on tables and not on floor. Proper area should be provided and heating should be done in that area. This area should be kept clear of combustible material. 13) Burners, hoses and gas line valves should be checked and maintained once in fortnight, Burners should be lighted with electronic lighters, to be fixed near heating tables. 14) Tongs should be used for feeding lead and other material to the container used for heating the same. Splashes of molten lead may cause bum injuries. 15) Heating of cores with gas burners should never be done in closed rooms. In case of gas leakage, the room will be full of gas, fire and explosion, may take place as ‘there will be no ventilation. I 16) Painting of cores should be done' in proper paint booths and exhaust arrangements should be provided. Paint booth should be cleaned regularly and accumulated paint removed. 17) Hoists, trolleys, wire ropes etc., should be visually checked by the users, for any defects, before taking them into use. 18) Industrial waste, spilled sand, cotton waste, scrap, broken cores should be removed from core room regularly. 19) While making cores on hot end shell core making machine, vapours from resins will be generated. Those vapours are only a nuisance because the concentration needed to produce toxic effects cannot be usually tolerated by men. 20) Employees making cores by hand may suffer from dermatitis due to contact with core oil and sand. Washing with soap and water will prevent this. MOULDING A) Operations: Sand plant prepares and supplies blended sand for making the molds Sand is fed to sand mixer through a conveyor. After the sand is blended it is supplied to molding machines. Molds are made on molding machines. Some molds are made by hand also. After drag (bottom mould) is ready it is placed on the mould car conveyor. Cursor core assemblies are placed in position. Drag is then closed by cope (top mould). After placing the cope of drag clamps are put. (to avoid metal run out during pouring). In some foundries the molds are placed on floor for pouring. Thereafter the mould moves forward to pouring stage for pouring. Pouring is done manually by ladles traveling on gantry. Small ladles (crucibles) are handed manually. Bigger ladies are handled by crane. After pouring, the mould is allowed to cool down and the castir.gs are knocked out on the knock-out machines. Some castings are knocked out manually. Sometime the hot castings are also knocked out. From knock out stage, castings are taken for shaking out operation and then carried to fettling section for further finishing. After knocking out of the castings from mould box, the sand is reprocessed. It falls on the return sand conveyor below the knock out machine and passes through the magnetic pulley
- 277. for separation ofmetallic pieces from sand Then through the r eturn sand eleva’. jr and a small conveyor the sand is stored in sand bunkers. From bunkers the sand falls on mix id sand conveyor where fresh sand is also added and then through a screen and mixed sand elevator the sand is stored in surge hoppers. Sand is fed to sand mixers from surge hopper through a conveyor. B) Machines Used: Sand Mixers, Blended Sand Conveyor, Blended Sand Elevator, Sand Plant Aerator, Distribution Belt Conveyors, Molding Machines (Jolt squeeze type), Mould Car Conveyor, Knock Out Machines, Return Sand Conveyor, Return Sand Elevator, Vibrating Screen, Mixed Sand Conveyor, Mixed Sand Elevator, Hoist and Lifting Machines. Motors, belt conveyors etc. in pits. C) Hazards in MoldingOperations: 1.Sand mixer platforms, approach to belt conveyors and hoppers, maintenance platforms and steps leading to those platforms should -be provided side rails. Platforms should have toe boards. All pits and openings at floor level to be provided with fencing and gratings. 2.Sand mixer should be kept covered with a hood, hood should be provided with an interlocking arrangement and a small opening for sampling of sand. 3.Bucket type elevators to be property fenced. Before opening the fencing doors for maintenance work, electrical isolation procedure to be strictly followed. M.S. Rod to be inserted in between the elevator and over the elevator's frame to prevent accidental movement of the elevator. Clamps may be used for locking. 4.Individual safety switch fuse units should be provided for machines. This switch should be put off and fuses removed before entering these machines for maintenance etc. This should be done by the mechanic himself who has been assigned the maintenance work. This is an additional safety measure over and above the electrical isolation procedure. 5.Dust, fumes and smoke generated during various molding and knocking out operations should be arrested at source and exhausted out. Dust masks to be used. 6.Knocking out to be done in separate enclosures to minimize noise pollution. Ear protection to be provided. 7.Magnetic pulley used for separation of metallic pieces from sand some time allows these pieces to escape. These pieces further escape through the damaged screen and fall on mould boxes through the hoppers, injuring the employees engaged in making molds. Screen's mesh to be checked regularly Strong metal gratings to be put over the screen to arrest bigger pieces and sand lumps. 8.Core assembly fixtures, hook fixtures used for turning the mould boxes are left hanging at height on the gangways near molding area. Employees may dash against these fixtures and receive injuries. These fixtures to be kept in proper place and not allowed to hand on the gangways. 9.Mould boxes should be inspected regularly by a competent authority. Heat, moisture and jolting impacts cause damage to these boxes. Damaged boxes should be removed from the
- 278. operations area toprevent their accidental usage. (Damaged boxes may explode during pouring or cause metal runout. 10. While making mould on machines and while handling it for placing on the mould car conveyor, placing the cope over the drag, hand molding, hazard of fingers getting caught, trapped or presses between the boxes and other equipment. job Safely Training to the employees, proper supervision, two button system for molding machines (jolt squeeze type) to operate its arm. Small wooden blocks to be provided with handles. 11. Hazard of mould boxes and castings falling on feet and toes while handling manually and by using hooks and hoists due to breaking of wire ropes or hooks or slipping from hooks. Visual inspection of lifting machines before use, job safety training to employees, proper supervision and safety shoes to be used. Castings fall down due to overloading of wheel barrow, resulting in feet and toe injuries. Safety shoes to be used. 12.Proper clamping of mould boxes, before pouring, with clamps to prevent accidental separation and metal runout. 13.Vent holes of the mould boxes should be kept clear for proper ventilation and for exhausting out the hot gases, generated dung pouring due to heating of undried sand, to avoid explosion. 1. Empty mould boxes and poured mould boxes should not be stacked too high (one over the other) as these could fall down due to vibration and tilting. T beam fencing to be provided. MELTING/POURING A) Operations: Receiving of scrap and coke, breaking of scrap and coke, handling of scrap and coke on wheel barrows to charging area, filling up of the skip charger with scrap, coke and additives, firing of cupola, charging of cupola, slag discharging, tapping of molten metal in the ladles, closing of cupola tap hole with clay bots. Handling of molten metal ladles on gantry to different pouring bays, manual handling of small ladles (crucibles). Pong, dropping of cupola, cupola lining. Feeding of molten metal from cupola through ladles to electric induction furnaces for super heating. Lighting the burner of cupola recuperate, starting cupola blower. Cooling down operations, removal of slag and waste. B) Machines Used: Cupola charges, Cupola Blower, Cupola Recuperate, Cupolas, Electric Induction Furnaces and ladles. C) Hazards in Melting and Pouring Operations: 1) Employees engaged in breaking of scrap and coke will be exposed to flying chips and cuts, falling of scrap on feet & toes while removing the same from pile. Safety goggles and safety shoes to be used.
- 279. 2) Scrap tobe checked properly before charging for any moisture or water accumulation. Cylinders, cans and drums to be broken to avoid explosion risk. 3) While leading the scr ap and coke on wheel barrows for carrying to charging area, it falls on feet & toe due to overloading, tilting of wheel barrows due to imbalance or uneven floors. Overloading to be stopped, flooring to be maintained in good condition, safety shoes to be used. 4) Cupola charger pit and charging area to be properly fenced to avoid injuries due to falling of scrap pieces while charging. 5) Hazard of cupola getting clogged due to clogging of tap hole or while dropping. Vibrating device to be used or hot air to be blown inside the cupola. 6) Slag tap hole to be properly fenced, to avoid slag sparks flying in all directions. 7) Molten metal spout should be dried before use. It should be covered with a circular metal guard to safe guard the cupola operator against bum injuries, due to accidental spurting of molten metal, 8) Ladies should be dried completely before use, Safety locks provided for ladles, to prevent accidental tilting, should be checked before use and maintained in good condition. This lock must be used all the time, except when the pouring is done. 9) Cupola operators and pourers should be instructed against the use of wet scrapper for clearing metal or slag spouts and removing slag from ladles 10) Cupola Operators and Pourers must use helmets, safety goggles with green glasses, leather arms, hand gloves, aprons, leg guards & slip type safety shoes. 11) Cupola platforms to be maintained in good condition and provided with side rails and toe boards. 12) Area around cupola, charging area, trapping area and pouring area should be kept clear of unwanted material and water accumulation. There should be no obstruction whatsoever for the movement of operator. 13) Sufficient light at pounng stage (operators may not be able to see the pouring spout due to usage of dark green goggles). 14) Exhaust arrangements for smoke and gases. Hood and ducting to be provided so as to enclose the mould car conveyor completely and arrest the stroke and gases at source and to exhaust the same out of foundry.
- 280. 15) Hoists usedfor handling molten metal ladles and cupola chargers should be visually checked every day in addition to the fortnightly inspection and maintenance and quarterly testing by the competent authority. Mechanical locking arrangements at the gantry ends, provided to prevent the gantry trolley from coming out of the gantry, to be cleaned and lubricated periodically, (side supports may be provided to stop the gantry trolley from coming out of the gantry end and falling down along with molten metal ladle). 16) Precautions to be taken while dropping cupola should be written down and everyone starting from Engineer In charge to Helper must be familiar with these precautions. Cupola dropping must be done under strict supervision of a responsible person. drop area should be completely free of any water accumulation or moisture. After connecting the hook of the wire rope to the locking bolt, for pulling out the belt from a distance, opening below the cupola must be closed and everyone should clear the area. One person should: sure that no one is in the dropping area. Alarm to be sounded before and during dropping Wire rope connecting the bolt of the cupola door, should be pulled from a distance. After the bolt or pin is pulled out, cupola doors open by dropping down. After dropping of the cupola, 10-15 minutes should be given for cooling, before starting the cooling operations by water hoses. 17) Persons repairing cupola lining should use helmets, goggles and safety shoes to safe guards against injuries due to falling o bricks, clay pieces and scrap. Persons breaking slag should also use goggles and safety shoes. 18) Before cleaning the cupola charges pit, a beam should be placed over the pit to avoid any injury due to accidental fall of the charger. 19) Cupola recuperate, cupola blower room and other rooms housing electrical switch boards etc. should be kept clean and clear of any unwanted material. These rooms should not be used as rest rooms. FETTLING SECTION A. Operations: Shaking out of the castings on shakeout machine, shot blasting, chipping of fins & flashes, parting lines, grinding, welding, painting and dispatch. B. Machines used: Shakeout machines, Grinders of all types, Wheel Arborator, Monorail Wheel Arborator, Chipping Guns (pneumatic) and Paint Booth. C. Hazards in Fettling Operations: 1) Shakeout machines generate lot of dust and noise. These machines should be isolated in closed rooms. Pit around those machines should have proper gratings and railings. Motor drive of the machine should be fenced. Wet or dry (bag filter type) dust collectors should be provided to arrest the dust at the point of generation. Dust make for protection against dusts, ear muffs or ear plugs for protection against noise should be used. 2) Hazards of castings falling down due to slipping from hooks of the hoist while loading or unloading on shakeout machines, while loading on the hooks of monorail wheel
- 281. arborator, while handlingmanually or on wheel barrows. Job Safety Training to the employees. Safety shoes to be used. 3) Flying of small chips & cuts during various fettling operations. Face shield and safety goggles to be used. 4) Grinders should be provided peripheral guards. V-belt drives of the swing grinders to be guarded. Handles of the swing grinders to be provided additional protectors so as to prevent the hands dashing against the castings. 5) Mounting of the grinding wheel should be done by persons trained for such work. Mounting procedure should be strictly followed i.e. visual inspection of the wheel for any cracks or damages, checking of the expiry date of the wheel, checking of the speed mentioned on the wheel and the speed of the grinding machine, sound of ring test, flanges of proper size washers, tightening of the nuts etc. 6) Fortnightly inspection & maintenance of grinders including checking of the speed and any defects in the speed governors, to avoid accidental breaking of the wheel due to over speeding. 7) Grinding wheels should be stored in racks or storage provided for the same. Precautions should be taken while handling the wheel to avoid any damage. This is most important specially for the machines where guards cannot be used due to nature of operation. Such areas should be enclosed to expose minimum number of employees in case of any breakage of the wheel. Employees should be provided leather aprons, face shields and helmets. 8) Dust collectors to be provided for pedestal grinders. Dust should not be allowed to fall on floors. It should be collected in closed containers and removed as and when the containers are full 9) Dust masks, goggles, face shields, safety shoes, ear muffs/plugs, aprons should be used for protection against various hazards during fettling operations. 10) Roller conveyors, work tables/ benches to be provide for handling of castings and fettling operations. Dome time the chipping of castings is done on floor and the floor gets damaged. Castings fall down due to uneven flooring. Employees strain/sprain their backs due to bending. 11) Welding booths with exhaust arrangements to be provided for welding. 12) Rocks, wire ropes and hoists used for handling castings should be checked visually before taking into use.
- 282. 13) Grinding machines,when not in use, should be stopped and not left running. Employees may dash against running wheels while moving around and got injured. Wheel may also get damaged. 14) Side plates of the wheel arborator should be checked regularly. Damaged plates should be replaced. These plates get worn out due to nature of operation and steel shots fly out injuring the employees. 15) Steel shots get scattered on floor near wheel abrators. These should be swept & removal regularly. Metal gratings to be provided for safe movement of employees and to prevent falls due to slipping on these shots (grating allow the shots to remain in grooves). SAFE PRACTICES & PROCEDURES IN FOUNDRY 1) Employees required to enter various pits for removal of dust and for maintenance work should use dust mask (supplied air respirators will be preferable) and helmets. Proper ladders with side rails for climbing up and down proper lighting in the pits should be provided. 2) Fortnightly inspection and maintenance of all lifting machines, hoists, cranes, hooks, wire ropes, slings, in addition to half yearly testing by a competent authority. Lifting machines used hot areas should be tested once in three months. Defects noticed should be rectified immediately. 3) Ail pressure vessels should be tested and inspected once in a year. 4) Monthly inspection and maintenance of all gas lines, valves and hoses including LPG lines. 5) After coolers and moisture separators of the compressor should be cleaned regularly Sometime after coolers get choked. Sometime the carbon gets deposited on the moisture separator and the separator may become red hot due to burning of carbon. The carbon may also get deposited at joints and bends of compressed air lines and around the valves and may catch fire due to sparks and not air (in case the after coolers are not functioning or not provided) 6) Fortnightly inspection and maintenance of all safety devices, guards, covers, hoods, interlocking switches, safety switch fuse unit, red lights and warning bells. 7) Fortnightly inspection and maintenance of grinders (check speed governors, speed of the machine, cracks, on wheels, flanged and guards). 8) Electrical lockout &isolation procedure should be strictly followed. All the concerned employees specially from maintenance & electrical department should be trained and made familiar with this procedure. Surprise checks should be carried out to ensure that this procedure is followed. This procedure should be written down and displayed on safety bulletin boards at conspicuous locations. The procedure may be as follows: - Switching off of the main switch, removing the fuses, locking the switch in off position, switching off of the additional switch fuse unit provided on various machines by the
- 283. person undertaking repairs,removal of the fuse, display of warning signs and ensuring that no one is in the danger zone before starting the machine after repairs. 9) Area around electrical switch boards should be clearly marked and provided with sturdy fencing. Approach to the boards and area inside the fencing should be kept clear of unwanted material and waste. 10) Use of roof ladders, cat walks or duck boards should be strictly enforced for any work on A.C. sheet roofs. Safety bolts and helmets must be used. 11) Work permit must be issued for any work at heights, work on LPG lines and hot lines, and for entry in confined spaces. 12) Use of compressed air for cleaning body and clothes to be stopped. It is a common unsafe practice. Improper use of compressed air hose and horseplay have caused severe Injuries. 13) Unsafe practice of blowing sand from castings and patterns without regard to the cloud of dust produced should be stopped. Vacuum cleaning equipment can be used instead of cleaning by compressed air. 14) Leakages of rain water during monsoon should be avoided, especially in pouring & melting area, (some time drainage gets choked and starts overflowing. At times water jets out of the drain) 15) Employees may be sleeping or resting near stacks of mould boxes, on or abound sand bags and sand storage area. • This should be stopped. 16) Production incentive scheme should not be introduced in foundry. Employees tend to overwork resulting in various health problems. SAFETY IN FORGING OPERATIONS Forging process is used for the deformation of metals & alloys, either hot or cold by applying the compressive forces. Hammer or impact forging exerts multiple forces while press or roll forging exerts single force. Accidents in forge shops are generally due to hot & cold metal coming out, falls on the top, accidental starting of the machine, crushing, radiant heat, burns, high noise etc. Forge workers may suffer chronic rheumatism, digestive disorders, inflammatory skin disease, respiratory trouble & hearing loss due to noise & vibration. General safety measures Good plant layout, uncongested machine and process layout, good housekeeping, proper ventilation, good draft to furnace, efficient exhaust of gases, water curtains and reflective or insulating screens for protection against radiant heat and hot air, local exhaust system at the furnaces, cold air showers at hot work places, noise absorbent panels, deep & massive foundations to suppress vibrations. Protective heat-resistant armlets, aprons, safety foot wear, eye & face shield, ear muffs or plugs should be given to workers and their pre-employment & periodical medical examinations and safety training are also necessary.
- 284. Storage - Adequatestorage facilities should be provided with overhead crane or hoist facilities (or safe mechanical handling. When piling is done in racks, retaining posts separating the materials should be used to retain max. load. The bundles should be separated by tie timber of sufficient strength. Forging Furnaces When lighting the oil-fired furnaces, a lighting torch should be provided and placed on the furnace hearth near the burner opening where the mixture of oil and air will strike the torch flame. The operator should stand clear of the furnace openings. With gas fired furnaces, the charge & discharge doors should be opened and the furnace purged to remove any cone, of gas. Forging furnaces should be shielded as much as possible to protect employees from radiant heat. This can be done by means of asbestos covered screens, metal shield backed by refractory material and stainless steel or aluminium sheet stock having radiant heat reflective qualities. Types of Forging Hammers Open frame hammers The anvil assembly is separate from the foundations of the frame and operating mechanism for the hammer. Flat dies are generally used on these hammers the work done allows for more materials to be machined off later These hammers are used where the quantities of forgings are rather small to warrant the expense of costlier impression dies or where the forgings are very large or are such irregular shape as to contained in the usual impression dies. Gravity drop hammers Drop forgings in closed impression dies are produces on these hammers. The impact of the hammer shapes the forging*- , through one or more stages to the finished shape. The forgings rang in weight from very small ones to as large as 40 to 50 kg. (About 100 lbs.) they may be made from any type of malleable metal such as steel, brass, bronze or magnesium allows. The alignment between the dies is maintained by the use of guides, die - pins, die -locks or by a combination of these devices. On these hammers, the ram and the upper die are raised to the
- 285. top of thehammer stroke and the impact blow is given by the free fall of the ram and the upper-die. Steam Hammer They are also classified drop hammers. Most of these steam hammers are double - acting and use steam) or compressed air) pressure through the medium of a piston and cylinder to raise the ram and the dire and this medium also employ to assist in striking the impact blow. Since steam or air power is used in addition to the weight of the falling ram and the die this type of hammer will strike a heavier blow than will a gravity drop hammer, using an equivalent falling weight the 1000 to 50000 lbs. the forgings produced range from small ones to above 500 lbs. and at times up to 2000 lbs. Hammer Hazards I All types of forging hammers have identical hazards.' These re the following: a) Workers can be struck by flying drift and key fragment or by flash or slugs. b) Using feeler gauges to check guide wear or the matching of dies. c) Using materials handling equipment such as tongs etc. improperly. d) Crushing of fingers, hands or arms between the dies. e) Crushing of fingers between tong handles. f) Receiving kick - backs from tongs. g) Using tools / or scale blowing pipes with short handles h) Receiving bums by hot scale. i) Dropping of stock on the feet. Guarding of Hammers A variety of simple guarding devices are employed on hammers. These would mainly include the following: a) A positive sweep device which moves form back to front and is actuated by the hammer ram
- 286. b) Two -handed tripping controls are provided where the operator is also required to hold the material being forged by his hands or by hand tools or where a sweep device, safety stop or a tripping lever cannot be installed. c) Provision of a ram stop and a safety chain (on a stem hammer a safety basket will hold the piston road, when the steam is hut off. The ends of the steel bars of the basket around the chain eyes are bent which hold the basket) d) A scale guard is provided to confine pieces of flying scale on the back of the hammer. e) In addition to the above, may other sophisticated safeguard devices be also employed such as trapping of steam lines a quick shut off valve to regulate steam or air pressure etc. Safety Props These equipped with handles should also be provided and their use is required when repairs or adjustments are to be made on the dies or when the dies are to be changed. Tie props should be held in place, while the power is released to permit the weight of the upper die and the ram to rest safely on the props. The n best be chained to the hammers so that they cannot slip out of position etc. the material most commonly used for ram props not is hardwood timber of not less than 4" square in cross - section. Hand tools These usually are pliers, tongs and such other specially designed devices used for feeding the material so that the operators’ hand need not be placed under the hammer at any time. Oil swabs and scale brushes or pipes used should have handles long enough to make it unnecessary for the operator to place his hands or underneath the die Safe Operating Practices Theses play a vital role in the subject of safety in forging operations. The hammer man controlling the activities of the crew should be made responsible for the following safety practices. There is a big list of safe operating practices. Some of the more important ones are
- 287. given hereafter. Beforestarting work, the hammer crew must make its own inspection to ensure that the working conditions and the equipment’s employed are in good order and state of repair and maintenance. Drop hammers should never be operated when the dies are cold. They should be preheated before use. Whenever an operator leaves the hammer even if only for a few minutes the upper die should be left resting on the lower die, to prevent its accidental descent. Fly wheel speeds must be carefully observed and should not exceed the RPM or the peripheral speed given on the specification sheets. Setting up dies etc. This again a big subject and would cover safe set - up and removal of dies, design of dies and such other related matters. Maintenance & Inspection of forging hammers Planned preventive maintenance programmer forging hammers will help to reduce the frequency and severity of accidents by minimizing part breakage and wear out. Regular inspections will highlight production units which are not operating up to the standard, so the repairs or adjustments can be made in time. Maintenance check - lists for hammers will form the basis for formulating a definite planned inspection programme. A written check - list is a great often forgotten or misunderstood. HAZARD ASSOCIATED WITH PROCESS OF MELTING: Molten metal is a serious hazard in melting pouring applications of metal casting. Workers who execute tasks with or near the molten metal are highly prone to risks, such as coming in contact with metal splashes or be exposed to electromagnetic radiation. Some of the circumstances that may increase the risk of hot metal splashes are - Charging a furnace with impure or moist scrap metal and alloys Using damp tools, moulds or other material when touching the molten metal Pouring or tipping the molten metal into a holding furnace or ladle Slagging or skimming processes Pouring the molten metal from ladles into moulds Extreme caution should be taken to ensure that the metal or metal slag does not come in contact with water, as it may result in an explosive reaction or ejection of molten metal with catastrophic effects. Molten metal also emits electromagnetic radiation in the furnace and pouring areas. Foundry workers are primarily endangered to infrared and UV radiation.
- 288. Workers and othervisiting people with medical implants, plates, joints or similar objects should move into the induction furnace region with care as the magnetic fields of the melting process may cause a charge in the metallic implant. People with cardiac pace makers are especially at risk and should be restrained from entering the induction furnace or touching the equipment. Health consequences of molten metal Splashes of the molten metal and the radiant heat during the melting and pouring process may result in serious burns on the body. Sparks from molten metal may also affect the eyes. Vulnerability to infrared and ultraviolet rays may result in the damage of eyes including cataract. Control measures There are several measures and options, which can be adopted alone, or in combination, to prevent or minimize the risks associated with the handling of molten metal in foundries. Mechanical control measures The risks associated with the molten metal can be reduced or minimized by implementing mechanical controls. Barriers and other protecting covering, including the mobile shields should be used or set up to protect workers against the splashes of molten metal and electromagnetic radiation. Administrative control measures Administrative controls include the development and inclusion of safe working practices and procedures. Some of common examples of administrative control measures for molten metals include - Keep all the combustible materials and volatile liquids at a safe distant place from the melting and pouring areas.
- 289. Make surethat the molten metal does not come in contact with water or other contaminants. All charge materials, ladles and other equipment, which may come in contact with the molten metal should be totally dry. Restrain the unauthorized access by barriers and signages to the furnace and pouring areas. Restrain the workers and other personnel from wearing synthetic clothing, including undergarments while entering the furnace and pouring regions. Ensure proper use and maintenance of personal protective equipment. Personal protective equipment Personal protective equipment is a must to reduce or eliminate the risks associated with the handling of molten metal in foundries. These may include - Heat resistant protective clothing - headgear, footwear, face shields, aprons, fire retardant spats, coats and gaiters Eye protection with side shields Special UV and infra-red glasses HAZARD AT WORKPLACE: Hazards exist in every workplace, but how do you know which ones have the most potential to harm workers? By identifying hazards at your workplace, you will be better prepared to control or eliminate them and prevent accidents, injuries, property damage, and downtime. In a hazard assessment, it is important to be as thorough as possible because after all, you can’t protect your workers against hazards you are unaware of. Avoid blind spots in your workplace safety procedures by taking into consideration these six main categories of workplace hazards. Safety Hazards: Safety Hazards are unsafe working conditions that that can cause injury, illness, and death. Safety hazards are the most common workplace hazards. Anything that can cause spills or trips such as cords running across the floor or ice Anything that can cause falls such as working from heights, including ladders, scaffolds, roofs, or any raised work area Unguarded machinery and moving machinery parts that a worker can accidentally touch Electrical hazards like frayed cords, missing ground pins, improper wiring Confined spaces. Biological Hazards: Biological Hazards include exposure to harm or disease associated with working with animals, people, or infectious plant materials. Workplaces with these kinds of hazards include, but are not limited to, work in schools, day care facilities, colleges and universities, hospitals, laboratories, emergency response, nursing homes, or various outdoor occupations. Blood and other body fluids Fungi/mold
- 290. Bacteria andviruses Plants Insect Bites Animal and bird droppings Physical Hazards: Physical hazards can be any factors within the environment that can harm the body without necessarily touching it. Radiation: including ionizing, non-ionizing (EMF’s, microwaves, radio waves, etc.) High exposure to sunlight/ultraviolet rays Temperature extremes – hot and cold Constant loud noise Ergonomic Hazards: Occur when the type of work, body positions, and working conditions put a strain on your body. They are the hardest to spot since you don’t always immediately notice the strain on your body or the harm that these hazards pose. Short-term exposure may result in “sore muscles” the next day or in the days following the exposure, but long-term exposure can result in serious long-term illness. ERGONOMIC HAZARDS INCLUDE: Improperly adjusted workstations and chairs Frequent lifting Poor posture Awkward movements, especially if they are repetitive Having to use too much force, especially if you have to do it frequently Vibration Chemical Hazards: Are present when a worker is exposed to any chemical preparation in the workplace in any form (solid, liquid or gas). Some are safer than others, but to some workers who are more sensitive to chemicals, even common solutions can cause illness, skin irritation, or breathing problems. BEWARE OF: Liquids like cleaning products, paints, acids, solvents – ESPECIALLY if chemicals are in an unlabeled container! Vapors and fumes that come from welding or exposure to solvents Gases like acetylene, propane, carbon monoxide and helium Flammable materials like gasoline, solvents, and explosive chemicals Pesticides Work Organization Hazards: Hazards or stressors that cause stress (short-term effects) and strain (long-term effects). These are hazards associated with workplace issues such as workload, lack of control and/or respect, etc. EXAMPLES INCLUDE:
- 291. Workload demands Workplace violence The intensity and/or pace Respect (or lack thereof) Flexibility Control or say about things Social support or relations Sexual harassment Remember that these lists are non-exhaustive. When you are completing a workplace hazard assessment, consider these six larger categories to think of factors that may affect your workers in their particular circumstances. TEXTILE INDUSTRY The textile industry consists of a number of units engaged in spinning, weaving, dyeing, printing, finishing and a number of other processes that are required to convert fibre into a finished fabric or garment. There are several safety and health issues associated with the textile industry. This article aims at studying each of these issues in relation to the US and Indian textile industries in detail, along with the possible solutions for these problems. The major safety and health issues in the textile industry can be stated as under: 1) Exposure to cotton dust 2) Exposure to chemicals 3) Exposure to noise 4) Ergonomic issues AUTOMOBILE INDUSTRY This is a part of an engineering industry and carries out various processes like casting, forging, machining, electroplating, painting, assembly, testing etc. the safety measures include: 15. Noise and vibration control 16. Dust, fumes and gas pollution control by exhaust ventilations 17. High temperature control near furnaces by insulating material or heat - reflective surfaces to heat source 18. Heat protective clothing, eye and face protection 19. Mechanical lifting 20. Guarding of drilling, reaming, grinding milling machines, power presses, conveyor belt etc.Machine tools with splash guard 21. Barrier creams and oil - resistant aprons 22. Welding and soldering precautions 23. Electroplating baths with special lip ventilation and anti - farming surface tension agents
- 292. 24. Solvent andspray fumes controls with special booths in painting requiring worker outside are safer. 25. Driers with exhaust ventilation 26. Controls for chemicals which are toxic, flammable and explosive 27. Electrical safety 28. Precautions against silicosis, solvent poisoning, lead poisoning, skin diseases, X-rays for non - distractive testing etc. ELCTRONICS INDUSTRY The use of electronic items is day by day increasing in industry, at homes and many places. Their manufacturing should include. 1. Exhaust ventilation for fumes of lead, zinc, etc. and also for molten- solder tanks 2. Eye protection for organic peroxide hardeners and respirators for quartz flour, epoxies with phenol compound and airborne concentrations 3. Prevention of flammable or explosive mixtures of solvents, and source of ignition 4. Exhaust ventilation for printing process 5. Acid resistant and non - slip flooring, exhaust ventilation, eye bath and PPE in etching processes. Use closed containers for etching liquids 6. Good industrial hygiene. FERTILISER INDUSTRY Fertilizers are natural (measures) or artificial. Artificial fertilizers are produced in chemical plants and they may be organic or inorganic, nitrogenous, phosphatic, potash and fertilizers. In the warehousing stage, phosphate, potassium -. alt and other dusts are released. In chemical processing plant air pollution by toxic gases (fluorine compounds, H.SQ4, NO, HCL, CO, NH3) and dust, high air temperature and nose are notice. Closed and efficient ventilation is necessary. In finishing processes, weighing begging and storing, gaseous emissions and fluorine compounds are released Phosphates and other raw material contain 10% or more free silica which may cause pneumoconiosis. The dust of soluble fertilizers causes irritation. The safety measures include Mechanization and automation of production processes, provision of remote control, careful assembly and operation of equipment and heat insulation Process segregation and wall floors covering to absorb fluorine compounds General ventilation, exhaust ventilation of enclosed plant, cleaning of exhaust air and waste water Education personal hygiene Use of PPE Safety and sanitary supervision Pre and post medical examination including radiographs of the locomotors system and lungs. PESTICIDE INDUSTRY Pesticide is a chemical used to destroy an organism detrimental to human interest. It includes insecticides, fungicides, herbicides, rod pesticides, bactericide, miticides, nematicides, molluscicids. They are generally halogenated (Cyclodirenes, Bischlorophenyls, Cycloparaffins and Chlorinated terpenes) or organ phosphorus (parathion, malatblone, TEPP,
- 293. OMPA, DDVP, abate,chordin etc.) type. They classified as extremely hazardous, highly hazardous moderately hazardous, slightly hazardous etc. for these classifications and their details including LD5o values see reference no. 1 given at the end of this Chapter. Strict safety rules are necessary during their processing, handling, packaging etc. exhaust ventilation and use of PPE is essential. PETROCHEMICAL INDUSTRY This is relatively a recent industry. The plants are modern, mostly automatic and totally enclosed. It uses gaseous, liquid or solid hydrocarbons. Toxic exposures and high pressure - high temperature reactions pose health fire and explosion hazards Proper FFEs and PPEs should be used. Pre and post medical examinations are necessary. Other aspects similar to chemical industry. PETROLEUM REFINERY A simple refinery carries out atmospheric and vacuum distillation and produce naphtha's and limited products. Other refineries have more processing units such as cracking, alkylation's, reforming, isomerization hydro treating and lubricant processing. A refinery operation includes 7 areas 1. Separation of crude oil 2. Conversion of hydrocarbon molecules 3. Treating crude oil fraction 4. Blending hydrocarbon products 5. Auxiliary operating facilities 6. Refinery offsite facilities and 7. Emission and diffluent control Safety measures include: 1. Continuous monitoring of hydrogen Sulphide gas, carbon monoxide and other toxic gases 2. Safer shutdown procedure and startup procedure should be followed" with sequential steps 3. Good maintenance by blinding or blanking off electrical lockouts, gas tests and hot work permits. 4. Protective clothing and equipment. 5. Ventilation and air pollution control. 6. Gas monitoring programs. 7. Leak and fault detection. 8. Control of catalysts hazards. 9. Medical checkups and industrial hygiene. 10. Fire protection.
- 294. PHARMACEUTICAL INDUSTRY Because ofthe strict requirements of Drugs Act and Rules, generally pharmaceutical factories are neat and clean and the plants are properly laid out. Some safety measures include. 1. Safe operating procedures. 2. Safe chemical handling procedure. 3. PPE. 4. Guarding of all machineries, their drives and dangerous parts. 5. Hood and exhaust ventilation for solvent baths and similar processes. 6. Temperature controls for heaters and driers. 7. Extremely sensitive methods of sampling and analysis. 8. Medical check – ups. 9. Good manufacturing practice. 10Good housekeeping. Safety in Docks Operations: This information sheet provides guidance on some of the main hazards encountered in port and dock operations. It will be of assistance to employers when conducting a risk assessment of their or their employees’ work activities in ports and docks. It will also be of interest to anyone who visits ports and docks during the course of their work. When conducting the risk assessment, the following non-exhaustive list of hazards should be considered and appropriate control measures put in place. Wherever possible, avoid the need for people to climb onto vehicles. If people cannot work from the ground, appropriate safe access must be provided for sheeting etc. • Appropriate ship to shore access must be provided and should comply with relevant Marine Notices (see www.dttas.ie/maritime). • Appropriate measures and safe systems of work must be in place to prevent falls from height and to ensure compliance with Part 4 of the Safety, Health and Welfare at Work (General Application) Regulations 2007, as amended. Falls from Height Falls from height can occur whilst carrying out trimming, sheeting and container lashing, securing loads, accessing ships, working on board a ship or working on heavy machinery. • Edge protection must be in place on all open edges where there is a risk of falling from height. • Falls through openings in holds or from cargo must be prevented. • All access or lashing cages must be appropriately protected with guard rails and toe boards and have robust gates or doors. Documented instructions for their safe use should be available. Wherever possible, avoid the need for people to climb onto vehicles. If people cannot work from the ground, appropriate safe access must be provided for sheeting etc. • Appropriate ship to shore access must be provided and should comply with relevant Marine Notices (see www.dttas.ie/maritime). • Appropriate measures and safe systems of work must be in place to
- 295. prevent falls fromheight and to ensure compliance with Part 4 of the Safety, Health and Welfare at Work (General Application) Regulations 2007, as amended. Falling Objects Whilst carrying out loading and unloading operations and stacking and stowing goods there is a risk of falling objects. Items may be loose and incorrectly or poorly slung or stacked. Fittings and fixtures used during lashing operations may be dropped. Loads or objects may collapse or fall having become unstable during transport or having been poorly loaded. Safe systems of work must be in place to ensure that pre-slung and loose loads can be lifted safely. • All securing equipment, such as twist locks and lashing bars, must be adequately inspected and maintained. • Loads must be appropriately secured especially during movement around the dock. • Marked safe areas should be provided for lorry drivers during loading and unloading operations, especially in container terminals. • Marked safe areas should be provided for customs officials to carry out examination and sealing of containers. • Good ship to shore liaison and cooperation is required for the loading and unloading of solid and rigid bulk cargoes. • Appropriate documented safe systems of work must be in place for the stacking of full and empty containers. Empty containers should not be stacked within 7 meters of occupied buildings. • Stacks adjacent to buildings and perimeter fences should be stepped back. • If linking containers together, a safe system of work must be in place to enable the attachments that link the containers to be put in position, and removed, safely. Lifting Equipment • All lifting equipment must be inspected and tested and records of such tests kept in accordance with the Safety, Health and Welfare at Work (General Application) Regulations 2007, as amended. • A register of lifting equipment and lifting accessories must be maintained. • Appropriate procedures must be in place to verify that a ship’s lifting equipment, has been inspected and tested, in accordance with legal requirements, prior to allowing workers to use it, including cargo lifts. • All lifting equipment must be capable of lifting the required load. Fire/Electrocution • All electrical equipment and installations must be designed, constructed, installed, maintained, protected and used so as to prevent danger. • All such equipment and installations, including distribution boards, sockets and connections, must be protected from the ingress of moisture and from foreseeable impacts. • Any equipment used in wet, dirty, flammable or explosive environments must be suitable for use in such conditions. Page 2 • Loading and unloading activities must not be carried out in the vicinity of overhead electric power lines. • Flammable liquids and gases must be properly transported and stored. Moving Vehicles and Equipment
- 296. An appropriate trafficmanagement system must be in place and will aid both safety and operational control of the port. • As far as reasonably practicable, vehicles and pedestrians must be segregated. • Marked and signposted walkways should be in place. • Signage should be in place advising drivers of the side of the road on which they should drive. • Members of the public, private vehicles, taxis and delivery vehicles should be restricted from accessing operational areas. • Appropriate control and supervision of vehicle and pedestrian movements should be in place, especially on vessel ramps. • Documented safe systems of work should be in place for: o Personnel who have to enter areas where vehicles and plant are operating, such as container stacking areas or bulk storage warehouses. o People carrying out maintenance work in operational areas, for example tire repairers or reefer engineers. o Trailer coupling and uncoupling activities. • All port users should be aware of the traffic plan and the safe systems of work. Where traffic routes have to change for operational reasons, sufficient notice of the change should be provided. • All operational areas and access routes to them should be provided with suitable and sufficient lighting to ensure safe working during hours of darkness or at other times of reduced visibility. • All vehicle drivers and plant operators (including terminal tractor drivers, straddle carriers and forklift truck and side loader operators) should be carefully selected and must have appropriate instruction, information and training for the vehicles and plant that they operate. • Only authorized drivers should operate vehicles or plant. Adequate supervision is required to ensure that drivers are competent and that safety standards do not deteriorate. • All vehicles and plant must be adequately maintained in accordance with the manufacturer’s recommendations. • Appropriate high visibility clothing should be worn by all workers. Noise Equipment and engines may produce noise which is augmented when they are operated in a ship’s hold or a warehouse. As a rule of thumb, you may be at risk if you have to shout to be clearly heard by someone 2 meters away, if your ears are still ringing after leaving the workplace or if there are noises due to impacts such as those caused by hammering. • Noisy areas need to be identified and a risk assessment carried out. • Appropriate measures must be in place to ensure compliance with Part 5, Chapter 1 of the Safety, Health and Welfare at Work (General Application) Regulations 2007, as amended. Slips and Trips The majority of dock accidents reported to the HSA are due to slips, trips and falls on the same level. • The employer or person in control to any extent of the place of work must ensure safe access and egress. • Appropriate pedestrian routes must be provided to the waterside and to ships. • All parts of the port should be kept in a clean, orderly condition. Poor housekeeping and badly stowed ropes, cables and other equipment can all be a hazard. • All access and emergency routes and operational areas must be kept free of objects and materials that may result in accident and injury.
- 297. CHAPTER 6:Destructive Testing,Non-Destructive Testing and Heat Treatment Break Strength Testing: One of the most common of all testing requirements is the determination of break strength. Break strength is generally the tensile or compressive load required to fracture or to cause the sample to fail. To determine the failure point or break strength, you will need to define what a break is (break detector). Generally, there are two common types of breaks: the sharp break is referred to the measurement when load or force drops by 5% from its peak load measurement. A percentage break is another form of break and is generally determined by the sample material and its relationship to load degradation from a peak load measurement. A plastic material is likely to have a load drop of 5%, but will not represent a break. In this case, a percentage break would need to be applied. In a tensile test, the breaking load is the break strength. Virtually any test standard for a product or material will have a break strength characteristic. Pass/fail criteria can be defined for each test for quality control purposes. There are many ASTM standards for break strength for specific materials. Other common results available for break strength are: - Maximum Load at Break - Deflection at Maximum Load - Load at Break - Deflection at Break Typical graph showing break strength test:
- 298. Tensile Stress Loadtesting: A tensile test, also known as a tension test, is one of the most fundamental and common types of mechanical testing. A tensile test applies tensile (pulling) force to a material and measures the specimen's response to the stress. By doing this, tensile tests determine how strong a material is and how much it can elongate. Tensile tests are typically conducted on electromechanical or universal testing instruments, are simple to perform, and are fully standardized. We can learn a lot about a substance from tensile testing. By measuring the material while it is being pulled, we can obtain a complete profile of its tensile properties. When plotted on a graph, this data results in a stress/strain curve which shows how the material reacted to the forces being applied. The point of break or failure is of much interest, but other important properties include the modulus of elasticity, yield strength, and strain. Ultimate Tensile Strength One of the most important properties we can determine about a material is its ultimate tensile strength (UTS). This is the maximum stress that a specimen sustains during the test. The UTS may or may not equate to the specimen's strength at break, depending on whether the material is brittle, ductile, or exhibits properties of both. Sometimes a material may be ductile when tested in a lab, but, when placed in service and exposed to extreme cold temperatures, it may transition to brittle behaviour.
- 299. Nondestructive Testing: Non-destructive testing(NDT) is the process of inspecting, testing, or evaluating materials, components or assemblies for discontinuities, or differences in characteristics without destroying the serviceability of the part or system. In other words, when the inspection or test is completed the part can still be used. In contrast to NDT, other tests are destructive in nature and are therefore done on a limited number of samples ("lot sampling"), rather than on the materials, components or assemblies actually being put into service. These destructive tests are often used to determine the physical properties of materials such as impact resistance, ductility, yield and ultimate tensile strength, fracture toughness and fatigue strength, but discontinuities and differences in material characteristics are more effectively found by NDT. Today modern non-destructive tests are used in manufacturing, fabrication and in-service inspections to ensure product integrity and reliability, to control manufacturing processes, lower production costs and to maintain a uniform quality level. During construction, NDT is used to ensure the quality of materials and joining processes during the fabrication and erection phases, and in-service NDT inspections are used to ensure that the products in use continue to have the integrity necessary to ensure their usefulness and the safety of the public. It should be noted that while the medical field uses many of the same processes, the term "non-destructive testing" is generally not used to describe medical applications. NDT Test Methods: 1. Magnetic particle Testing: Magnetic Particle Testing uses one or more magnetic fields to locate surface and near-surface discontinuities in ferromagnetic materials. The magnetic field can be applied with a permanent magnet or an electromagnet. When using an electromagnet, the field is present only when the current is being applied. When the magnetic field encounters a discontinuity transverse to the direction of the magnetic field, the flux lines produce a magnetic flux leakage
- 300. field of theirown as shown in Figure 1. Because magnetic flux lines don't travel well in air, when very fine coloured ferromagnetic particles ("magnetic particles") are applied to the surface of the part the particles will be drawn into the discontinuity, reducing the air gap and producing a visible indication on the surface of the part. The magnetic particles may be a dry powder or suspended in a liquid solution, and they may be colored with a visible dye or a fluorescent dye that fluoresces under an ultraviolet ("black") light. 2. Electromagnetic Testing: Electromagnetic testing is a general test category that includes Eddy Current testing, Alternating Current Field Measurement (ACFM) and Remote Field testing. While magnetic particle testing is also an electromagnetic test, due to its widespread use it is considered a stand-alone test method rather as than an electromagnetic testing technique. All of these techniques use the induction of an electric current or magnetic field into a conductive part, then the resulting effects are recorded and evaluated. Eddy Current Testing Eddy Current Testing uses the fact that when an alternating current coil induces an electromagnetic field into a conductive test piece, a small current is created around the magnetic flux field, much like a magnetic field is generated around an electric current. The flow pattern of this secondary current, called an "eddy" current, will be affected when it encounters a discontinuity in the test piece, and the change in the
- 301. eddy current densitycan be detected and used to characterize the discontinuity causing that change. A simplified schematic of eddy currents generated by an alternating current coil ("probe") is shown in Figure 14-a. By varying the type of coil, this test method can be applied to flat surfaces or tubular products. This technique works best on smooth surfaces and has limited penetration, usually less than ¼". Encircling coils (Figure 14-b) are used to test tubular and bar-shaped products. The tube or bar can be fed through the coil at a relatively high speed, allowing the full cross-section of the test object to be interrogated. However, due to the direction of the flux lines, circumferentially oriented discontinuities may not be detected with this application. 3. Ultra-sonic Testing: Ultrasonic testing uses the same principle as is used in naval SONAR and fish finders. Ultra- high frequency sound is introduced into the part being inspected and if the sound hits a material with a different acoustic impedance (density and acoustic velocity), some of the sound will reflect back to the sending unit and can be presented on a visual display. By knowing the speed of the sound through the part (the acoustic velocity) and the time required for the sound to return to the sending unit, the distance to the reflector (the indication with the different acoustic impedance) can be determined. The most common sound frequencies used in UT are between 1.0 and 10.0 MHz, which are too high to be heard and do not travel through air. The lower frequencies have greater penetrating power but less sensitivity (the ability to "see" small indications), while the higher frequencies don't penetrate as deeply but can detect smaller indications. The two most commonly used types of sound waves used in industrial inspections are the compression (longitudinal) wave and the shear (transverse) wave, as shown in Figure 10. Compression waves cause the atoms in a part to vibrate back and forth parallel to the sound direction and shear waves cause the atoms to vibrate perpendicularly (from side to side) to the direction of the sound. Shear waves travel at approximately half the speed of longitudinal waves. Sound is introduced into the part using an ultrasonic transducer ("probe") that converts electrical impulses from the UT machine into sound waves, then converts returning sound
- 302. back into electricimpulses that can be displayed as a visual representation on a digital or LCD screen (on older machines, a CRT screen). If the machine is properly calibrated, the operator can determine the distance from the transducer to the reflector, and in many cases, an experienced operator can determine the type of discontinuity (like slag, porosity or cracks in a weld) that caused the reflector. Because ultrasound will not travel through air (the atoms in air molecules are too far apart to transmit ultrasound), a liquid or gel called "coolant" is used between the face of the transducer and the surface of the part to allow the sound to be transmitted into the part. Thermography testing: Thermal/Infrared Testing, or infrared thermography, is used to measure or map surface temperatures based on the infrared radiation given off by an object as heat flows through, to or from that object. The majority of infrared radiation is longer in wavelength than visible light but can be detected using thermal imaging devices, commonly called "infrared cameras." For accurate IR testing, the part(s) being investigated should be in direct line of sight with the camera, i.e., should not be done with panel covers closed as the covers will diffuse the heat and can result in false readings. Used properly, thermal imaging can be used to detect corrosion damage, delamination’s, disbands, voids, inclusions as well as many other detrimental conditions. Radiography Testing: Industrial radiography involves exposing a test object to penetrating radiation so that the radiation passes through the object being inspected and a recording medium placed against the opposite side of that object. For thinner or less dense materials such as aluminium, electrically generated x-radiation (X-rays) are commonly used, and for thicker or denser materials, gamma radiation is generally used. Gamma radiation is given off by decaying radioactive materials, with the two most commonly used sources of gamma radiation being Iridium-192 (Ir-192) and Cobalt-60 (Co- 60). IR-192 is generally used for steel up to 2-1/2 - 3 inches, depending on the Curie strength of the source, and Co-60 is usually used for thicker materials due to its greater penetrating ability.
- 303. The recording mediacan be industrial x-ray film or one of several types of digital radiation detectors. With both, the radiation passing through the test object exposes the media, causing an end effect of having darker areas where more radiation has passed through the part and lighter areas where less radiation has penetrated. If there is a void or defect in the part, more radiation passes through, causing a darker image on the film or detector, as shown in Figure 8. Safety in IT and Electronic Industry and Service Sector: Various hazards in electronics industries: Ergonomic hazards Musculoskeletal Disorder Electrical Hazards Physical Hazards Radiation Hazards Fire Hazards Computer Vision Syndrome (CVS) Carpal Tunnel Syndrome ( CTS) Repetitive Strain Injury (RSI) PHYSICAL HAZARDS A physical hazard is defined as "A factor within the environment that can harm the body without necessarily touching it. Vibration and noise are examples of physical hazards" electricity, radiation, pressure, noise, heights and vibration. Slips, trips and falls: Slips occur when a person's foot loses traction with the ground surface, trips occur when a person unexpectedly catches their foot on an object or surface. Falls may result from a slip or trip but many occur during falls from low heights or into a hole, ditch or body of water.
- 304. Slips andtrips result in thousands of injuries each year with the most common injuries being musculoskeletal. Cuts, bruises, fractures, dislocations and more serious injuries also occur. Control of Slips, trips and falls a) Eliminate the hazard: Remove slip and trip hazards at the design stage such as eliminating changes in floor levels and installing more power outlets to avoid trailing cords. b) Substitution: Replace flooring with a more slip-resistant surface. c) Isolation: Replace flooring with a more slip-resistant surface Prevent access to high risk areas, for example cordon off wet floor areas while cleaning is in progress. d) Engineering controls (redesign): Apply floor treatments to increase slip resistance, improve lighting, stop leaks from equipment or pipes, provide adequate drainage, clearly mark edges of steps and any changes in floor heights. e) Administrative controls: Implement good housekeeping practices including keeping access ways clear and cleaning up spills promptlyUse signage to warn of wet or slippery areas, Provide training and supervision. f) Personal protective equipment Wear slip-resistant footwear I. COMPUTER VISION SYNDROME (CVS) 1) Computer vision syndrome (CVS), also referred to as Digital Eye Strain, is a condition resulting from focusing the eyes on a computer or other display device for protracted, uninterrupted periods of time. Some symptoms of CVS include headaches, blurred vision, neck pain, fatigue, eye strain, dry eyes, irritated eyes, double vision, vertigo/dizziness, polyopia, and difficulty refocusing the eyes. 2) Dry eye is a major symptom that is targeted in the therapy of CVS. The use of over- the-counter artificial-tear solutions can reduce the effects of dry eye in CVS. 3) Asthenopia symptoms in the eye are responsible for much of the severity in CVS. Proper rest to the eye and its muscles is recommended to relieve the associated eye strain. Various catch-phrases have been used to spread awareness about giving rest to the eyes while working on computers. A routinely recommended approach is to consciously blink the eyes every now and then (this helps replenish the tear film) and to look out the window to a distant object or to the sky—doing so provides rest to the ciliary muscles. One of the catch phrases is the "20 20 20 rule" every 20 mins, focus the eyes on an object 20 feet (6 meters) away for 20 seconds. This basically gives a convenient distance and timeframe for a person to follow the advice from the optometrist and ophthalmologist. Otherwise, the patient is advised to close his/her eyes (which has a similar effect) for 20 seconds, at least every half-hour. 4) Many of the visual symptoms experienced by users are only temporary and will decline after stopping computer work or use of the digital device. However, some individuals may experience continued reduced visual abilities, such as blurred distance vision, even after stopping work at a computer.
- 305. 5) CAUSES OFCVS OR DES (Digital eye strain) i. Viewing a computer or digital screen is different than reading a printed page. Often the letters on the computer or handheld device are not as precise or sharply defined, the level of contrast of the letters to the background is reduced, and the presence of glare and reflections on the screen may make viewing difficult. ii. Viewing distances and angles used for this type of work are also often different from those commonly used for other reading or writing tasks. As a result, the eye focusing and eye movement requirements for digital screen viewing can place additional demands on the visual system. iii. In addition, the presence of even minor vision problems can often significantly affect comfort and performance at a computer or while using other digital screen devices. Uncorrected or under corrected vision problems can be major contributing factors to computer-related eyestrain. 6) SIX STEPS TO REDUCE THE IMPACTS OF CVS i. Keep blinking. It washes your eyes in naturally therapeutic tears. ii. Remember 20-20-20. Every 20 minutes, spend 20 seconds looking at something 20 feet away, minimum. iii. Get the right light. Good lighting isn’t just flattering – it’s healthy for your eyes. So, keep bright lighting overhead to a minimum. Keep your desk lamp shining on your desk, not you. Try to keep window light off to the side, rather than in front or behind you. Use blinds and get a glare screen. Position the computer screen to reduce reflections from windows or overhead lights. iv. Monitor your monitor. Keep it at least 20 inches from your eyes. Center should be about 4 to 6 inches below your eyes. Also, make sure it’s big enough and with just the right brightness and contrast. Adjust the screen so you look at it slightly downward and are about 24 to 28 inches away. Adjust the screen settings to where they are comfortable — contract polarity, resolution, flicker, etc. v. Wear those computer glasses. Your doctor can prescribe a pair of eyeglasses just for viewing the computer screen well. If necessary, wear the appropriate corrective lenses while at the computer. vi. Talk to your doc. Have a comprehensive eye exam by a doctor. During your eye exam, your eye doctor can check for more than just computer vision problems. They’ll look for signs of health conditions like diabetes, high cholesterol, high blood pressure, glaucoma, and macular degeneration. It’s an important part of your overall health routine.
- 306. 7) VIEWING OFCOMPUTER Proper body positioning for computer use. Some important factors in preventing or reducing the symptoms of CVS have to do with the computer and how it is used. This includes lighting conditions, chair comfort, location of reference materials, position of the monitor, and the use of rest breaks. i. Location of computer screen - Most people find it more comfortable to view a computer when the eyes are looking downward. Optimally, the computer screen should be 15 to 20 degrees below eye level (about 4 or 5 inches) as measured from the center of the screen and 20 to 28 inches from the eyes. ii. Seating position - Chairs should be comfortably padded and conform to the body. Chair height should be adjusted so your feet rest flat on the floor. If your chair has arms, they should be adjusted to provide arm support while you are typing. Your wrists shouldn't rest on the keyboard when typing. iii. Rest breaks - To prevent eyestrain, try to rest your eyes when using the computer for long periods. Rest your eyes for 15 minutes after two hours of continuous computer use. Also, for every 20 minutes of computer viewing, look into the distance for 20 seconds to allow your eyes a chance to refocus. iv. LIGHTING ANTIGLARE BLINKING ARE OTHER MEASURES TO BE TAKEN. II. CARPEL TUNNEL SYNDROME 1) Carpal tunnel syndrome (CTS) is a medical condition due to compression of the median nerve as it travels through the wrist at the carpal tunnel. The main symptoms are pain, numbness, and tingling, in the thumb, index finger, middle finger, and the thumb side of the ring fingers. 2) Symptoms typically start gradually and during the night. Pain may extend up the arm. Weak grip strength may occur and after a long period of time the muscles at the base of the thumb may waste away. 3) The median nerve and several tendons run from your forearm to your hand through a small space in your wrist called the carpal tunnel. The median nerve controls movement and feeling in your thumb and first three fingers (not your little finger). 4) Suggested healthy habits such as avoiding repetitive stress, work modification through use of ergonomic equipment (mouse pad, taking proper breaks, using keyboard alternatives (digital pen, voice recognition, and dictation), and have been proposed as methods to help prevent carpal tunnel syndrome. 5) Stretches and isometric exercises will aid in prevention for persons at risk. Stretching before the activity and during breaks will aid in alleviating tension at the wrist. [61] Place the hand firmly on a flat surface and gently press for a few seconds to stretch the wrist and fingers. An example for an isometric exercise of the wrist is done by clenching the first tightly, releasing and fanning out fingers. 6) The carpal tunnel is a space in the wrist surrounded by wrist bones and by a rigid ligament that links the bones together. 7) Through this small tunnel pass the flexing tendons of the fingers and thumb as well as the median nerve. These tendons attach muscles to bones in the hand and transfer the
- 307. movement of thefingers from muscles to bones. The median nerve carries signals from the brain to control the actions of the fingers and hand. 8) It also carries information about temperature, pain and touch from the hand to the brain, and controls the sweating of the hand. The thumb, index, middle and ring fingers are under the control of the median nerve. FIG 1 FIG2-The Carpal Tunnel with Tendon and Median Nerve 9) Diagnosis of carpal tunnel syndrome is confirmed by performing certain tests to detect damage to the median nerve. Tinel's test - The physician taps the median nerve at the wrist. A tingling response in one or more fingers indicates damage to the median nerve. Phalen's test - The patient puts the backs of the hands together and bends the wrists for one minute. Tingling of the fingers indicates damage to the median nerve. Electromyography - Electrodes are placed on the forearm and electrical current is passed through the patient. Measurements on how fast and how well the median nerve transmits messages to muscles indicate if there is damage to this nerve. 10) Generally accepted treatments include: physiotherapy, steroids either orally or injected locally, splinting, and surgical release of the transverse carpal ligament. Splints corticosteroids, surgery and physical therapy. III. REPETITIVE STRAIN INJURY (RSI) 1) A repetitive strain injury (RSI) is an "injury to the musculoskeletal and nervous systems that may be caused by repetitive tasks, forceful exertions, vibrations, mechanical compression, or sustained or awkward positions" OR “Repetitive strain injury (RSI) is a general term used to describe the pain felt in muscles, nerves and tendons caused by repetitive movement and overuse.”
- 308. It's also knownas work-related upper limb disorder, or non-specific upper limb pain. 2) The condition mostly affects parts of the upper body, such as the a) forearms and elbows b) wrists and hands c) neck and shoulders 3) CAUSES OF RSI: RSI is related to the overuse of muscles and tendons in the upper body. Certain things are thought to increase the risk of RSI, including: i. repetitive activities ii. doing a high-intensity activity for a long time without rest iii. poor posture or activities that require you to work in an awkward position 4) 5) Some of symptoms experienced by patients with RSI are aching, pulsing pain, tingling and extremity weakness, initially presenting with intermittent discomfort and then, with a higher degree of frequency 6) The most-often prescribed treatments for early-stage RSIs include analgesics, my feedback, biofeedback, physical therapy, relaxation, and ultrasound therapy. Low- grade RSIs can sometimes resolve themselves if treatments begin shortly after the onset of symptoms. However, some RSIs may require more aggressive intervention including surgery and can persist for years. 7) PREVENTION OF RSI maintaining good posture at work – see how to sit at a desk correctly i. taking regular breaks from long or repetitive tasks – it's better to take smaller, more frequent breaks than one long lunch break ii. trying relaxation techniques if you're stressed iii. If you work at a computer all day, make sure your seat, keyboard, mouse and screen are positioned so they cause the least amount of strain. 8) There are three pieces of equipment that require special attention: i. Keyboard: positioned above your thighs, you shoulder be able to reach the keys with your elbows at your side and bent at 90 degrees, and your forearms roughly parallel to the ground. If your elbows are at more than a 90 angle, it will surely tire you out quickly. ii. Mouse: just to one side of your keyboard, so that you don't have to lean, stretch, or hunch to work it. Many people have one shoulder noticeably lower than the other - this can be caused by repetitive stretching for a mouse; iii. Monitor: directly in front of you (not off to the side), such that your eye level is somewhere between the top of the screen and 20% from the top. The screen should be about 15-25 inches from your eyes. 9) There are three keys to proper typing technique. i. Keep your wrists straight: the straighter your wrists, the less strain you put on the tendons and nerves that run through your wrist. A split keyboard may aid you in keeping your wrists straight. ii. Let your hands float: This means don't rest your wrists on the desk, keyboard, or a wrist rest when you are typing. Let them hover over the keys. This has three advantages: (i) You allow the big muscles in your back to share some of the work; (ii) It allows you to keep your wrists straight, which is
- 309. impossible if they'replanted on a wrist rest; (iii) It's easier to reach the hard- to-reach keys (next item). iii. Don't strain your fingers: When you need to press a hard-to-reach key, like CTRL, SHIFT, BACKSPACE, etc., don't stretch out your pinky. Instead, move your whole hand and use your index or middle finger to press the key. Don't use one hand when you need to hit two keys simultaneously, e.g. CTRL- X, SHIFT-Y. Think before you type: unnecessary retyping/editing can add up. Use a light touch when typing: don't pound the keys. 10) Stretching and strengthening(i) Wall stretch (ii) Doorway stretch (iii) back and neck stretching IV. VARIOUS HAZARDS IN MALL/COMMERCIAL SECTOR – PREVENTIVE AND CONTROL MEASURES 1) Security threat to the shopkeeper and visitors. security structure provides a comprehensive coverage of all area and provide a comprehensive safer environment. 2) Terrorism concern are common this days, fake bomb threats exist and to counter that a specialized team terror prevention and protection should be readily available within a call reach. 3) Moving parts of escalators or elevators Keep your hands and any loose clothing clear when using escalators and elevators to avoid getting pinched or caught in the mechanism. 4) Large Crowds Avoid large store openings with large crowds, especially if you have children with you. You may easily be pushed or could trip, causing injury. “Lost children” is a one of the major concern/hazards at crowded area. “Children safe zone system” are prominently provided to assist the process of informing and identifying the child lost through surveillance camera and other security feature. always keep small children securely in a stroller and do not let them wander away from you. 5) Theft individual store are increasingly at risk of becoming victims of shoplifting. 6) RIOTS 7) NIGHT TIME DUTY security guardLet deliveries in to the center and assist with the process patrolling the shopping center in the night. feature of intruder alarm if some burglaries or theft happen.
- 310. 8) Heavy itemsmay fall and strike unsuspecting customers. 9) Other hazards are Unrestricted access to peripheral areas such as parking lots, Unrestricted access to areas adjacent to buildings, Limited employee background checks, Limited security force, Large number of access points, Lack of exercises for emergency plans,etc. 10) Mobbing: Psychosocial terror or mobbing in working life as ‘hostile and unethical communication, which is directed in a systematic way by one or a few individuals mainly towards one individual who, due to mobbing, is pushed into a helpless and defenseless position, being held there by means of continuing activities 11) Bullying Workplace bullying is repeated, unreasonable behavior directed towards an employee, or group of employees, that creates a risk to health and safety. Bullying often involves a misuse or abuse of power, where the targets can experience difficulties in defending themselves. 12) Harassment: The term harassment covers undesirable hostility or offensive behavior. It may also include sexual harassment. 13) Working hours
- 311. QUALITY CONTROL INOCCUPATIONAL SAFETY, HEALTH & ENVIRONMENT MANAGEMENT CONTENT Page No. 1 Safety Appraisal & Control Techniques, Plant Safety Rules & Procedures, Plant Safety Observation Plan, Safety Survey, Plant Safety Inspection, Job Safety Accident Prevention Tags. 2 Hazard Identification Analysis & Risk Assessment Chart, HAZOP Study, Failure Mode Effect Analysis, Event Analysis, Safety Sampling, Fault Tree Analysis, Risk Assessment (Quantitative Analysis), System Safety Technique Management Oversight & Risk Tree (MORT) 3 Accident rate – definition, accident reporting, investigation & analysis, safety performance measures (frequency/severity rates), accident reports & records. 4 Major Accident Hazard (MAH) Factory, Maximum Credible Accident 5 Safety Inventory, Safety Programme, Safety Tour, Critical Incident Technique, Damage Control, Total Loss Control. 6 Safety Inventory, Safety Programme, Safety Tour, Critical Incident Technique, Damage Control, Total Loss Control.
- 312. Chapter 1: SafetyAppraisal & Control Technique Safety appraisal system is a system, method, practice, & procedure to measure the safety performance of standard for the purpose of evaluating its effectiveness and reliability, to find out drawbacks or deficiency if any to suggest the safety measures to raise its safety value. This is first step of any safety organisation in i0ts march towards accident or loss prevention programmes. TYPES OF SAFETY APPRAISAL SYSTEM: 1. QUANTITATIVE APPRAISAL: - Quantitative Appraisal is the method of computing accident frequency, severity, incidence & their index rates and a safety activity rate. Frequency rate and severity rate are useful in comparing safety performance of different units in a given time. 2. QUALITATIVE APPRAISAL: - Qualitative Appraisal is carried out to find the areas where safety improvement is necessary. It includes safety inspection, safety audit, accident analysis etc. Safety inspection, safety audit help to identify 3. PREVENTIVE APPRAISAL: - preventive Appraisal includes preventive maintenance before any accident occurs. Safety sampling, safety survey, fault tree analysis, HAZOP &HAZAN studies, safety inventory, system safety, safety standards, work permit system, safety tags, are used for this purpose. 4. CORRECTIVE APPRAISAL: - Corrective Appraisal includes corrective maintenance after any accident takes place or any defect (crack, corrosion etc ) detected Accident investigations, analysis, application of remedy are carried out for this objective. 5. STATUTORY APPRAISAL: - It includes statutory inspection & testing of boilers, unfired pressure vessels, lifting tackles & tools, hoist &lifts. It also includes work place monitoring, medical check- up etc. PLANT SAFETY RULES AND PROCEDURES NEED FOR RULES AND PROCEDURE :- Safely rules are not new things. They were formed hundred year ago as and when need arise. Fire precaution rules are such oldest rules. Industrialization. Need for safety rules, procedures, codes and standards are. (a) To fix the safe standard to be followed (b) To measure the performance with such rule or standard. (c) Human behaviour needs to be regulated by safety rules: otherwise it may cause more accidents. (d) Management’s safety policy can be conveyed by rules and regulations for all employees. (e) They are necessary for safe job performance, orderliness and security. (f) If the rule is fixed (enacted or accepted), its breach can be easily shown to explain duty or responsibility for its observance. (g) Disciplinary action is possible for violation of rules.
- 313. (h) Follow upof rules increases and maintains good discipline. (i) Even if the rules are enforced, their need is permanent cannot be denied. (j) Safety rules are the good foundation of training. Therefore there exists a strong need of safety rules which may be statutory or non statutory. FORMULATION OF RULES :- Criteria to be observed in formulating safety- rules are : Each rule should be short, clear and unambiguous. It should be need based. Unwanted rules should not be formulated. Where there is no combustible material rule against smoking may not be necessary. Rule should exactly describe the course of action to be followed and should cover all safety points. The number of general rules should be minimum necessary. Rule should be practicable so that it can be enforced. Safety rules should be formulated from real experience of knowledge and with active participation of employee concerned. TYPES OF RULES: A. STATUTORY RULES:- statutory acts, rules and forms are enacted by parliament and legislative assemblies. They are applicable to larger area and enforceable by government authorities. Non statutory plant rules are formulated by individual companies. But , such rules should not be in derogation with statutory rules need not be covered by non – statutory rules. Statutory rules are generally under some Act. The Act provides major items and their details are provided by rules. The Factories Act 1948 is a Central Act applicable to the whole of India, while different states have enacted different rules under that. B. NON STATUTORY RULES PSYCHOLOQICAL SAFETY RULES a) Prevention is better than cure. b) Accidents do not happen, they are caused. Safety is my responsibility. It begins from me, I will maintain it. It also needs cooperative and coordinate efforts. c) Safety is duty as well as right performs the duty and enjoys the right. d) Small things make perfection but perfection is not a small thing. Safety should be made perfect by smallest precaution. e) Solutionof a problem lies through the problem. To achieve safety try through all stages in sequence. f) It is the knowledge that works and not the designation. Increase the knowledge of safety perpendicular (in your own branch) and then horizontal (in other or side branches) g) Rules of safety are absolute and not negotiable. RULES FOR SAFE CONDITION :- These rules are most important as they supply engineering, health and hygiene controls to make plant, premises, process, equipment etc. safe and sound from the design stage to the maintenance stage
- 314. such rules shouldbe grouped subject wise and classified systematically. Majority chapters of this book deal with such rules. RULES FOR SAFE ACTION:- These rules touch the behaviour aspect of work-people and cover work methods, procedures and human actions connected with work performance they may be philosophical if they cover the material behaviour, thinking or action and may be physical, mechanical, electrical, chemical etc. if they cover such environmental subjects. PLANT SAFETY RULES AND PROCEDURES NEED FOR RULES AND PROCEDURE: - Safely rules are not new things. They were formed hundred year ago as and when need arise. Fire precaution rules are such oldest rules. Industrialization. Need for safety rules, procedures, codes and standards are. (k) To fix the safe standard to be followed (l) To measure the performance with such rule or standard. (m) Human behaviour needs to be regulated by safety rules: otherwise it may cause more accidents. (n) Management’s safety policy can be conveyed by rules and regulations for all employees. (o) They are necessary for safe job performance, orderliness and security. (p) If the rule is fixed (enacted or accepted), its breach can be easily shown to explain duty or responsibility for its observance. (q) Disciplinary action is possible for violation of rules. (r) Follow up of rules increases and maintains good discipline. (s) Even if the rules are enforced, their need is permanent cannot be denied. (t) Safety rules are the good foundation of training. Therefore there exists a strong need of safety rules which may be statutory or non statutory. FORMULATION OF RULES :- Criteria to be observed in formulating safety- rules are : Each rule should be short, clear and unambiguous. It should be need based. Unwanted rules should not be formulated. Where there is no combustible material rule against smoking may not be necessary. Rule should exactly describe the course of action to be followed and should cover all safety points. The number of general rules should be minimum necessary. Rule should be practicable so that it can be enforced. Safety rules should be formulated from real experience of knowledge and with active participation of employee concerned. TYPES OF RULES: C. STATUTORY RULES:- statutory acts, rules and forms are enacted by parliament and legislative assemblies.
- 315. They are applicableto larger area and enforceable by government authorities. Non statutory plant rules are formulated by individual companies. But , such rules should not be in derogation with statutory rules need not be covered by non – statutory rules. Statutory rules are generally under some Act. The Act provides major items and their details are provided by rules. The Factories Act 1948 is a Central Act applicable to the whole of India, while different states have enacted different rules under that. D. NON STATUTORY RULES PSYCHOLOQICAL SAFETY RULES h) Prevention is better than cure. i) Accidents do not happen, they are caused. Safety is my responsibility. It begins from me, I will maintain it. It also needs cooperative and coordinate efforts. j) Safety is duty as well as right performs the duty and enjoys the right. k) Small things make perfection but perfection is not a small thing. Safety should be made perfect by smallest precaution. l) Solutionof a problem lies through the problem. To achieve safety try through all stages in sequence. m) It is the knowledge that works and not the designation. Increase the knowledge of safety perpendicular (in your own branch) and then horizontal (in other or side branches) n) Rules of safety are absolute and not negotiable. RULES FOR SAFE CONDITION:- These rules are most important as they supply engineering, health and hygiene controls to make plant, premises, process, equipment etc. safe and sound from the design stage to the maintenance stage such rules should be grouped subject wise and classified systematically. Majority chapters of this book deal with such rules. RULES FOR SAFE ACTION:- These rules touch the behaviour aspect of work-people and cover work methods, procedures and human actions connected with work performance they may be philosophical if they cover the material behaviour, thinking or action and may be physical, mechanical, electrical, chemical etc. if they cover such environmental subjects. PLANT SAFETY RULES AND PROCEDURES NEED FOR RULES AND PROCEDURE: - Safely rules are not new things. They were formed hundred year ago as and when need arise. Fire precaution rules are such oldest rules. Industrialization need for safety rules, procedures, codes and standards are. (u) To fix the safe standard to be followed (v) To measure the performance with such rule or standard. (w) Human behaviour needs to be regulated by safety rules: otherwise it may cause more accidents. (x) Management’s safety policy can be conveyed by rules and regulations for all employees. (y) They are necessary for safe job performance, orderliness and security. (z) If the rule is fixed (enacted or accepted), its breach can be easily shown to explain duty or responsibility for its observance. (aa)Disciplinary action is possible for violation of rules.
- 316. (bb) Follow upof rules increases and maintains good discipline. (cc)Even if the rules are enforced, their need is permanent cannot be denied. (dd) Safety rules are the good foundation of training. Therefore there exists a strong need of safety rules which may be statutory or non statutory. FORMULATION OF RULES: - Criteria to be observed in formulating safety- rules are : Each rule should be short, clear and unambiguous. It should be need based. Unwanted rules should not be formulated. Where there is no combustible material rule against smoking may not be necessary. Rule should exactly describe the course of action to be followed and should cover all safety points. The number of general rules should be minimum necessary. Rule should be practicable so that it can be enforced. Safety rules should be formulated from real experience of knowledge and with active participation of employee concerned. TYPES OF RULES: E. STATUTORY RULES:- statutory acts, rules and forms are enacted by parliament and legislative assemblies. They are applicable to larger area and enforceable by government authorities. Non statutory plant rules are formulated by individual companies. But , such rules should not be in derogation with statutory rules need not be covered by non – statutory rules. Statutory rules are generally under some Act. The Act provides major items and their details are provided by rules. The Factories Act 1948 is a Central Act applicable to the whole of India, while different states have enacted different rules under that. F. NON STATUTORY RULES PSYCHOLOQICAL SAFETY RULES o) Prevention is better than cure. p) Accidents do not happen, they are caused. Safety is my responsibility. It begins from me, I will maintain it. It also needs cooperative and coordinate efforts. q) Safety is duty as well as right performs the duty and enjoys the right. r) Small things make perfection but perfection is not a small thing. Safety should be made perfect by smallest precaution. s) Solution of a problem lies through the problem. To achieve safety try through all stages in sequence. t) It is the knowledge that works and not the designation. Increase the knowledge of safety perpendicular (in your own branch) and then horizontal (in other or side branches) u) Rules of safety are absolute and not negotiable. RULES FOR SAFE CONDITION:- These rules are most important as they supply engineering, health and hygiene controls to make plant, premises, process, equipment etc. safe and sound from the design stage to the maintenance stage
- 317. such rules shouldbe grouped subject wise and classified systematically. Majority chapters of this book deal with such rules. RULES FOR SAFE ACTION:- These rules touch the behaviour aspect of work-people and cover work methods, procedures and human actions connected with work performance they may be philosophical if they cover the material behaviour, thinking or action and may be physical, mechanical, electrical, chemical etc. if they cover such environmental subjects. Safe Operating System: Definition: A standard operating procedure is a set of instructions having the force of a directive, covering those features of operations that lend themselves to a definite or standardized procedure without loss of effectiveness. Standard Operating Policies and Procedures can be effective catalysts to drive performance improvement and improving organizational results. Every good quality system is based on its standard operating procedures (SOPs). A Safe Work Procedure is a working risk control document created by teams within the company that describes the safest and most efficient way to perform a certain task. This document stays in the Health & Safety system for regular use as a guide when completing that particular task on site. Safety Checklist: Safety checklists are documents used during safety inspections for the identification of potential hazards. OSHA has provided a wide range of checklists for the identification of potential hazards in a variety of industries and applications. Each workplace and industry has its own set of hazards, and health and safety professionals must be able to identify which checklists are appropriate to specific workplaces and processes in order to ensure that full compliance with safety standards is achieved in the workplace. Safety checklists provide a tool for determining possible workplace hazards and should be completed during inspections, reported on, used as a basis for safety recommendations and filed for record-keeping purposes. OSHA provides checklists for industries including: radiation safety, explosion safety, fall protection, electrical safety work practices, fixed stars and ladders, occupational injury and illness reporting and more. A workplace health and safety audit checklist is a tool used in performing internal and external audits of an office or any working environment. Use this digital checklist to assess if workplace health and safety (WHS) practices are followed. Maximize this template by using the points below as a guide:
- 318. 1. Perform asite inspection and assess areas of the workplace including emergency procedures, first aid, and PPE’s in place 2. Take or attach photo of issues identified 3. Add notes or comments to inspections 4. Assign corrective measures for non-compliant items. 5. Sign off with digital signatures Inspectors: Date: (O)Satisfactory (X) Requires Action Location Condition Comments Fire Emergency Procedures Is there a clear fire response plan posted for each work area? Do all workers know the plan? Are drills held regularly? Are fire extinguishers chosen for the type of fire most likely in that area? Are there enough extinguishers present to do the job? Are extinguisher locations conspicuously marked? Are extinguishers properly mounted and easily accessible? Are all extinguishers fully charged and operable? Are special purpose extinguishers clearly marked? Electrical Is the Canadian Electrical Code followed for operation, use, repair and maintenance? Are all machines properly grounded? Are portable hand tools grounded or double insulated? Are junction boxes closed? Are extension cords out of the aisles where they can be abused by heavy traffic? Is permanent wiring used instead of extension cords? Confined Spaces Are the confined space procedures and training available and followed by all involved? Are entry and exit procedures adequate? Are emergency and rescue procedures in place (e.g. trained safety watchers)? Housekeeping Is the work area clean and orderly? Are floors free from protruding nails, splinters, holes and loose boards? Are aisles and passageways kept clear of obstructions? Are permanent aisles and passageways clearly marked? Are covers or guardrails in place around open pits, tanks and ditches?
- 319. Safety Tag System: Safetytags are used to prevent accidents in hazardous or potentially of the ordinary, unexpected, or not readily apparent. Tags shall be used until the identified hazard is eliminated or the hazardous operation is completed. Tags give their safety alert with a signal word and a major message. Just as with safety signs, the signal word is the one that leaps out and gets your attention. It can be DANGER, CAUTION, BIOLOGICAL HAZARD, BIOHAZARD or the biohazard symbol. Tags may also use a signal word we didn’t discuss with signs: WARNING. Accordi tag that says WARNING for a situation whose hazard level is somewhere between DANGER and CAUTION. Sometimes a tag may use a picture instead of, or in addition to, words. The pictures are usually easy to understand. For instance, if the tag contains a message about wearing hard hats or ear protection, there might be a picture of a head wearing a hard hat or ear muffs. Again, the point of all this is to use colors, pictures, and words to get your attention what to do to stay safe. By defining the meaning of the signal words like DANGER and CAUTION, OSHA is trying to make sure you do not misjudge the seriousness of a hazard. One of the techniques used for identification of hazards, safety inspection is carried out with the help of “Check List”. ADVANTAGES OF SAFETY INSPECTION ARE : 1. Day to day or fortnightly, management is provided with clear picture of accident potential. 2. Defects (unsafe practices) are cleared on the spot. 3. Managers/supervisors are accountable if they fail to take action after the defects have been pointed out by inspection team. Check Safety tags are used to prevent accidents in hazardous or potentially hazardous situations that are out of the ordinary, unexpected, or not readily apparent. Tags shall be used until the identified hazard is eliminated or the hazardous operation is completed. Tags give their safety alert with a signal word and a e. Just as with safety signs, the signal word is the one that leaps out and gets your attention. It can be DANGER, CAUTION, BIOLOGICAL HAZARD, BIOHAZARD or the biohazard symbol. Tags may also use a signal word we didn’t discuss with signs: WARNING. According to OSHA, you use a tag that says WARNING for a situation whose hazard level is somewhere between DANGER and Sometimes a tag may use a picture instead of, or in addition to, words. The pictures are usually easy to understand. For instance, if the tag contains a message about wearing hard hats or ear protection, there might be a picture of a head wearing a hard hat or ear muffs. Again, the point of all this is to use colors, pictures, and words to get your attention and communicate quickly what kind of risk you’re facing and what to do to stay safe. By defining the meaning of the signal words like DANGER and CAUTION, OSHA is trying to make sure you do not misjudge the seriousness of a hazard. PLANT SAFETY INSPECTION One of the techniques used for identification of hazards, safety inspection is carried out with the help of ADVANTAGES OF SAFETY INSPECTION ARE : Day to day or fortnightly, management is provided with clear picture of accident potential. Defects (unsafe practices) are cleared on the spot. Managers/supervisors are accountable if they fail to take action after the defects have been pointed out by inspection team. Check-List Observation Location Action Taken hazardous situations that are out of the ordinary, unexpected, or not readily apparent. Tags shall be used until the identified hazard is eliminated or the hazardous operation is completed. Tags give their safety alert with a signal word and a e. Just as with safety signs, the signal word is the one that leaps out and gets your attention. It can be DANGER, CAUTION, BIOLOGICAL HAZARD, BIOHAZARD or the biohazard symbol. ng to OSHA, you use a tag that says WARNING for a situation whose hazard level is somewhere between DANGER and Sometimes a tag may use a picture instead of, or in addition to, words. The pictures are usually easy to understand. For instance, if the tag contains a message about wearing hard hats or ear protection, there might be a picture of a head wearing a hard hat or ear muffs. Again, the point of all this is to use colors, and communicate quickly what kind of risk you’re facing and what to do to stay safe. By defining the meaning of the signal words like DANGER and CAUTION, OSHA is One of the techniques used for identification of hazards, safety inspection is carried out with the help of Day to day or fortnightly, management is provided with clear picture of accident potential. Managers/supervisors are accountable if they fail to take action after the defects have been Action Taken
- 320. 1 House keeping 2Access 3 Condition of floor, staircase, railing, platform etc. 4 Electrical fillings 5 Leakages 6 Bonding/earing 7 Pipeline supports 8 Noise/vibration 9 Use of PPE 10 Guards 11 Display of instructions boards 12 Condition of storm drain water 13 Fire extinguishers PLANT SAFETY OBSERVATION PLAN It is the one of the plant safety inspections. Each & every time inspection team encourages & motivates employee to correct any unsafe method, conditions of work and unsafe act. The inspection of work practices is done by observing the activities of worker. In actual practice, although the workers are instructed to work safely, they may not do so, the reason may be either they forgot safety instructions/rules or they do not give much importance to the rules/instructions. Such behaviour may lead to accident. To prevent accident an effective observation pan is required, hence concept of ‘Plant Safety Observation Plan’ come to existence. PROCEDURE/TECHNIQUE Team should fix the priority – like safety first, improvement of operation second and need of training third. Team should know about the job & responsibility of the operator. Team should go ahead with a check-list for actual observation and make a report of inspection which should be simple & practical. Main objective of safety observation plan is to identify violation of commonly accepted safe procedure of work with ultimate aim of making all operations safe and efficient. Safety observation plan
- 321. ensures that thesupervisors a various levels being responsible for workers safety observe work while it is in process. Safety sampling is one of the technique of plant safety observation plan. SAFETY SAMPLING It is method of measuring hazard or accident potential by random sampling procedure sampling procedure and by conducting safety survey while louring specific location. The survy team, experienced in safety sampling, walks through specific (decided) location in the plant and observes all the workers doing their task. Safety sampling team records number of workers those performing their task safety those performing task unsafely. STEPS : 1. Team meets at desided location and decides route for survey 2. Takes round for 15 minutes. 3. With the use of “check-list” list out the safety defects & hazards in that area. 4. Results of sampling are added to summary & plots a graph 5. Previous and present graphs are compared and safety performance is measured. EXAMPLE : N1 (number if safe practices) = 160 N2 (number of unsafe practices) = 40 Total Observations = 200 N = 4(1-P) /y2 P Where, N = number of observations required for desired degree of accuracy Y = degree of accuracy (10% = 0.1) P = % of unsafe practices P = 40/200 20%=0.2 N = 4(1-0.2)/(0.1)2 x 0.2 = 1600 observations If N1 (number of safe practices) = 150 N2 (number of unsafe practices)= 50 Total Observation = 200 Then N= 1200 observations It means that % of the unsafe acts (p) is inversely proportion to the number of observations. SAFETY SAMPLING CHECK-LIST ITEM CHECK-LIST COUNT ROUTES TOTAL
- 322. A Protective Equipment Guards increaseor missing Machine under repair-switch unlocked Fire Extinguisher-blocked condition Inspection cover-misplaced Safety notices-defective Other items B House Keeping Blocked passageway Blocked stairways Tripping hazard Slippery patches Chemical spillage Blocked drains C Tools Wrong tool used Defective tools Power tools, plugs, wiring SAFETY SURVEY A safety survey is a detailed examination of a narrow or specific major key area identified by safety inspection or audit, individual plant, procedure or particular problem common to a works as whole. It is followed by a formal report. Action plan and subsequent monitoring. Its different with safety audit is evident. Safety audit covers all parts of a plant one by one, while safety picks up out bu an expert team. In case, if employees of a chemical plant, complaint about ill-health, then expert team carries safety survey in that plant and study the procedure of handling of chemicals, their storage conditions, safety system in the plant to take care of gases/vapour and also team refers the medical reports of such employees. After carrying out in depth study of that pant, team submits their expertise comments. If toxic chemicals are really affecting the health of exposed employees, then measure are recommended to provide safe working conditions.
- 323. SAFETY TOUR It isan unscheduled examination of a work area carried out by works mangers or safety committee members to ensure that the standards of housekeeping are at an acceptable level, hazards are removed and safety standards are observed. Its scope is less than that of a safety inspection. Accident analysis gives the target area where accident rates are high; more emphasis is given at such places or locations. The constituted team takes round of such identified area/location and note down the unsafe practices. Team recommends the corrective measures and immediate action is taken to implement the recommendations. SAFETY INVENTORY It is a safety data collecting technique and is carried out to promote full employee co-operation in the implementation of the company’s safety programme. The inventory is well publicized in the plant in advance. This help in planning the annual safety programme and provide clues to needed action. This is done once a year like the annual stock inventory. Select persons at random and cover about 30% of employees. The questionnaire card given to each employee and he is required to take stock of his job and the surrounding with regard to safety, fill the card fully, sign it and submit by certain data. The answers to many of the questions may provide clues to needed action. Need of more or better guarding More or better PPE Many cases revealed in the safety inventories, year after year called for tightening up of inspection as well as more attention to safety by at least the supervisor involved. The root causes of some of the unsafe practices were found out, say in case of safety shoes it was found that: Majority of workers did not wear shoes because they were not fitting properly or that they have no faith in the efficiency of the safety shoes. This calls for better sales job. Majority of workers did not know where the first-aid box was loaded. The results of such safety inventory survey can be discussed in safety committee and desired action can be determined. In many cases experience and engineering judgment permit an engineer to decide whether or not a proposed design provides adequate availability & reliability. So data collected are use full in evaluating the overall reliability of system the most fundamental factor which determines the scale of the hazard is the inventory of hazardous in process & storage also grow.
- 324. SAFETY INVENTORY QUESTIONNARE Name:Dept.: Group: Division: Occupation: Equipment used by: M/c No. Is the equipment properly guarded? Kind of safety device What safety improvements you recommend? List of PPE use What PPE you use? Any work stress/strain? The posture required for the job Do you know the safety rules? Are the rules benefit? What can you suggest to improve working condition? Have you attended safety training? Do you want to attend safety training? Signature of Employee:………………. PRODUCT SAFETY: Product safety is the ability of a product to be safe for intended use, as determined when evaluated against a set of established rules. TOTAL LOSS CONTROL The concept of accident prevention when applied to prevent human injuries only, it is called “injury Prevention or Control”. When it is applied to control property damage only, it is called “Damage Control”. When it is applied to control by management system, human injuries and property damage both and also extended to include injuries and property damage to society or surrounding, it is called “Total Loss Control”. THE CONCEPT OF TLC IS ALSO DEFINED AS :- It is an evolution from injury prevention to the control of all business losses by the application of sound management principles.
- 325. It is asystem of reporting and controlling all incidents, however small, whether the associated loss is small or large. It is a programme to eliminate unnecessary cost by means of identification of grading situations, measurement of the loss potential, selection of methods to control the situation and finally implementation of the methods. THE FUNDAMENTALS OF LOSS CONTROL 1. Accidents, unsafe conditions and unsafe actions are symptoms of something wrong in the management system 2. Certain sets of circumstances can be predicted to produce severe injuries, which can be identifies and controlled 3. Safety should be manages like any other company function. Management must direct the safety efforts by setting achievable goals by planning, organizing, and controlling to achieve them. 4. The key to effective line safety performance is management procedures that fix responsibility and accountability 5. The function of safety is to locate and define the operational errors that allow accidents to occur. MANAGEMENT FOR LOSS CONTROL 1. Formulation of Total Loss Control Policy 2. Constitution of Loss prevention committee to execute the policy 3. Assigning responsibility 4. Attention to employees selection, placement, training, participation 5. Adopting safety in design 6. Safety inspection & safety audit CONTROL MEASURES MONITORED BY THE LOSS CONTROL DEPARTMENT ARE 1. Rules & regulation 2. Traffic laws 3. Standard procedures 4. Measurement of safety performances 5. Occupational safety standards/rules 6. Investigation of losses 7. Summary analysis
- 326. PERMIT TO WORKSYSTEM: A safe work permit is a written record that authorizes specific work, at a specific work location, for a specific time period. Permits are used for controlling and co-ordinating work to establish and maintain safe working conditions. They ensure that all foreseeable hazards have been considered and that the appropriate precautions are defined and carried out in the correct sequence. The permit is an agreement between the issuer and the receiver that documents the conditions, preparations, precautions, and limitations that need to be clearly understood before work begins. The permit records the steps to be taken to prepare the equipment, building, or area for the work, and the safety precautions, safety equipment, or specific procedures that must be followed to enable the worker(s) to safety complete the work. The safe work permit helps to identify and control hazards, but does not, by itself, make the job safe, Any industry that has a significant risk because of particular hazards. Any prime contractor who lets out or sub-contracts work to others to do maintenance or other hazardous work. Organizations that have individual employees working in isolated areas and performing non- routine work. All work exposes the worker to some degree of hazard. This degree of hazard determines the type of safeguards required to protect the worker. Most routine work has defined safe work practices or procedures. In the absence of such procedures, safe work permits should be used. Workers engaged in maintenance work may be at risk if the machinery they are working on is started unexpectedly. Such machinery and equipment needs to be isolated by blanking, blinding, or a power lockout system. These procedures can be clearly identified by a work permit system. Certain types or conditions of work, such as confined space entry, flammable or explosive situations, exposure to harmful substances or high voltage electrical equipment, and the transfer of hazardous work from one work shift to the next are examples of where safe work practices or the use of work permits is essential.
- 327. Types of safework permits The type of safe work permit required is determined by the nature of the work to be performed and the hazards that must be controlled or eliminated. The range of activities and locations makes it impossible for a single type of permit to be suitable for a and examples are provided at the end of this Safety Bulletin. The type of safe work permit required is determined by the nature of the work to be performed and the hazards that must be controlled or eliminated. The range of activities and locations makes it impossible for a single type of permit to be suitable for all situations. The following types are most commonly used he end of this Safety Bulletin. The type of safe work permit required is determined by the nature of the work to be performed and the hazards that must be controlled or eliminated. The range of activities and locations makes it impossible ll situations. The following types are most commonly used
- 328. Hot Work Permit Hotwork permits are used when heat or sparks are generated by work such as welding, burning, cutting, riveting, grinding, drilling, and where work involves the use of pneumatic hammers and chippers, non- explosion proof electrical equipment (lights, tools, and heaters), and internal combustion engines. Three types of hazardous situations need to be considered when performing hot work: (a) the presence of flammable materials in the equipment; (b) the presence of combustible materials that burn or give off flammable vapours when heated; and (c) the presence of flammable gas in the atmosphere, or gas entering from an adjacent area, such as sewers that have not been properly protected. (Portable detectors for combustible gases can be placed in the area to warn workers of the entry of these gases.) Cold Work Permit Cold work permits are used in hazardous maintenance work that does not involve “hot work”. Cold work permits are issued when there is no reasonable source of ignition, and when all contact with harmful substances has been eliminated or appropriate precautions taken.
- 329. Confined Space EntryPermit A space that has all three of the following criteria: Large enough and so configured that an employee can physically enter Limited or restricted mea occupancy Examples of confined spaces are tanks, vessels, silos, storage bins, hoppers, vaults, and pits. It can be any enclosed or partially enclosed space where there is a risk of death or serious hazardous substances or dangerous conditions (e.g., lack of oxygen, toxic or combustible gases) may be present. Confined space entry permits are used when entering any confined space such as a tank, vessel, tower, pit or sewer. The permit should be used in conjunction with a “Code of Practice” which describes all important safety aspects of the operation. Work at Height: Any work at height of 1.8 meter or more from the ground level or floor. Elevated working positions where the hazard of a fall exists and where there is no physical protection such as handrails. Types of work covered include working from all types of ladders, scaffolds, mechanical lifts, working on transmission towers and conductors, inside confined spaces, sloped roofs overhead tie-off points, when working within 6 feet (1.8mt) of the edge of a flat roof, erecting steel or installing/replacing roofing and in pipe racks. This does not include normal work on low stepladders, loading platforms, or similar locations. A space that has all three of the following criteria: Large enough and so configured that an employee can physically enter Limited or restricted means for entry or exit Not designed for continuous employee occupancy Examples of confined spaces are tanks, vessels, silos, storage bins, hoppers, vaults, and pits. It can be any enclosed or partially enclosed space where there is a risk of death or serious hazardous substances or dangerous conditions (e.g., lack of oxygen, toxic or combustible gases) may be Confined space entry permits are used when entering any confined space such as a tank, vessel, should be used in conjunction with a “Code of Practice” which describes all important safety aspects of the operation. Any work at height of 1.8 meter or more from the ground level or floor. Elevated working positions of a fall exists and where there is no physical protection such as handrails. Types of work covered include working from all types of ladders, scaffolds, mechanical lifts, working on transmission towers and conductors, inside confined spaces, sloped roofs, areas where there are no off points, when working within 6 feet (1.8mt) of the edge of a flat roof, erecting steel or installing/replacing roofing and in pipe racks. This does not include normal work on low stepladders, similar locations. A space that has all three of the following criteria: Large enough and so configured that an employee can ns for entry or exit Not designed for continuous employee occupancy Examples of confined spaces are tanks, vessels, silos, storage bins, hoppers, vaults, and pits. It can be any enclosed or partially enclosed space where there is a risk of death or serious injury from hazardous substances or dangerous conditions (e.g., lack of oxygen, toxic or combustible gases) may be Confined space entry permits are used when entering any confined space such as a tank, vessel, should be used in conjunction with a “Code of Practice” which describes Any work at height of 1.8 meter or more from the ground level or floor. Elevated working positions of a fall exists and where there is no physical protection such as handrails. Types of work covered include working from all types of ladders, scaffolds, mechanical lifts, working on , areas where there are no off points, when working within 6 feet (1.8mt) of the edge of a flat roof, erecting steel or installing/replacing roofing and in pipe racks. This does not include normal work on low stepladders,
- 330. Electrical Isolation: An electricalpermit is require for work on electrical systems where there is a possibility of contacting energized electrical conductors. For all electrical isolation and energisation of electrical equipments Permit is required. To work on High Tension (HT) and Low Tension (LT) line and / or equipment is required. For Trip reset of HT and LT equipment, the clearance shall be taken on format. includes 1. Work involving the installation or repair of 2. Reaching into any panel and transformer which may have energized circuits, capacitors, wiring, etc 3. Work on instrumentation, instrument panels, or telecom equipment 4. Where removal of a part of the circuit takes place outside normal ope Excavation: An excavation permit is a critical component of the excavation procedure, and is always required in the event of any excavation. An electrical permit is require for work on electrical systems where there is a possibility of contacting For all electrical isolation and energisation of electrical equipments Permit is required. To work on High Tension (HT) and Low Tension (LT) line and / or equipment is required. For Trip reset of HT and LT equipment, the clearance shall be taken on format. Work involving the installation or repair of electrical conductors transformer which may have energized circuits, capacitors, wiring, etc Work on instrumentation, instrument panels, or telecom equipment Where removal of a part of the circuit takes place outside normal operating conditions An excavation permit is a critical component of the excavation procedure, and is always required in the An electrical permit is require for work on electrical systems where there is a possibility of contacting For all electrical isolation and energisation of electrical equipments Permit is required. To work on High Tension (HT) and Low Tension (LT) line and / or equipment is required. For Trip reset of HT and LT equipment, the clearance shall be taken on format. Some examples transformer which may have energized circuits, capacitors, wiring, etc rating conditions An excavation permit is a critical component of the excavation procedure, and is always required in the
- 331. Identify undergroundservices prior to any excavation which involves o A proper review of site o A review of dial before you dig information o A physical inspection of the excavation site and area, usually accompanied by a utility services person or someone who has an understanding of that particular area o All buried services (found by mean and properly marked in line with requirements (more about these specific detailed requirements can be found here) o Completing and having an excavation permit approved. Working On Fragile Roof: Due to their inherent danger, access to all roofs is restricted to authorized personnel only. This document sets out the intended policy for the safe access to roofs of University buildings.. Identify underground services prior to any excavation which involves A proper review of site plans and drawings A review of dial before you dig information A physical inspection of the excavation site and area, usually accompanied by a utility services person or someone who has an understanding of that particular area All buried services (found by the methods above) must be located via non mean and properly marked in line with requirements (more about these specific detailed requirements can be found here) Completing and having an excavation permit approved. Due to their inherent danger, access to all roofs is restricted to authorized personnel only. This document sets out the intended policy for the safe access to roofs of A physical inspection of the excavation site and area, usually accompanied by a utility services person or someone who has an understanding of that particular area the methods above) must be located via non-destructive mean and properly marked in line with requirements (more about these specific detailed Due to their inherent danger, access to all roofs is restricted to authorized personnel only. This document sets out the intended policy for the safe access to roofs of
- 332. Policy 1. Working onuniversity roofs has been identified as a potentially hazardous activity. 2. A formal procedure of roof access and safety management has been put in place to manage this risk. 3. Each roof must be specifically inspected and risk assessed so that anyone visiting a roof is not put at undue risk. See the Roof Hazard Sheet. 4. Access to university roofs is via an authorization process. 5. Doors leading to roofs will be kept locked at all times. All locks and keys will be distributed by Facilities Management. Only certain personnel will be assigned keys. 6. Doors leading to roofs will have a warning sign “Authorized Personnel Only“. 7. All work on roofs will require a written risk assessment. General procedure: Safe work permits are usually made out in either duplicate or triplicate. When a duplicate system is used, one copy of the permit is retained by the issuer at the work site and the other is held by the worker/department doing the work. The permit should always be available at the work site. The permit is handed back to the issuer at the end of the shift or when the work is completed. In a triplicate permit system, the third copy is used by the safety department to audit the work to see if the requirements of the permit are being met. Content Of Work Permit: A safe work permit is a written record that identifies: (1) The date, time of issue, and time of expiry of the permit; (2) The location of the work —it must be as specific as possible; (3) The department or company doing the work; (4) A description of the work to be done; (5) Any toxic, corrosive, flammable, or other dangerous materials in the immediate work area; (6) Whether the work area has been inspected and found free of the above materials; (7) The need for fire protection; (8) the need for isolation — electrical and mechanical hazards locked out and tagged, piping blanked off, tagged, disconnected, drained, or vented; (9) The need for ventilation — air, steam, inert gas purge; (10) The need for testing prior to or during the work for: ƒ harmful substances; ƒ combustible gases; oxygen deficiency; ƒ other hazards e.g. radiation;any specific health hazard — is Material Safety Data Sheet information required?; (11) The need for specific personal protective equipment to protect the worker from the hazard; (12) The need for specific personal protective equipment to protect the worker from the hazard; (13) The need for emergency procedures and competent rescue personnel;
- 333. (14) A specialinstructions and comments section — special procedures, special precautions; (15) A general instruction-to-receiver section; (16) The name and job title of the person who issued the permit and when; (17) The name and job title of the person who received the permit and when; (18) That the work has been completed and the permit signed by the person returning it; and (19) The name of the person signing off the permit and whether or not the work has been completed. Lock Out and Tag Out (LOTO) System: It goes without saying that industrial equipment can be dangerous when it’s being used. That’s why machines are designed with safety equipment and operators wear personal protective equipment when using them. But machinery can also present hazards when it’s not in operation. As long as energy sources such as electricity, natural gas, steam, pressurized water, and compressed air are attached to the machine, a hazard exists. Workers who maintain or repair the equipment, or who will be working in close proximity to it, need to be made aware of these hazards and recognize that steps have been taken to protect them. That’s why OSHA requires a formal lockout/tagout program. While it may seem that having a formal program with multiple steps may be overkill, it actually makes good sense. After all, most companies use a variety of equipment that has very different safety practices. In addition, any number of workers may be asked to deal with the equipment, and some will be more familiar with it than others.
- 334. An effective lockout/tagoutprogram should include the following eight steps. Step 1: Detailed procedures for equipment Begin by making sure you’ve identified the equipment correctly and accurately, including its specific location. Next, determine the correct procedure for shutting that procedure, step by step, in writing. Consider all of the energy sources that may be connected to the equipment. Be very specific, because ambiguous language could lead to an incorrect or even dangerous action. Step 2: Notify affected employees When maintenance is going to be performed, all of the employees that may be affected should be notified. Let them know the timing of the work, and how long the equipment may be unavailable. If the unavailability of the equipment requires a change in work processes, be sure they are familiar with the steps to be taken. Step 3: Shut down equipment properly Explain the shutdown process in detail. It’s not enough to say something like “disconnect the machine.” To ensure everyone’s safety and reduce the potential for damage, the shutdown instructions should be detailed. Spell out the exact actions to be taken and the correct sequence for performing those actions. Step 4: Disconnect all primary energy sources Although this may seem fairly self the primary energy sources include electricity, steam, water, gas, compressed air, or others, don’t assume that the person performing maintenance will know the correct proc what needs to be done. Step 5: Address all secondary sources While disconnecting the primary energy sources may remove much of the potential danger, it’s possible that there sources of residual energy, such as trappe vented, or even tension in a spring assembly. Identify the process that will relieve any remaining pressure or other energy. Also consider other hazards, such as moving equipment that must be secured be begins. Step 6: Verify the lockout Once you’ve disconnected all primary and secondary sources of energy, attempt to start the equipment to program should include the following eight steps. Step 1: Detailed procedures for equipment Begin by making sure you’ve identified the equipment correctly and accurately, including its specific location. Next, determine the correct procedure for shutting down and restarting the equipment. Detail that procedure, step by step, in writing. Consider all of the energy sources that may be connected to the equipment. Be very specific, because ambiguous language could lead to an incorrect or even dangerous Step 2: Notify affected employees When maintenance is going to be performed, all of the employees that may be affected should be notified. Let them know the timing of the work, and how long the equipment may be unavailable. If the uipment requires a change in work processes, be sure they are familiar with the Step 3: Shut down equipment properly Explain the shutdown process in detail. It’s not enough to say something like “disconnect the machine.” ne’s safety and reduce the potential for damage, the shutdown instructions should be detailed. Spell out the exact actions to be taken and the correct sequence for performing those actions. Step 4: Disconnect all primary energy sources em fairly self-explanatory, once again, it’s important to be very detailed. Whether the primary energy sources include electricity, steam, water, gas, compressed air, or others, don’t assume that the person performing maintenance will know the correct procedure to follow. Again, explain exactly Step 5: Address all secondary sources While disconnecting the primary energy sources may remove much of the potential danger, it’s possible that there sources of residual energy, such as trapped heat in a thermal system, fumes that may need to be vented, or even tension in a spring assembly. Identify the process that will relieve any remaining pressure or other energy. Also consider other hazards, such as moving equipment that must be secured be Once you’ve disconnected all primary and secondary sources of energy, attempt to start the equipment to Begin by making sure you’ve identified the equipment correctly and accurately, including its specific down and restarting the equipment. Detail that procedure, step by step, in writing. Consider all of the energy sources that may be connected to the equipment. Be very specific, because ambiguous language could lead to an incorrect or even dangerous When maintenance is going to be performed, all of the employees that may be affected should be notified. Let them know the timing of the work, and how long the equipment may be unavailable. If the uipment requires a change in work processes, be sure they are familiar with the Explain the shutdown process in detail. It’s not enough to say something like “disconnect the machine.” ne’s safety and reduce the potential for damage, the shutdown instructions should be detailed. Spell out the exact actions to be taken and the correct sequence for performing those actions. explanatory, once again, it’s important to be very detailed. Whether the primary energy sources include electricity, steam, water, gas, compressed air, or others, don’t assume edure to follow. Again, explain exactly While disconnecting the primary energy sources may remove much of the potential danger, it’s possible d heat in a thermal system, fumes that may need to be vented, or even tension in a spring assembly. Identify the process that will relieve any remaining pressure or other energy. Also consider other hazards, such as moving equipment that must be secured before work Once you’ve disconnected all primary and secondary sources of energy, attempt to start the equipment to
- 335. verify that thelockout has been successful. Before you try to start it, verify that nobody is in a position where they could be hurt. Assuming that the procedures have been successful, return all switches and other equipment back to their “off” positions so the machine won’t start unexpectedly when the energy sources are reconnected. Once you’ve verified the lockout, attach a lockout or tagout device to the equipment to ensure that it cannot be started without removing the device. Step 7: Keep it in force during shift changes The equipment must remain in lockout/tagout condition across shift changes, so that workers arriving at the site are aware that the equipment is out of service. If individual locks or tags are used, the individual responsible for designating the lockout/tagout and the individual responsible for it during the next shift must both be present as the locks or tags are switched. Step 8: Bring the equipment back on line When the work is done and all tools and other materials have been removed, the machine can be brought back into operation. Here again, the procedure should spell out the exact steps that are involved, along with the correct sequence. For example, you may need to open a particular machine’s discharge valves before you open the inlet, so any unexpected water or steam remaining in the lines has a place to go.
- 336. CHAPTER- 2 ACCIDENT/INCIDENT/ NEAR-MISS/ DANGEROUS OCCURENCE REPORTING, INVESTIGATIONS ACCIDENT REPORTS: Accident starts with near-misses, further leads to minor injury accidents and finally ends in major one. If we report and investigate each & every incident/accident then it is possible to prevent accident. A good management should keep a system of identifying and recording all accidents as well as damage to property cases. Accidents Register (separate register for reportable, non-reportable cases), health register must be kept update. Accident reports must be filled in details attached with the detailed investigation reports, properly classified & filled. Causes analysis reports should also be prepared to compare the year to year performance. REPORTABLE ACCIDENTS (REPORTING TO STATURITY AUTHORITY) In any factory an accident occur with causes death or which causes any bodily injury by reason of which the person injured is prevented from working for a period of 48hrs or more immediately following the accident. Reportable Minor Injury Accident Reportable Accident Of Serious Nature Reportable Dangerous Occurrence Reportable Polsoning Or Disease Minor Injury not of serious nature. 1. Accident which cause death to any person. 2. Immediate loss of any part of the body. 3. Crushed or serious injury to any part of the body due to which loss of the same is obvious. 4. Unconsciousness. 5. Severe burns. 1. Bursting of vessel (Boilers). 2. Explosion, fire. Bursting out, leakage or escape of any molten metal, hot liquor, or gas causing bodily injury or damage to factory. 3. Explosion of receiver or container used in process, for storage under pressure. 4. Collapse or failure of a crane, derrick, winch, hoist. 5. Collapse of any floor, Poisoning by hazardous chemicals- List is given in So 1 & 2 of “The Maharashtra Factories (Control of Industrial Major Accident Hazards) Rules, 2003”. Occupational Disease- List is given in “ The Third Schedule of the
- 337. gallery, roof, bridge, tunnel, chimney,wall, building. factories Act, 1948” Reporting to Jt./Dy. Director of Industrial safety & Health at Regional office in…. Form – 24 Within 24 hrs Form – 24 Within 4 hrs Form – 24 A Within 4 hrs Form – 25 Within 4 hrs ACCIDENT RECORS Necessary to transform a hazard, costly and ineffective work into a planned safety program more specifically. To create interest in accident prevention To provide up to date information on the accident To provide information on frequent unsafe practice/unsafe conditions. To measure the effectiveness of safety program. FIVE BASIC DOCUMANTS 1. Personal injury record 2. Damage control records for property & equipment 3. Register of injuries (progressive & monthly) 4. Register of damage to equipment (progressive & monthly) PERSONAL INJURY RECORD They tell who keeps getting hurt Enable grouping injuries quickly Provide details of accurate costing Provide quick reference for analysis CONTENTS OF PERSONAL INJURY RECORD Name: Token No: Occupation: Age: Dept: Date of occurrence: Nature of injury: Type of injury: Description of incident: Signature of witnesses: Signature of supervisor
- 338. ACCIDENT REPORTING INVESTIGATIONAND ANALYSIS Name & Address of the Factory: Sr. No. ____________ Tick Type of Incident: Date ______________ First Aid Minor Major Fatal Near Miss Fire Properly Damage Dangerous Occurrence Environmental 1. Name of the injured person : 2. Contractor : 3. Plant/Section : 4. Employee Code No./Designation : 5. Age/Sex : 6. Date & Time of Incident : 7. Normal Working Hours : 8. Location of Incident : Area Equipment No. Name of Equipment 9. Type of Incident : 10. Body part injured : 11. Nature of Injury/Incident : 12. Extent of Material LOSS/Property Damage : 13. Details of Incident a. Sequential Occurrence Description : b. Activity of the injured at the time of Incident : c. Observations & Inference: 14. Conclusion: Probable Causes: a. Immediate causes: b. Basic/Root causes: 15. Preventive Measures :
- 339. Sr. No RecommendationsAction By Date Status 1. 2. 16. Evaluation: Severity Potential Probability Potential Major Serious Minor Frequent Occasional Rare 17. Investigated By Contractor : Fire & Safety Dept : Plant concerned : 18. Discussed & Reviewed OR to be discussed & reviewed at Forum: 19. Copies for Action to : Signature Name & Designation
- 340. REPORTING AND ACCIDENT Accidentsare of vital concern to anyone involved with safety. They are the end resuit of many fauits both on the part of the employees and the part of management. It is the primary objective of safety practitioners to reduce accident rates. Before an accident can be analysed &its causes established, it must be reported concerned authority or to the safety department. Reporting minor accidents is important because. If a pattern of minor accidents can be spotted, control measures can more likely be instituted to correct the situation before a severe accident occurs. Because of unsafe acts / unsafe conditions near-misses accident starts, if near-miss accidents are not reported & investigated then minor accidents are obvious to occur and if we have not paid any attention to these accidents finally major accident is possible. REPOTABIE ACCIDENT (REPORTING TO STATULORY AUTHORITY) In any factory an accident occurs which causes death or which causes any bodily injury by reason of which the person injured is prevented from working for a period of 48 hrs or more immediately following the accident. 1. MINOR INJURY ACCIDENT – Reportable Minor injury accident to be reported to statutory authority in Form 24 within 24 hrs. 2. Accident of serious nature – Reportable Accident of serious nature, to be reported to statutory authority, in Form 24 within 4 hrs. 3. Dangerous occurrence – Reportable Dangerous occurrence to be reported to statulory authority, in Form 24 A within 4hrs. 4. Poisoning or Disease – Poisoning or Disease to be reported to statutory authority in Form 25 within 4 hrs. A register in F-30 format is to be maintained to record the reportable accidents. Separate register is to be maintained for non – reportable accident. Accident reportable under various statues Sr. No. Under Act Required Form No. 1 Factory act 1948 Form No. 24 2 ESIC Act 1948 Form No. 12 3 BOCW Act 1996 Form No. 18 ACCIDENT INVESTIGATION Once an accident has been reported, it is the department supervisor’s responsibility to investigate all accidents no matters how small. This helps make the supervisor responsible &accountable for safety actions. There are cases, where safety officer & departmental supervisor investigate accidents. And for major or critical accident management constitute an investigation committee. In case of statutory reportable accidents, generally factor inspectors investigate serious and fatal accidents and give detailed report showing the facts, breach of law, if any, and remedial measures. They may order to prohibit the use of some plant, equipment, process or premises, if it is found of imminent danger to them.
- 341. In the investigation,the following points to be considered : Do not fix blame for an accident; only isolated the causes. Be as objective and factual as possible; do not let personal feeling become part of the accident report. Look for the primary and secondary causes of accidents, not just symptoms Typical unsafe acts and unsafe conditions that are line primary causes of many accidents and which show underlying patterns of organizational problems are as follows: UNSAFE CONDITION 1. Unguarded or inadequate guarding of dangerous part of moving machinery. 2. Inadequate design and construction (noisy, poorly lighted, machine controls difficult to operate) 3. Faulty equipment etc UNSAFE ACTS 1. Using improper operating procedures or lack of safe performances ( improper lifting, for example ) 2. Horseplay (kidding around) 3. Not wearing correct personal protection equipment 4. Disobeying instruction or not informing supervisor about current activities 5. Ignoring warning 6. Inattention on job of employee to the task. Situational factors affecting employees can be the root causes of longterm accident patterns. These situational factors can be divided in to the subdivisions of (1) Physical environment factors (2) Physical characteristics of employees (3) Psychological characteristics of employees & (4) Psychological environmental factors. PHYSICAL ENVIRONMENT FACTORS The physical environment can contribute to the accident rate. Such factors as temperature, insufficient lights, and the length of the working day have been shown to be contributing causes of accidents. PHYSICAL CHARACTERISTICS OF EMPLOYEES: This category includes situational factors that are physical in nature. Age has been the most often investigated physical aspect of the relationship of employee to job. In most of these studies it has been shown that the accidents rates are higher among younger or more inexperienced employees, older workers, workers with longer experience on the job & the percentage of married men in the industrial population were factors contributing to successful low-accident plants. PSYCHOLOGICAL CHARACTERISTICS OF EMPLOYEES: An employee who is working under optimal physical environment condition and who is aware of his or her equipment may till likely to have an accident. Although bad physical environment and individual
- 342. physical characteristics havebeen shown to contribute to higher accident rates, the most important contributing factors are psychological. PSYCHOLOGICAL ENVIRONMENT FACTORS: There is ample evidence that the psychological environment does play an importantpart in accidents. One comparison between employees indicated that accident occur with the greatest frequency in those departments with the lowest intra company transfer mobility rates & least promotion possibility. Injury frequency was also the greatest where employees showed disfavour toward high-producing employees and where there was a record of garnished wages. Safety consciousness by management is another psychological environmental factor that appears to lower accident frequency. PURPOSE OF ACCIDENT INVESTIGATION & REPORT The main purposes are: 1. To learn accident causes so that similar accident can be prevented by improvement of working conditions, actions and supervision. This helps in designing accident prevention strategies. 2. To make the hazard known to the management, workers and supervisors to direct their attention to accident prevention. 3. To determine the ‘change’ or deviation that produced an ‘error’ that in turn resulted in an accident (systems safety analysis). 4. To find out injury rates to compare safety performance. 5. To use the record for the purpose of job safety analysis. 6. To develop safety rules, procedures, bulletins, posters and material for safety meetings and motivation. TECHNIQUE (PROCEDURE) FOR INVESTIGATION The basic steps are: Observation at site, interrogation, findings and recommendations. Some objective questions to be considered and answered by the investigator are: Who was injured, what was he doing at that time, where he was, who was with him, what he has to say about happening, what part of the injured is involved, how was he injured, what was unsafe the condition, the method the action of the injured, what does the medical report The first requirement for the injured person is to provide him medical treatment. It is a mistake to make him up by questions. It is advisable to wait till he recollects his thought and gets his nerves under control. Initial story should be collected from spot-checking and interrogation with co-workers and eyewitnesses. They should not be delay in initial inquiry. The conditions should be kept unaltered pending the investigation, Photographs, sketches, notes etc. will help much. Chronological questions should be ask and the concerned facts should be collected viz. testing report, registers, documents, instructions, defective or damage parts etc. The facts finding should aim to determine exact causes of the accident. All causes should be considered classified according to severity and responsibility for preventive purpose. As the last step, suggestions and recommendation for the prevention should be submitted in the writing emphasis should be given put to suggest engineering controls then to suggest human responsibilities.
- 343. CLASSIFICATION (ANALYSIS) OFACCIDENT (AS PER IS 3786-1983) Investigation and analysis go together. The facts found from the investigation are first analysed. The analysis should reveal one hypothesis to explain all the facts adequately. If the accidents are classified as per IS 3786, by taking two years or three years or five years accident statistics (data), then it is easy to find out the weak or key areas or target areas where accidents are more and upon concentrating on those area it is possible to reduce the rate considerably in coming year. FACTORS THOSE ARE CONSIDERED IN ACCIDENT ANALYSIS: 1. Agency 2. Unsafe mechanical or physical condition. 3. Unsafe Act. 4. Types of accidents. 5. Nature of injury and 6. Location of injury In analysis following factors are also considered: 1. Department 2. Category 3. Age 4. Time EXAMPLE-I A lathe operator lost his two fingers of left hand when it was trapped in the nip of unguarded speed- changing pulley belts when the start switch lever war accidentally turned to ‘on position’ by striking his body to the lever. Analyze the accident as per I.S classification. classification Key Factors (causes) 1 Agency Speed-changing pully-belt of the lathe 2 Unsafe Act Taking unsafe position or posture 3 Unsafe condition Unguarded pully-belt and, Start switch of the wrong type. 4 Type of accident Caught between moving objects 5 Nature of injury Amputation of two fingers. 6 Location of injury Fingers EXAMPLE-II
- 344. A helper ina chemical plant while transforming 2,4 dichlorophenol in a carboy through pumping and light fitting rubber hose-pipe inserted in the carboy without venting was sprayed by the chemical spray come-out due to rupture of the pipe, died within 15 minutes. He had not worm the PVC overall and hand gloves. Analyze this accident as per I.S classification. Classification Key Factors (causes) 1 Agency Toxic chemical 2 Unsafe Act Not wearing protective equipment Not allowing air-vent in the carboy i.e. unsafe placing 3 Unsafe condition Rubber hose-pipe and no venting while filling i.e. hazardous arrangement 4 Types of accident Contact by absorption of harmful substance 5 Nature of injury Death by acute poisoning 6 Location of injury Upper limb multiple locations. Corrective Action: Action taken to eliminate basic cause of accident to avoid reoccurrence of similar type of accident. Preventive Action: Horizontal Deployment of the corrective Action at other similar places & situation to avoid recurrence of the accident occurred. Corrective Action Process Locate and document the root cause of the nonconformity. Scan the entire system to ensure no other similar nonconformity could occur. Analyze the effect such nonconformity may have had on a product or service produced before the nonconformity was discovered, and take action appropriate to the severity of the situation by either recalling the product, notifying the customer, downgrading or scrapping product. Establish thorough follow-up to ensure the correction is effective and recurrence has been prevented. Preventive Action Process Take proactive steps to ensure a potential nonconformity does not occur. Employ process and system analysis to determine how to build in safeguards and process changes to prevent nonconformance. For example, use a failure mode and effects analysis to identify risks and potential deficiencies and to set priorities for improvement.
- 345. CHAPTER 3 MEASUREMENTAND EVALUATION OF SAFETY PERFORMANCE as per IS:3786 defines as under : Accident - Accident is an unintended occurrence arising out of and in the course of employment of a person resulting in an injury. Incident: an instance of something happening; an event or occurrence. Near miss Accident: Near miss Accident: When an Incident takes place without an Injury, it is termed as Near miss Accident. Dangerous Occurence: A near miss that could have led to serious injury or loss of life. Disabling injury: (Lost Time Injury): An injury causing disablement extending beyond the day of shift on which the accident occurred. Accidents reportable under the Factories Act & ESI Act: If a person is disabled for 48 hours or more & not able to attend his duties within next 24 hrs, than it is called as Reportable Accident. ( as per F.A.1948 & MFR 1963 ) & such accident is to be reported to local Jt. DISH office in Form no. 24 in 24 hours after the 48 hrs of the happening of an Accident with Injury. Non-disabling Injury - An injury which requires medical treat- ment only, without causing any disablement whether of temporary or permanent nature. Reportable Disabling Injury ( Reportable Lost Time Injury ) - An injury causing death or disablement to an extent as prescribed by the relevant statute. Reportable Accident: If a person is disabled for 24 hours after 48 hours of the happening of an accident, than it is called as Reportable Accident. ( as per F.A.1948 & MFR 1963 ) Non-Reportable Accident: If a person is disabled after an accident & resumes his duty within 48 hours of happening of an accident, than it is called as a non-reportable accident. Days of Disablement ( Lost Time ) - In the case of disablement of a temporary nature, the number of days on which the injured person was partially disabled. In the case of death or disable- ment of a permanent nature whether it be partial or total disablement man-days lost means the charges in days of earning capacity lost due to such permanent disability or death as specified in Appendix B. In other cases the day on which the injury occured or the day the injured person returned to work are not to be included as man-days lost; but all intervening calendar days ( including Sundays or, days off, or days of plant shut down ) are to be included. It after resump!ion of
- 346. work, the personinjured is again disabled for any period arising out of the injury which caused his earlier disablement, the period of such subsequent disablement is also to be included in the man-days lost. Temporary Disablement and permanent Disablement Partial and Total Disablement Time Charges : Partial Disablement: This is of two types; (i) disablement of a temporary nature which reduces the earning capacity of an employed person in any employment in which he was engaged at the time of the accident resulting in the disablement and (ii) disablement of a permanent nature which reduces his earning capacity in every employment which he was capable of undertaking at the time. Total Disablement: Disablement, whether of a temporary or permanent nature, which incapacitates a workman for all work which he was capable of performing at the time of the accident resulting in such disablement, provided that permanent total disablement shall be deemed to result from every type of injury specified in Part A of Appendix A or from any combination of injuries specified in Part B of Appendix A where the aggregate percentage of the loss of earning capacity, as specified in that part against those injuries, amounts to one hundred percent. found worsening. Temporary Disability vs. Permanent Disability Temporary Disability (TD): If your injury prevents you from doing your usual and customary job while recovering, you may be eligible for temporary disability benefits, if: Your treating physician issues a report stating that you are unable to perform your usual and customary job for more than 3-days; or you are hospitalized; or your employer does not offer you alternate or modified work that pays your usual wages. If you are entitled to temporary disability, you will receive a check. Permanent Disability (PD): These are benefits paid if your injury or illness results in permanent impairment which impacts your ability to compete in the job market. After your last medical appointment, your primary treating physician will issue a final report, known as a permanent & stationary report (more commonly known as a P&S report). Contained within this report will be any permanent impairment that your physician indicates based upon his or her final examination. Next a permanent disability rating will be calculated based upon your age and occupation at the time of your injury or illness, which is added to your whole person impairment rating. The injured worker receives TD at the PD rate. Man-Hours Worked - The total number of employee-hours work- ed by all employees working in the industrial premises. It includes man- agerial, supervisory, professional, technical, clerical and other workers including contractors’ labour. Scheduled Charge - Charges in days of earning czpacity lost due to permanent disability or death
- 347. Restricted Work Case:(RWC) Restricted Work Case is when a person is so injured that they cannot perform their normal duties. Therefore they are transferred, temporarily to some other jobs (light duties) First Aid Case: First aid refers to medical attention that is usually administered immediately after the injury occurs and at the location where it occurred. It often consists of a one-time, short-term treatment and requires little technology or training to administer. First aid can include cleaning minor cuts, scrapes, or scratches; treating a minor burn; applying bandages and dressings; the use of non- prescription medicine; draining blisters; removing debris from the eyes; massage; and drinking fluids to relieve heat stress. Fatal Accident: If a person dies as a consequence of an accident, than it is termed as a fatal accident. Non-fatal Accident: If a person does not dies but disabled as a consequence of an accident, it is called as Non-fatal accident. Lost time accident: : An Accident other than near miss accidents are lost time accidents in which an injured person is not able to work for the time as prescribed by the medical officer. SAFETY PERFORMANCE INDICATIORS: Frequency Rate: It can be defined as no. of loss time accidents occurred per million man-hours worked. Frequency Rate = No. of Loss Time Accidents x 1000000 Average man-hours worked NOTE 1 - If the injury does not cause loss of time in the period in which it occurs but in a subsequent period, the injury should be included in the frequency rate of the period in which the loss of time begins. NOTE 2 - If an injury causes intermittent loss of time, it should only be included in the frequency rate once, that is, when the first loss of time occurs. NOTE 3 - Since frequency rate & is based on the lost time injuriestreportable to the statutory authorities, it may be used for official purposes only. In all other cases, frequency rate FA should be used for comparison purposes. Severity Rate: It is no. of days lost due to loss time accidents per million man-hours worked. Severity Rate = No. of days lost due to Loss Time accidents x 1000000 Average man-hours worked Man-days lost due to temporary total disability; Man-days lost according to schedule of charges for death and permanent disabilities as given in Appendix A. In case of multiple injury, the sum of schedule
- 348. charges shall notbe taken to exceed 6 000 man-days; Days lost due to injury in previous periods, that is, if any accident which occurred in previous period is still causing loss of time in the period under review, such loss of time is also to be included in the period under review; d) In the case of intermittent loss of time, each period should be incjuded in the severity rate for the period in which the time is lost; and e) If any injury is treated as a lost time injury in one statistical period and subsequently turns out to be a permanent disability; the man-days charged to the injury shall be subtracted from the schedule charge for the injury when permanent disability becomes ‘known. Incidence Rate: General incidence rate is the ratio of the number of injuries to the number of employees during the period under review. It is expressed as the no. of accidents or injuries, per 1000 persons employed. IL = No. of lost –time accidents or injuries x 1000 Average No. of persons employed I R = No. of reportable lost time accidents or injuries x 1000 Average No. of persons employed Frequency Severity Index or Indicator: FSI = Sq. root of Frequency rate x Severity rate 1000 This is the square root of Disabling Injury Index. It gives combined effect of frequency and severity rate. This index can be used to compare-plant to plant. This can be used to indicate degree of improvement. Safe T-Score: It is given by SafeT-Score = Frequency rate now – Frequency rate past If STS is : It indicates Between +2 & -2 Change is not significant. There may be random fluctuation only. More than +2 Records is worsening than it was in the past. Something wrong has happened. Less than – 2 Record is improving than it was in the past. Something better has happened. Thus Safe-T-Score is useful to compare our safety record with the past and to control it if it is Temporary & Permanent Disablement. Cost factor: An element or condition related to a unit of product or to an activity or to a service for which money must be spent (as raw material, direct labour, and burden)
- 349. Methods of Collatingand Tabulating Data : For analysing a small number of reports the tabulation by hand sorting and tallyingis efficient. Its advantage is that the original records are being used and all the information is available for reference.For analysing and filing a large number of reports, keysort cards may be used.This card contains the information of the original report. The code numbers assigned to the various factors may be punched in the cards so that they can be sorted by a special needle. Sorting is a hand operation. A third method of tabulation uses card tabulating machine. Here the code numbers only are punched into the cards which can be quickly and accurately arranged into various groups. This methods is very useful when the number of reports is very large, when many classification and cross or sub classifications are required or when tabulation of numerical data such as days lost etc. are necessary. Modern method of computer processing can also be utilised for such tabulation.See part 13 of Chapter5 for management information system (MIS). Follow-up for Corrective Action : Merely obtaining, recording and tabulating of safety data is of no use. It must be followed by necessary corrective action to provide safe working condition, to teach safe working actions, to improve existing training system,, to make new safety rules necessary to improve inspection techniques and analysis to design -posters, safety manual and positive actions to minimise accidents. Follow up action must be and should consider every compliance. Reasons of prompt and immediate recommendation for not following the recommendation or delays necessary to make changes should be explained. The accident causation should be applied to all identical cases in other departments also to prevent similar recurrences. Record Keeping : Record of accidents reported to the plant management and to the Government authorities, facts collected as a result of investigation, analysis of the facts, conclusion about remedial measures necessary and status of implementation of those measures must be kept in a well documented form. Computer is more useful in this regard. In DCS system, printouts of accident situations at the time of accident should be kept out and preserved. Safety department should design formats of safety records applicable to the factory, train personnel to fill such records and maintain them. Records keeping may be ordinary or computerized and in much details. Good record is always useful for 1. Studying past accident causes and remedial measures concluded. 2. Monitoring status of implementation of safety measures. 3. Taking decisions regarding future action in the matters of safety. Period of maintaining record should be decided depending on the utility of the subject matter. Fatal Accident Frequency Rate: Fatal Accident Rate (FAR) is an indicator of accidents used to classify the dangerousness that is a measure of individual risk expressed as the estimated number of fatalities per 100 million hours (approximately 1000 employee working lifetimes) of this same activity. A Fatal Accident Frequency Rate (FAFR) is a number of fatalities per 100 million man-hours worked.
- 350. Leading & LaggingIndicator: Lagging indicators are typically “output” oriented, easy to measure but hard to improve or influence while leading indicators are typically input oriented, Leading and lagging indicators are two types of measurements used when assessing performance in a business or organisation. A leading indicator is a predictive measurement, for example; the percentage of people wearing hard hats on a building site is a leading safety indicator. A lagging indicator is an output measurement, for example; the number of accidents on a building site is a lagging safety indicator. The difference between the two is a leading indicator can i record what has happened. Leading & Lagging Indicator: Lagging indicators are typically “output” oriented, easy to measure but hard to improve or influence while leading indicators are typically input oriented, hard to measure and easy to influence. Leading and lagging indicators are two types of measurements used when assessing performance in a business or organisation. A leading indicator is a predictive measurement, for example; the percentage of ing hard hats on a building site is a leading safety indicator. A lagging indicator is an output measurement, for example; the number of accidents on a building site is a lagging safety indicator. The difference between the two is a leading indicator can influence change and a lagging indicator can only Lagging indicators are typically “output” oriented, easy to measure but hard to improve or influence while hard to measure and easy to influence. Leading and lagging indicators are two types of measurements used when assessing performance in a business or organisation. A leading indicator is a predictive measurement, for example; the percentage of ing hard hats on a building site is a leading safety indicator. A lagging indicator is an output measurement, for example; the number of accidents on a building site is a lagging safety indicator. The nfluence change and a lagging indicator can only
- 351. Classification of industrialaccidents and special cases according to IS-3786 Machines, Prime-movers, except electrical motors Steam engines Internal combustion engines, Others Transmission Machinery Transmission shafts Transmission belts, cable pulleys, pinions, chains, gears, Others Metal Working Machines Power presses Lathes Milling machines Abrasive wheels Mechanical shears Forging machines Rolling mills, Others Wood and Associated Machines . Circular saws Other saws Molding machines Overhand planes ,Others Agricultural Machines Reapers ( including combined reapers ) Threshers, Others Mining Machinery Drilling and boring machine including augurs Cutting machine Loading machine including scrapers Cutter-loaders including other continuous miners, Others
- 352. Other Machines Earth-movingmachines Spinning, weaving and other textile machines Machines for the manufacture of foodstuffs and beverages Machine for the manufacture of paper and leather Printing machines Means of Transportation and Mooing Equipment Lifting Machines and Appliances Cranes Lifts and elevators Winches Pulley blocks Means of Rail Transportation Inter-urban railways Rail transportation in mines, tunnels, qrlarries, industrial establishments, docks, etc, Others Other Wheeled Means of Transportation, Excluding Raii Tractors Lorries Trucks Motor Animal-drawn vehicles Hand-drawn vehicles Means of ,4ir Transportation Means of Water 7ransportation Motorized means of water transportation Non-motorized means of water transportation Means of Transport Cable cars Mechanical except cable-cars Conveyors
- 353. Other Equipment PressureVessels Boilers Pressurised containers Pressurised piping and accessories Gas cylinders Vacuum vessels Furnaces, Ovens,. Kilns Blast furnaces Refining furnaces Other furnaces Kilns Ovens Refrigerating Plants Electrical Installations, Including Electric Motors but Excluding Elect+ Hand Tools Rotating machines Conductors Control apparatus Others Electric Hand Tools Tools, Iu#ements and Appliances Except Electric Hand Tools Power-driven hand tools, except electric hand tools Hand tools, not power-driven Ladders, Mobile Ramps Scaffolding Other Equipment not Elsewhere CLass$ed Mate&is, Substances and Radiations Explosives Dusts, Gases, Liquids and Chemicals, Excluding Explosives Dusts Gases, vapours, fumes Liquids Chemicals not elsewhere classified 2329 Flying Objects Other Than Due to Explosion
- 354. Radiations Ionisingradiations Other Materials and Substances not Elsewhere Classijicd Working Environment Outdoor Weather Traffic and working surfaces Water Fire Others Confined quarters Stairs Other traffic and working surfaces Floor openings and wall openings Environmental factors ( Lighting, ventilation, temperature, noise, etc ) Water Fire Others Other Agencies - Mining and Tunneling Underground Mining and Tunneling Roof Side and face Floor Mine shaft Water Fire Others Opencast Mining ( Including Quarrying) Overhang Side face Ground Water Fire Others Other Agencies, not Elsewhere Classified Animals Live animals Animal products
- 355. Other Agencies NotElsewhere Classified Assessment of Special Cases General - Before inclusion in the record special cases should be assessed. Clauses 5.2.2 to 5.2.15 are intended to assist in such assessment but these provisions/rules should not be used to exclude a genuine work injury from the record. 5.2.2 Inguinal Hernia - An inguinal hernia shall be considered a work injury only if it is precipitated by an impact, hidden effort, or severe strain, and meets, after investigation, all of the following conditions: a> There is clear evidence of an accidental event or an incident, such as a slip, trip or fall, sudden effort or over-exertion; b) There was actual pain in the hernia region at the time of the accident or incident; and c) The immediate pain was so acute that the injured employees was forced to stop work long enough to draw the attention of his foreman or fellow employee, or the attention of a physician was secured within 12 hours. 5.2.3 Back Injury - A back injury or strain shall after investigation, be considered a work injury if: a) There is clear evidence of an accident event or an incident such as a slip, triF or fall, sudden effort or over-exertion, or blow on the back; and b) A medical -practitioner, authorized to treat the case, is satisfied after a complete review of the circumstances of the accident or incident that the injury could have arisen out of the accident or incident. 5.2.4 Aggravation of Pre-existing Condition - If aggravation of pre- existing physical deficiency arises out of or in the course of employment, the resulting disability shall be considered a work injury and shall be classified according to the ultimate extent of the injury except that if the injury is an inguinal hernia or a back injury the requirement of 5.2.2 or 5.2.3 shall apply. 5.2.5 Aggravation of Minor Injury - If a minor injury is aggravated because of diagnosis or treatment, either professional or non-professional, or if infection or other symptoms develop later, either on the job or off-the-job the injury shall be classified according to its ultimate extent. 7 5.2.6 Cardiovascular Diseases - This term is used to cover the following groups: a) Rheumatic heart disease, b) Hypertensive disease, c) Ischemic disease, d) Heart disease secondary to pulmonary disease, e) Cerebrovascular disease, f) Diseases of arteries, arterioles and capillaries, and g) Disease of veins and lymph vessels. 5.2.6.1 Cardiovascular diseases shall not be recorded as work injuries unless:
- 356. a) the symptomswere so severe during working hours that the atten- tion ‘of a supervisor was drawn to them; and b) a medical practitioner, authorized to treat the case, satisfied after a thorough investigation, that the disease or aggravation of the disease was work caused. 5.2.7 Miscellaneous - The category includes the following: a) Purposely inflicted injuries - An injury purposely inflicted by the employee or another person shall be considered a work injury if it arises out of or in the course of employment; b) Skylarking - An injury inflicted by or arising out of skylarking during employment shall be considered a work injury. 5.2.8 Other Disabilities - The following are examples of injuries which shall be considered work injuries if they arise out of or in the course of employment: a) Animal and insect bites; b) Skin irritations and infections; c) Muscular disability; d) Injuries arising from exposure to extreme temperature (hot or cold); and e) Loss of hearing, sight, taste, feel or sense of smell. Methods of Collating and Tabulating Data : For analysing a small number of reports the tabulation by hand sorting and tallying is efficient. Its advantage is that the original records are being used and all the information is available for reference. For analysing and filing a large number of reports, keysort cards may be used. This card contains the information of the original report. The code numbers assigned to the various factors may be punched in the cards so that they can be sorted by a special needle. Sorting is a hand operation. A third method of tabulation uses card tabulating machine. Here the code numbers only are punched into the cards which can be quickly and accurately arranged into various groups. This methods is very useful when the number of reports is very large, when many classification and cross or sub classifications are required or when tabulation of numerical data such as days lost etc. are necessary. Modern method of computer processing can also be utilised for such tabulation. See part 13 of Chapter5 for management information system (MIS). Record Keeping : Record of accidents reported to the plant management and to the Government authorities, facts collected as a result of investigation, analysis of the facts, conclusion about remedial measures necessary and status of implementation of those measures must be kept in a well documented form. Computer is more useful in this regard. In DCS system, printouts of accident situations at the time of accident should be kept out and preserved.
- 357. Safety department shoulddesign formats of safety records applicable to the factory, train personnel to fill such records and maintain them. Records keeping may be ordinary or computerised and in much details. Good record is always useful for 1. Studying past accident causes and remedial measures concluded. 2. Monitoring status of implementation of safety measures. 3. Taking decisions regarding future action in the matters of safety. Period of maintaining record should be decided depending on the utility of the subject matter.
- 358. CHAPTER 4 HAZARDIDENTIFICATION, RISK ASSESSMENT AND CONTROL The identification, analysis and assessment of hazards are different than the identification, analysis and assessment of risks, though both are interrelated. Factors of tune, frequency or ill effects (consequence) are added in 'risk' distinguishing it from 'hazard'. Some definitions relevant to risks are as under : 1. Exposure to Risk : A situation created whenever an act or omission gives rise to possible gain or loss that cannot be predicted. 2. Cost of Risk : The cost imposed upon organisation because of the presence of risk. Its component parts are (1) the cost of losses that do occur and (2) the cost of uncertainty itself. 3. Risk Management : A general management function that seeks to identify, assess, address, control and review the causes and effects of uncertainty and risk on an organisation. It includes assessment, control, financing and administration of risk as defined herein below. 4. Risk Analysis : Technical process of identifying, understanding and evaluating risk (analysing cause and effect wise). 5. Risk Assessment : It is a judgement of significance or activities that enable the risk manager to identify, evaluate and measure risk and uncertainty and their potential impact on the organisation. This judgement can be taken when the measured value of hazard or risk is compared with the value or standard legally or otherwise prescribed. This calls for an expertise of an industrial hygienist. 6. Risk and Uncertainty Assessment : All activities associated with identifying, analysing, measuring, comparing and concluding risk and uncertainty. Fundamentals of Industrial Safety and Health 19 49 Hazards & Risk Identification, Assessment and Control Techniques 7. Risk Control : All activities associated with avoiding, preventing, reducing or otherwise controlling risks and uncertainties. 8. Risk Financing : Activities providing means of reimbursing losses (i.e. finance for the cost of risks and losses) that occur and that fund other programmes to reduce risks and uncertainties. 9. Risk Administration : Activities and strategies associated with the long-term and day-to-day operation of the risk management function.
- 359. 10. Risk Selection: The control technique best described as the conscious acceptance of risk in accordance with an organisation's overall goals, objectives and risk taking philosophy. 11. Risk Avoidance : A risk control technique whereby a risk is proactively avoided or abandoned after rational consideration. 12. Loss Prevention : Those strategies and activities intended to reduce or eliminate the chance of loss. 13. Loss Reduction : Activities minimising the impact of losses that do occur. 14. The Risk Chain : Five elements or links connected with accident i.e. hazard, environment, interaction, outcome and consequence. 15. Subrogation : Risk transfer by legal document as a loss reduction tool. 16. Risk Transfer : If risks cannot be controlled, the last resort is to transfer the risk by contract of job, or property or insurance to pay for losses. 17. Risk Retention : A risk financing method in which the organisation experiencing a loss retains the risk by self financing or borrowed funds, or by a group to which the organisation belongs. Retention may be passive or active, unconscious or conscious, unplanned or planned. 18. Information Management (as a risk reduction tool) : The use of information for the express purpose of reducing uncertainty or for enhancing stakeholder awareness or knowledge of organisational risks. Hazard detection techniques : Unsafe acts and unsafe conditions must be observed to find out hazards. Statutory accidents reports (e.g. Form 21 & 29 GFR) should be seen to detect past accident causes. Unsafe acts due to psychological and physiological personal factors should be detected. Hazards of unsafe conditions are mechanical, electrical, chemical (including radiation) and environmental. Some hazards are visible and some invisible. Visible hazards can be detected by various techniques such as (1) Plant inspection based on statutory requirement, checklist, safety survey, safety audit and safety sampling (2) Detection and monitoring systems (3) Functional test of machinery and equipment (4) Accident investigation
- 360. (5) Repair shop (6)Store consumption and (7) Shop feedback etc. Examples of visible hazards are unguarded machinery, bad housekeeping, wrong practices etc. To discover such hazards careful planning and inspecting system is necessary. Some steps are : (1) Make a list of all statutory applicable provisions of the Factories Act and other Acts, make a survey of the plant to compare the existing provisions and find out the missing provisions (hazards) for implementation (2) Make a list of materials, processes, operations, vessels, equipment, machinery and classify them as hazardous and non-hazardous. Chemicals should be classified according to their hazardous properties. (3) Prepare layout of plant, machinery, equipment, premises and utility services like power, water, air, gas Fundamentals of Industrial Safety and Health 19 50 Hazards & Risk Identification, Assessment and Control Techniques and heating / cooling media. From these prepare a list of possible hazards. (4) By means different techniques mentioned in Part I and 2. Further details of the hazards should be detected and (5) By means of a detailed inspection report preventive measures should be suggested. Invisible hazards like gas leaks, concentration of toxic and hazardous vapour, malfunction or failure of machinery, equipment, pressure plants and miscellaneous environmental factors may cause sudden accident and heavy damage. They must be detected and controlled by built in self corrective systems. The devices used are detectors, recorders, alarms, trips, probes, sensors, limit switches, meters, analysers, electronic or auto controls, scrubbers, incinerators etc. In modern machines various automatic movements take place near and around point of operation. Feeding devices, clamping action and work head movements should be interlocked with each other. Each position of these elements must be sensed and linked with command controls. Any malfunction of moving elements is indicated on audio-visual panel and the machine stops. Repair shop data reveals clues to unsafe conditions like poor design, defective material, poor construction, wear and tear etc. Repetitive repairs indicate major hazards. Similarly store consumption data also indicates some defects.
- 361. There should bea regular feedback of information from repair shop, stores, operators and foremen to monitor hazards and to take corrective actions. Heating equipment should have temperature controllers and additional thermostats for better protection and to give audio-visual signals and to cut off power supply or heat source. In furnaces using flammable fuel in scaled chamber, the components are charged through hydraulically operated carriages and such carriages, fuel flow and flame curtain are sensed by various gadgets like photo-sells, probes, limit switches etc. Failures are sensed and indicated o panel. Suitable corrective actions are automatically taken viz. purging nitrogen etc. Toxic exposures are neutralised by scrubbers. Flammable exposures are controlled by flameproof fittings, flare and vents. Effluents are treated in 'treatment plants to nullify their harmful effects HIRA is a process that consists of a number of sequential steps such as hazard identification, consequence & frequency assessment, risk estimation based on the existing controls and recommendations to reduce those risks which are not under acceptable limits. Objective of HIRA study is to: Carryout a systematic, critical appraisal of all potential hazards involving personnel, plant, services and operation methods Identify the existing safeguards available to control the risks due to the hazards Suggest additional control measures to reduce the risk to acceptable level Prepare a Risk Register that will help in continuously monitoring these risks, detect any changes and ensure the controls are effective. Scope of the Hazard Identification and Risk Assessment Study: The areas of focus would be
- 362. Study ofthe plant operations Identification of the individual tasks involved in carrying out the above operations Identification of potential health and safety hazards in these tasks Determination of the level of risk by combining the likelihood of a hazard occurring with its severity using the Risk matrix Analyzing the existing control measures available to control these risks Provide recommendations for additional risk control measures to bring the risk to acceptable level Compilation of the Risk register 1. Hazard Identification (Identify sources and causes of hazards). 2. Hazard Analysis (Analyse how hazards will occur and affect). 3. Risk Analysis (Estimate risk i.e. hazard occurring per unit time). 4. Risk Assessment (Compare the risk with acceptable criteria - legal, social or political - and decide whether the risk is lesser or higher than that criteria), and 5. Risk Management (Form organisation to carry out above exercises and to monitor, control, review and keep the risks within permissible limits). A stage of 'Hazard 'Assessment' is also possible after hazard analysis. When hazard is compared with its standard prescribed e.g. noise level, light, air flow or chemical exposure (TLV, STEL, LD/LC etc.) is compared with their statutory values or Indian Standards and inference is drawn about their difference (measured value- prescribed value), it is called hazard assessment.
- 363. Hierarchy of Control: hierarchyis just a fancy name for a list. Usually a list of things that have something in common and usually in some sort of order – big to small, good to bad, useful to useless – you get the idea, right? So a hierarchy of controls is just a list of types of controls from really good to less useful. Oh, did I hear you ask what the blazes is a control? Even if I didn’t I’ll explain it anyway. Control: A control is some type of action that reduces the chance that a risk will happen. So, using a seat-belt when you’re driving a car reduces the chance that your head will smack into the windscreen if you’re unfortunate enough to have a ding. So a seatbelt’s a type of control but it’s not as effective as an air bag in protecting your head because you don’t have to do anything for the airbag to do its job but you actually have to remember to put your seat belt on and if you forget then it doesn’t work. So some types of controls are better than others and the hierarchy of controls just lists the better types of risk controls at the top and the not so good ones at the bottom. Types of Controls in the Hierarchy Elimination If you stop and think about it you can probably figure out yourself what the best type of control is – avoiding the risk by eliminating it. If there’s no risk there’s no damage and that’s why it’s at the top of the hierarchy of controls.
- 364. So the bestway of avoiding smacking your head against your windscreen is not to have an accident while driving your car and the best way of avoiding an accident is to not drive the car. Problem solved, right? Wrong. It’s not really practical in our society to not drive a car or at least be a passenger in one. So elimination, while the best type of risk control, is not always the most practical. So what other options are there? Substitution If you can’t stop getting around in a car what other options do you have if you don’t want your head getting up close and personal with your windscreen? You could substitute riding in the front seat to riding in the rear seat but then you couldn’t drive. That’s the balancing act involved when we’re talking about controlling risk … sometimes the alternative, while safer, is not always something we want. The other thing to think about is that substitution doesn’t get rid of the risk; it just reduces it and it sometimes introduces different risks. So rather than smacking against the windscreen you now smack into the back of the front seats. Is that better or worse? Probably a bit better but still not really something you want to go through. Sometimes, though, substitution is a great idea. In the construction industry, for example, they substituted dry cement deliveries to either real small (5 kg) packages or really big ones (250 kg) to reduce manual handling injuries (the small ones are less likely to cause injury while people won’t try to lift the big ones without help). Often really dangerous chemicals can be replaced with safer ones that do the same job just as effectively. So substitution reduces the risk to people without them having to do anything which it’s the second choice in the hierarchy of controls. Isolation OK, back to the car. Elimination isn’t a real option and being a back seat driver doesn’t sound too appealing either. What if we put a barrier between your head and the windscreen? That would be great if you could see through it. But what if the barrier was only there if you were in an accident – I hope this ringing some bells because it sounds a lot like an air bag. If you’re in an accident while driving your car the air bag pops out and cushions your noggin preventing it from smacking into the steering wheel or the windscreen. Sounds great doesn’t it?
- 365. But for everysilver lining there’s gonna be a cloud and in this case it’s the airbag. These things fully inflate in less than 60 milliseconds (there’s a thousand milliseconds in a second) at a speed of about 250 kph so any part of your body that’s in its way is going to get hurt. And the powder, have you ever seen the inside of a car after the airbags have gone off … it’s like a talcum powder factory. So again, isolation isn’t a perfect solution and you have to consider if new and different risks are introduced into the process due to the method of isolation. In the real world of work, such things as guards around rotating shafts, splash screens where liquids are churned up, cages around auto-operating equipment such as robotic assemblers and acoustic enclosures around noisy plant and equipment are examples of isolation. When in place and working properly, isolation works great. But if the machine guard isn’t put on properly, if the door on the acoustic enclosure is closed properly they don’t work as intended. So some human intervention is necessary which is why it comes behind substitution in the hierarchy of controls. Engineering Isolation used to be thought of as a type of engineering control but times change and so do the definitions. If we return to the car, the engineering controls would be things like the airbag not going off unless the impact speed is more than a pre-set limit. The change from windscreen’s being made of safety glass to laminated glass prevents you getting sprayed with high speed glass particles in a collision or when a stone hits your windscreen. The head restraint on the back of the seat reduces the chance of whiplash injury by restricting head’s movement. Crush zones built into the car absorb much of the impact which would otherwise be transferred directly into the bodies of people in the car. Engineering controls are those that you can’t necessarily see but which work to reduce the chance of an injury happening when an unwanted event happens. Limit switches that prevent mechanical plant from moving beyond pre-set limits or key capture systems that switch off power to equipment when a key is removed from a lock are examples of engineering controls that are found in workplaces. Engineering controls are subject to failure if not looked after properly. The limit switch might stick or corrode, the laminated windscreen may prevent bits of glass flying around at high-speed
- 366. but if youhit one with your head you’ll bounce rather than go through it. Don’t know what’s worse really. So these types of controls aren’t as good as those that preceded them in the hierarchy of controls but they’re better than those that follow. Administrative Now we’re getting into the really dodgy options in the hierarchy of controls. These are things like defensive driver training (or any form of training) or telling people to drive more carefully. Those ads you see on the TV telling you not to speed or not to drive when drunk or high on drugs or tired. That annoying beeper that goes off when you go a little too fast or signs on the side of the road telling you how fast you’re supposed to drive or even those cops hiding behind billboards with their speed cameras. These are all attempts to persuade you to behave differently and so avoid an accident and by avoiding an accident you prevent your head coming into contact with the windscreen. But how often do hear or see these things and ignore them? How often do you think, “I’m not that tired” or “I’m not that drunk … I’m OK to drive”? How often do people curse the cops when they’re caught speeding? Exactly! While these things have a benefit, would you rather rely on these to protect your head or on the air bag? Me, I’ll go with the airbag because even if I’m doing everything right there’s no guarantee that some other fool (and there’s always another person to blame and they’re always a fool) is doing the same. If you’ve been at work for any length of time you’ll have seen examples of these types of controls. Warning signs telling you the surface is hot or cold or that the tank has dangerous chemicals. Safety posters on the walls, safety training courses, policies and procedures and so the lists go on. Sure they’re useful but certainly nowhere near as good as the other options from the hierarchy of controls that we’ve talked about. Personal Protective Equipment Now for the last and probably the most unreliable option in the hierarchy of controls – personal protective equipment (PPE ). Continuing with our car, PPE is the seat belt. You have to consciously use it, wrap it around you, click the end into the buckle, make sure it’s located properly and re-tension the belt. Then it’ll work and, if you do have an accident, at least your head and the windscreen aren’t going to get acquainted. But, if you forget or just decide not to use it then it does nothing and you are going to
- 367. get an upclose view of that gunk you’ve been meaning to clean off your windscreen – just before you bounce off it. If you have an airbag – as that’s inflating in one direction you’ll be flying into it from the other at a great rate of knots. Probably not as bad as hitting the windscreen but certainly not something you’d want to repeat too often. At work, you’ve probably got safety glasses, safety helmet, safety boots, gloves, ear muffs or plugs, overalls and so on. All are PPE and all are only effective if used and used properly as well as being maintained properly. Safety glasses pushed to the top of your head or ear muffs strung around your neck aren’t going to do the job they’re supposed to. Hazard analysis or Hazan Hazan is a hazard analysis and is a term used in safety engineering for the logical, systematic examination of an item, process, condition, facility, or system to identify and analyze the source, causes, and consequences of potential or real unexpected events which can occur. A hazard analysis considers system state (e.g. operating environment) as well as failures or malfunctions. Hazan is the identification of undesired events that lead to the materialization of a hazard, the analysis of the mechanisms by which these undesired events could occur, and, usually, the estimation of the consequences. Every hazard analysis consists of the following three steps. Estimating how often the incident will occur. Estimating the consequences for the employees, the process, the plant, the public and the environments. Comparing the results of first two steps with a target or criterion to decide whether or not action to reduce the probability of occurrence or to minimize the consequences is desirable, or whether the hazard can be ignored, at least for the time being. Hazan is therefore the essential prerequisite for the complete risk assessment process which includes (i) analysis of the hazards, (ii) assessment of the risks which the hazards present, and (iii) determination of ameliorating measures, if any, required to be taken.
- 368. Hazan is thefirst step in the process used for the assessment of the risk. The result of a hazard analysis is the identification of different type of hazards. A hazard is a potential condition which either exists or not exists (probability is 1 or 0). It may in single existence or in combination with other hazards (sometimes called events) and conditions become an actual functional failure or accident (mishap). The way this exactly happens in one particular sequence is called a scenario. This scenario has a probability (between 1 and 0) of occurrence. Often a system has many potential failure scenarios. It also is assigned a classification, based on the worst case severity of the end condition. Risk is the combination of probability and severity. Preliminary risk levels can be provided in the hazard analysis. The main goal of hazan is to provide the best selection of means of controlling or eliminating the risk. Tab 1 provides safety related severity definitions generally used in hazards analysis Tab 1 Safety related severity definitions Severity Definition Catastrophic Results in multiple fatalities and/or loss of the system Hazardous Reduces the capability of the system or the operator ability to cope with adverse conditions to the extent that there would be: (i) Large reduction in safety margin or functional capability (ii) Operators physical distress/excessive workload such that operators cannot be
- 369. relied upon toperform required tasks accurately or completely (iii) Serious or fatal injury to the work men (iv) Fatal injury to personnel and/or general public Major Reduces the capability of the system or the operators to cope with adverse operating conditions to the extent that there would be: (i) Significant reduction in safety margin or functional capability (ii) Significant increase in operator workload (iii) Conditions impairing operator efficiency or creating significant discomfort (iv) Physical distress to workmen including injuries (v) Major occupational illness and/or major environmental damage, and/or major property damage Minor Does not significantly reduce system safety. Actions required by operators are well within their capabilities. Include: (i) Slight reduction in safety margin or functional capabilities
- 370. (ii) Slight increasein workload (iii) Some physical discomfort to the operators (iv) Minor occupational illness and/or minor environmental damage, and/or minor property damage No safety effect Has no effect on safety Tab 2 gives typical likelihood of occurrence of an event for the hazard analysis Tab 2 Likelihood of the occurrence of an event Likelihood Definition Probable Qualitative – Anticipated to occur one or more times during the entire system/operational life of an equipment Quantitative – Probability of occurrence per operational hour is greater than 0.00001
- 371. Remote Qualitative – Unlikelyto occur to each item during its total life. May occur several times in the life of an entire system or group of equipment. Quantitative – Probability of occurrence per operational hour is less than 0.00001, but greater than 0.0000001 Extremely Remote Qualitative – Not anticipated to occur to each item during its total life. May occur a few times in the life of an entire system or group of equipment. Quantitative: Probability of occurrence per operational hour is less than 0.0000001, but greater than 0.000000001 Extremely Improbable Qualitative – So unlikely that it is not anticipated to occur during the entire operational life of an entire system or group of equipment Quantitative – Probability of occurrence per operational hour is less than 0.000000001 Some of the terms used in the hazan and their definition are given below. Hazard rate – The rate (occasions/year) at which hazards occur. Protective system – A device installed to prevent the hazard occurring. Test interval – The time interval between the testing of a protective system, and its replacement if necessary. Demand rate – The rate (occasions/year) at which a protective system is called to act. Failure rate – The rate (occasions/year) at which a protective system develops faults (fail- danger/fail-safe).
- 372. Maximum Credible AccidentAssessment (MCAA) : MCA means maximum credible accident i.e. an accident with a maximum reasonable damage distance possibility. MCAA means maximum credible accident analysis or assessment. Here probability of accident occurrence is not calculated but the probability of maximum damaging effect (potential and distance) is calculated to assess injury to people or/and properties in the surrounding area. (1) Type of material stored/processed (toxicity, flammability etc.) (2) Quantity of the material (it affects distance) (3) Process or storage conditions (temperature, pressure, flow etc.) (4) Location of the unit or activity with respect to adjacent population. Based on above factors, units/activities are selected, accident scenarios established and effect (domino or cascade) and damage calculations are carried out. Following steps are employed in MCAA : 1. Chemical Inventory Analysis. 2. Identification of hazardous processes in individual units. 3. Identification of chemical release and accident scenarios. 4. Data acquisition for MCAA. 5. Effect and damage calculations for the primary events' 6. Analysis of past accidents of similar nature. 7. Short listing of maximum credible accident scenarios. These steps are explained below in brief. The chemical inventory is to be identified by MSIHC Rules or Rule 68 J of the Gujarat Factories Rules (see Part 10.8 of Chapter-28), short listed and prioritised on the basis of hazard potential. The chemicals are generally classified as non-boiling and boiling liquids, gases/vapours and solids. Hazardous processes- are also identified by above statutory provisions. Runaway reactions need due consideration during preliminary MCAA. Quantitative Risk Assessment: Here hazard potential is quantified, possible risk is also determined if failure rate data available and then it is compared with the 'permissible standard'. This will indicate whether calculated risk is lower or higher than the permissible limit. Based on this, new control measures or modification in existing control measures can be decided. Values of following "Hazard potentials' can be quantified 1. Properties of the material. 2. Storage parameters. 3. Process parameters. Fundamentals of Industrial Safety and Health 19 53 Hazards & Risk Identification, Assessment and Control Techniques 4. Manual exposures.
- 373. 5. Visible ormeasured hazards. 6. Transportation hazards. 7. Pollution hazards. These values give 'severity' part of the risk. Similarly values of "Control Measures provided" can be quantified depending on the poor controls to the best controls. Proper classification of good, better and best control measures, is necessary. These values give 'probability' part of the risk. Then by using the formula. Risk = Severity x Probability, The existing risk level can be calculated and identified as low, high, higher or highest risk. This method is useful to carry out 'material wise' risk assessment. This method and other methods using ranking matrix are used to carry out 'activity wise' risk assessment also. HAZARD IDENTIFICATION TECHNIQUE: INCIDENT RECALL TECHNIQUE (After the event approach): This method is based on collecting information on hazards, near-misses, unsafe conditions and unsafe actions from working people. It can be used to investigate man-machine relationship and to improve equipment and operations. The technique consists of interviewing personnel regarding involvement in accident or near-misses, errors, mistakes, difficulties and conditions which may cause accident. It accomplishes the same result as an accident investigation. Even isolated incidents reported by the technique can be investigated to determine whether corrective action is necessary or advantageous. Plant people should be given accident case studies for reading and thinking. Then their memory should be recalled to know their understanding and further suggestions if any. CRITICAL INCIDENT REVIEW TECHNIQUE (Before the event approach): The Critical Incident Technique by W.E Tarrants, is a method of identifying or reviewing potential accident causes by collecting information on unsafe conditions and actions, near-misses, hazards etc. from experienced plant personnel. It can be used to study man-machine operation relationship and to use the information to improve equipment, operations and procedures. An experienced reviewer or surveyor first explains to key personnel what he wants to know. Then he asks each worker individually questions on safety matters. Workers involvement in accidents, near misses,
- 374. mistakes, errors, difficultiesin performance and probable causes of accidents are thoroughly discussed. Their comments including preventive measures are also asked. It has been estimated that for every mishap there are at least 400 near-misses. Information on possible accident causes can be obtained from participants of accidents and non-participants but having knowledge. When interviews report similar difficulties hazards or near misses with similar types of operation or equipment’s, it indicates an area to be investigated and results of investigation can suggest the remedial measures necessary. Inductive Approaches and Some Examples In an inductive approach to research, a researcher begins by collecting data that is relevant to his or her topic of interest. Once a substantial amount of data have been collected, the researcher will then take a breather from data collection, stepping back to get a bird’s eye view of her data. At this stage, the researcher looks for patterns in the data, working to develop a theory that could explain those patterns. Thus when researchers take an inductive approach, they start with a set of observations and then they move from those particular experiences to a more general set of propositions about those experiences. In other words, they move from data to theory, or from the specific to the general. Figure 2.5 "Inductive Research" outlines the steps involved with an inductive approach to research. Deductive Approaches and Some Examples Researchers taking a deductive approach take the steps described earlier for inductive research and reverse their order. They start with a social theory that they find compelling and then test its implications with data. That is, they move from a more general level to a more specific one. A
- 375. deductive approach toresearch is the one that people typically associate with scientific investigation. The researcher studies what others have done, reads existing theories of whatever phenomenon he or she is studying, and then tests hypotheses that emerge from those theories. Figure 2.6 "Deductive What IF: What will happen if toxic gases leak into a liquid pipeline? What if tank feed is increased or decreased? What if an earthquake occurs? Such questions can be critical in reducing or eliminating risks to people working in a laboratory environment. A What-if Analysis consists of structured brainstorming to determine what can go wrong in a given scenario; then judge the likelihood and consequences that things will go wrong. What-if Analysis can be applied at virtually any point in the laboratory evaluation process. Based on the answers to what-if questions, informed judgments can be made concerning the acceptability of those risks. A course of action can be outlined for risks deemed unacceptable. How to Conduct a What-if Analysis 1. Team Kickoff The team leader walks the team through each step of the What-if Analysis. The leader may use a detailed equipment diagram along with any prepared operating guidelines. (Include guidelines for determining acceptable level of safety.) 2. Generate What-if Questions
- 376. The team generatesWhat-if questions relating to each step of the experimental procedure and each component to determine likely sources of errors and failures. Things to consider when developing questions: Potential human error Equipment component failures Deviations from the planned/expected critical parameters (e.g., temperature, pressure, time, flow rate) 3. Evaluate and Assess Risk The team considers the list of What-if questions, one-by-one, to determine likely sources of errors. They then decide the probability of each error occurring and assess the consequences. 4. Develop Recommendations Risk deemed unacceptable: If the team concludes there’s a need for corrective action, a recommendation is recorded. Risk deemed acceptable: When probability is very low, consequences are not severe, and the action to correct the condition would involve significant cost and time, the team may note a “no recommendation” response. 5. Prioritize and Summarize Analysis The team’s analysis is summarized and prioritized. 6. Assign Follow-up Action Responsibilities are assigned for follow-up action(s). Consider adding a column to your What-if Analysis form to indicate the person or group responsible for each corrective action. Benefits Easy to use No specialized tools needed
- 377. People withlittle hazard analysis experience can participate meaningfully Leads to deeper insight, especially for person/people conducting the analysis Limitations Only useful if you ask the right questions Relies on intuition of team members More subjective than other methods Greater potential for reviewer bias More difficult to translate results into convincing arguments for change What-if Questions Following is a list of sample What-if questions to get your group thinking in the right directions. These questions can be modified according to experiment or process. Human Factor Human errors occur regardless of training and experience. Human error factors may drive consideration of written SOPs, a decision for engineering controls, etc. What if material used is too concentrated (or diluted)? What if the valve/stopcock does not open (or close)? What if the valve(s) are opened (or closed) in the wrong sequence? What if inert gas is omitted? What if unintended materials are mixed together? What if readings are missed or ignored? What if warnings are missed or ignored? What if there are errors in diagnosis? Utility The following questions concern utilities, which are key to the support of any experiment or process: What if power is lost? Consider: Automatic shutoffs and emergency power
- 378. What ifpower is restored automatically after loss? Consider: Manual restarts What if laboratory ventilation is lost? Consider: Automatic shutoffs, emergency power, and redundant mechanical exhaust fans Experimental or Ancillary Equipment Consideration of failure of materials or components may result in decisions for additional controls or changes to higher rated or alternative types of materials and components. What if there’s unexpected over-pressurization? Consider: Pressure relief devices and barriers; personal protective equipment (PPE) What if glassware breaks during reaction? Consider: Spill control; PPE What if there’s a failure of equipment cooling? Consider: Alarms, automatic shutoffs, and emergency shut-off procedures Personal Protection This should be included since, despite best efforts with hazard reviews and training, incidents will occur. What if a body is impacted by liquids or solids? Consider: Physical barriers What if someone is exposed to vapors or gases? Consider: PPE; ventilation What if someone is exposed to respirable particles? Consider: Use of wet contamination control methods, ventilation controls, and respiratory protection
- 379. FISHBONE ANALYSIS: • Alsoknown as Cause and Effect Diagram or Ishikawa Diagram • Visually displays multiple causes for a problem • Helps identify stakeholder ideas about the causes of problems • Allows the user to immediately categorize ideas into themes for analysis or further data gathering • Uses the “five-whys” technique in conjunction with the fishbone diagram The Fishbone Diagram, formally named the Ishikawa diagram, is a tool for managers to get to the root cause of an issue in production. This diagram is used in Root Cause Analysis and is a visual representation of the 5 Why’s strategy. Starting at the top of the diagram pictured on the left, the tail of the fish represents the main problem or issue that is trying to be solved. Each bone of the fish going down represents a “Why” in the analysis method, ending up at the head of the fish, symbolizing the true root of the problem. The Five Whys method is used to truly get to the bottom of an issue by using a process where, like the name implies, you ask why five times in order to get to the root cause of a problem. Here is an example of Five Whys being used in the real world:
- 380. 1. Why won’tthe car start? The battery is dead. 2. Why is the battery dead? Because the alternator is not working properly. 3. Why isn’t the alternator working? Because the serpentine belt has broken. 4. Why is the serpentine belt broken? Because the belt was not replaced when worn. 5. Why wasn’t it replaced? Because the owner did not follow the recommended service schedule As shown from the example, the true root of the problem is identified after the question why is asked five times. The car didn’t start just because the battery is dead, but the car wouldn’t start because maintenance was not kept up by the owner. By fixing that problem and not just charging the battery, the owner of the car can avoid this problem, and many others, in the future. Important note: Ask “Why” until the root cause is discovered, even if it is more than five times!
- 381. Root Cause Analysis: Asuccessful root cause analysis identifies all root causes —there are often more than one. Consider the following example: 1. A worker slips on a puddle of oil on the plant floor and falls. 2. A traditional investigation may find the cause to be “oil spilled on the floor” with the remedy limited to cleaning up the spill and instructing the worker to be more careful.5 3. A root cause analysis would reveal that the oil on the floor was merely a symptom of a more basic, or fundamental problem in the workplace. 4. An employer conducting a root cause analysis to determine whether there are systemic reasons for an incident should ask: – Why was the oil on the floor in the first place? – Were there changes in conditions, processes, or the environment? – What is the source of the oil? – What tasks were underway when the oil was spilled? – Why did the oil remain on the floor? – Why was it not cleaned up? – How long had it been there? – Was the spill reported? It is important to consider all possible “what,” “why,” and “how” questions to discover the root cause(s) of an incident. In this case, a root cause analysis may have revealed that the root cause of the spill was a failure to have an effective mechanical integrity program —that includes inspection and repair — that would prevent or detect oil leaks. In contrast, an analysis that focused only on the immediate cause (failure to clean up the spill) would not have prevented future incidents because there was no system to prevent, identify, and correct leaks.
- 382. Root Cause AnalysisTools Below is a list of tools that may be used by employers to conduct a root cause analysis. The tools are not meant to be used exclusively. Ideally, a combination of tools will be used. • Brainstorming • Checklists • Logic/Event Trees • Timelines • Sequence Diagrams • Causal Factor Determination For simpler incidents, brainstorming and checklists may be sufficient to identify root causes. For more complicated incidents, logic/event trees should also be considered. Timelines, sequence diagrams, and causal factor identification are often used to support the logic/event tree tool. Regardless of the combination of tools chosen, employers should use these tools to answer four important questions: • What happened; • How did it happen; • Why it happened; and • What needs to be corrected. Interviews and review of documents, such as maintenance logs, can be used to help answer these questions. Involving employees in the root cause investigative process, and sharing the results of those investigations, will also go a long way toward preventing future similar incidents. Benefits of Root Cause Analysis for Employers Conducting a thorough investigation that identifies root causes will help to prevent similar events from happening again. In this way, employers will reduce the risk of death and/or injury to workers or
- 383. the community orenvironmental damage. By using root cause analysis to prevent similar events, employers can avoid unnecessary costs resulting from business interruption, emergency response and clean-up, increased regulation, audits, inspections, and OSHA or EPA fines. Regulatory fines can become costly, but litigation costs can often substantially exceed OSHA and EPA fines. Employers may find that they are spending money to correct immediate causes of incidents that could have been prevented, or reduced in severity or frequency, by identifying and correcting the underlying system management failure. Finally, when an employer focuses on prevention by using root cause analysis, public trust can be earned. Employers with an incident free record may be more likely to attract and retain high performing staff. A robust process safety program, which includes root cause analysis, can also result in more effective control of hazards, improved process reliability, increased revenues, decreased production costs, lower maintenance costs, and lower insurance premiums. FAULT TREE ANALYSIS It is a deductive technique that focuses on one particular accident event and provides a method for determining basic causes of that event. This method is used to identify combinations of failures and human errors that can result in accident or an initiating event. FTA allows the safety analyst to focus on preventive measures on these basic causes to reduce the probability of an accident. SYMBOLS USED IN FAULT TREE CONSTRUCTION Top Event (Accident/Incident) Sub-Event (a fault) caused by a combination of contributing events ‘AND’ gate – the output exist only if all the inputs are present simultaneously. ‘OR’ gate – the output exist if any (or any combination) of the inputs are present. Basic cause (root cause) by a component failure or human error for which a probability can be assigned. A fault that is not developed further due to lack of information or due to less importance. Transfer Events – These symbols are used to transfer an entire part of the tree to other locations on the tree. House Event – This symbol represents a normal event (not a fault condition) There are four steps in performing the fault tree analysis: Problem definitions Fault tree construction Fault tree solution (determining minimal cut sets) Minimal cut set ranking
- 384. PROBLEM DEFINITION :-This consists of a) Defining accident event-top event of the fault tree analysis b) Defining analysis boundary including an allowed event, system physical boundry, level of resolution, other assumptions. c) Fault tree construction – It begins with top event and proceed level by level using symbols viz. “Or” “And” etc. until all the fault events have been developed to their basic contribution cause. FAULT TREE SOLUTION :- The completed fault tree provides us information by displaying the interaction of the equipment failures that could result in an accident. The matrix system of analysis gives the minimal cut sets, which are useful for ranking the ways in which accident may occur, and they allow quantification of the fault tree if appropriate failure data are available. To evaluate adequacy of hazard control To aim to design a foolproof system Types – System, sub-system, components EVENT TREE ANALYSIS (ETA) Event Tree Analysis is a forward thinking process beings with an initiating event develops the following sequences of events that potential accidents accounting for : 1. Successes and 2. Failure of the available safety function as the accident progresses. The safety function includes operator response or system response to the initiating event. The general procedure for the event tree analysis has four major steps: IDENTIFYING AN INITIATING EVENT This depends on the process involved and describes the system equipment failure, human error, or any other process upset that can result in other events. IDENTIFYING SAFETY FUNCTIONS Safety functions include automatic shutdown system, alarm system, operator’s action, containment method etc. The success and failure of the safety functions are accounted in the event tree. CONSTRUCTION OF EVENT TREE The event tree describes the chronological development of the accidents beginning with the ‘initiating event’. Considering each safety functions one nodal point is generated with the two alternatives (A1 & A2) that is success and failure of the safety system. At every safety system two alternatives that is success and failure is to be considered.
- 385. RESULTS OF ACCIDENTEVENT SEQUENCE The sequence of constructed event tree represents a variety of outcomes that can follow the initiating event. One or more of the sequences may represent the safe recovery and return to normal operation while the others may lead to shutdown of the plant or an accident. CCA (Cause-Consequence Analysis) Cause-Consequence Analysis identifies potential accident consequences and the basic causes of these accidents. Any hazard or risk assessment is incomplete if the consequences of a possible accident are not known. Therefore the last step in hazard assessment is to analyse the consequences that a potential major (credible) accident may-cause on the plant itself, on die workers, on the surrounding and on the environment. Therefore an accident consequence analysis should contain 1. Cause of the accident (fire, explosion, rupture of a vessel, pipe, valve etc.). 2. Estimate of the mass released (flammable, explosive, toxic quantity). 3. Calculation of the dispersion of the material released and the damage distance, (liquid, vapour or gas). 4. Estimate of the effects (heat radiation, blast wave, toxic, degree of burn, severity etc.). Management Oversight Review Technique: MORT Technique is developed by Bill Johnson in 1970’s in US Department of Energy (at the time of Atomic Energy Commission) for logical Analysis of Accident with the involvement of Management. MORT is Tree-based Methodology. MORT Analysi s includes Data collection based on Checklist & their associated Questions, in addition to evaluation Results. The information can be collected from Interviews, Studies of Documents & Investigations. MORT chart contains approximately 1500 items arranged into a large/complex fault tree Primarily used for accident investigation Purpose of MORT To provide a systematic tool to aid in planning, organizing, and conducting detailed accident investigation & Near misses to identify those specific that are LTA and need to be corrected to prevention the accident from recurring. Can also be used for inspection, audit & Planning of Safety Measures. Abbreviations used LTA - “less than adequate” DN - “did not” FT - “failed to”
- 386. HAP - “hazardanalysis process” JSA - “job safety analysis” CS&R - “codes standards and regulations” Symbols used in MORT are similar to that of Fault Tree Analysis Symbols Event s Symbols Event Symbols Logic Gates Transfers Definition Accepted or Assumed Risk - Very specific risk that has been identified, analyzed, quantified to the maximum practical degree, and accepted by the appropriate level of management after proper thought and evaluation. Losses from Assumed Risks are normally those associated with earthquakes, tornados, hurricanes, and other acts of nature. Amelioration - Post-accident actions such as medical services, fire fighting, rescue efforts, and public relations. Advantage It aids the accident investigator by identifying root causes of the accident. Provides a systematic method of evaluating the specific control and management factors that caused or contributed to the accident. Serve as planning and organizational tool for the collection of evidence and other relevant information. Disadvantage Extremely time consuming and tedious when learning about and first using the MORT chart. This approach would be classified as overkill for most accidents. Input Requirements : required regarding Hardware Facilities Environment Policies & Procedures Personnel Implementation plans Risk assessment programs Project documents, etc... General Approach MORT analysis effort begins immediately after the accident occurs. Performed by a trained investigator. MORT chart is used as a working tool to aid in the gathering and storage of information. General method for working through the chart is from known to unknown. The top of the chart is typically addressed very early in the investigation.
- 387. FAILURE MODE EFFECTANALYSIS (FMEA) The method is a tabulation of system/ plant equipment, their failure modes and each failure mode’s effect on system/plant. It is a description of how equipment fails (open, closed, on, off, leaks etc.) and the potential effects of each failure mode (fails to open or fails to close when required, transfers to a closed position, valve body rupture, leak of seal, leak of casing). The technique is oriented towards equipment rather than process parameters. FMEA identifies single failure modes that either directly result in or contributes significantly to an important accident. FMEA Example :- Pressure switch & Pressure transmitter are installed on storage tank. In case if pressure of storage tank increases, then pressure switch & pressure transmitter get activated and closes the pump to stop feed to storage tank. Failure Mode Effect Analysis of “Pressure Switch” is done to understand the method. The failure modes those considered are : Bellow cracking Below rupture Switch fails open Switch fails closed Spring breaks Pivot loose And with their failure effects “Risk Assessment” is with the help of given chart/map. SEVERITY CATEGORIES CATEGORY DEGREE DESCRIPTION I MINOR Functional failure No potential for injury II CRITICAL Failure without major damage No serious injury III MAJOR Major damage Serious injury IV CATASTROPHIC Complete system loss Potential for Fatal injury PROBABILITY LEVELS
- 388. LEVEL PROB. VALUEDESCRIPTION INDIVIDUAL FAILURE MODE A 10-1 Frequent Once in 10 Likely to occur frequently B 10-2 Probable Once in 100 Will occur several times in life of an item C 10-3 Occasional Once in 1000 Likely to occur sometime in life of an item D 10-4 Remote Once in 10,000 Unlikely but possible to occur in life E 10-5 Improbable Once in 1,00000 So unlikely that occurrence may not be experienced. FAILURE MODE AND EFFECT ANALYSIS WORSHEET COMPONENT FAILURE MODE FAILURE EFFECTS RISK ASSESSMENT (FROM CHART/MAP) SEV PROB RPC 1 Pressure switch Bellow cracking Small release II C 2 Bellow Rupture Large release IV D 1 Switch Fails open No pump trip IV C 1 Switch fails closed Pump stops I C 3 Spring breaks Pump stops I D 3 Pivot loose Pump stops at higher pressure II C 2 RPC-1 HIGH RISK RPC-2 MEDIUM RISK RPC-3 LOW RISK
- 389. JOB SAFETY ANALYSISWORK SHEET CONSTRUCTION ACTIVITIES In construction sites, numerous activities would be undertaken in various stages of construction. In this analysis, a few typical construction activities are analysed for indentifying the hazards, the consequences and the possible control measures. Activity Associated Hazard Effect of Hazard Preventive Measures/Recommendations 1 Working at heights Person can fall down May sustain severe injuries or prove fatal Provide guard rails/barricades at the work place. Use PPE like safety belt, full body harness with two life lines, helmets, safety shoes etc. Obtain work permit before starting the work at height above 2 meters. Fall arrest systems like safety nets, must be installed. Provide proper working space (min. 0.6m X 0.6m). Tie/weld working platform with fixed support. Avoid movement on beams Remove the scrap if stacked at the ground or in between. Material can fall down May hit the workers working at lower levels and provide fatal. Same as above plus Barricade the area at ground level Do not through or drop material or equipment from height All tools to be carried in a tool-kit bag. Ensure wearing of helmet by the workers at low level.
- 390. 2 Working in confined spaces suffocationUnconsciousness/death Use respiratory devices Avoid overcrowding inside a confined space Provide ventilation Do not use loose clothes. Keep the stand-by person out side the confined space (lank/vessel) with life lines. Check for presence of hydrocarbons, toxic gases, oxygen level. Obtain work permit before entering a confines space. All incoming lines to space blanked or isolated. Presence of foul smell and toxic substances Installation can pose threat to life Same as above Check for presence of toxic gases Depute one person outside the confined space for continuous monitoring. Ignition/flame can cause fire Person may sustain burn injuries or explosion may occur Keep fire extinguisher handy Remove surplus material Do not allow gas cylinders inside Use low voltage (24V) explosion proof lamps Use pneumatic tools or electric tools with max voltage of 24V (explosion proof) Remove all equipment at the end of the day. 3 Electrical installations & usage Short circuiting Electron or fire Use hand gloves & other PPE. Don’t lay wires under carpels, mats or door ways.
- 391. Employee licensed electriciansto carry out electrical installation Use one socket for one appliances Ensure usage of only fully insulated undamaged wires or cables. Don’t place bare wire ends in a socket Ensure earthing of equipment Avoid temporary connections Protect electrical cables/equipment from water and naked flame Check all connections before energizing 4 Hand/ Power tools Unguarded moving part like grinding wheel, drill bit It may injure the operator. Wheel may get detached & hit passer-by as flying missile causing serious injury Use proper guard Ensure tightening mechanism of the tool 5 Handling & lifting equipment Failure of load lifting and moving equipment Can cause accident and prove fatal Check periodically oil, brakes, gears, and pressure of all moving machinery Check quantity, size and condition of all chain pulley blocks, slings, U-clamps, D- shackles, wire ropes etc. Allow lifting slings as short as possible. Overloading of lifting equipment Can cause accident and prove fatal Safe lifting capacity of derricks & winches should be ascertained. The maximum safe working load shall be marked on all lifting equipment. Allow only trained operators
- 392. and riggers duringcrane operation. Product safety aims at ensuring safety in consumer product which may otherwise cause a substantial risk of injury or death to the consumer due to its hazardous charateristics or other defects in the product which by reason of its consumption, handling or use may load to ant physical harm or property damage should be adequately controlled or prevented. The user or consumer should be protected against impure, unsafe or unhygienic foods, drinks, drugs, cosmetics, toys, equipment and other products. To make product safe, consumer product act provides guidelines to the manufacturers. To develop safety standards and promote for research study To evaluate consumer product safety To recall, replace, repair, a hazardous product Standard for products varying according to the nature of but in general, should ensure the following basic requirements: Sharp comers, rough surface should be eliminated Product should not liberate toxic, flammable mixtures with air or poisonous gas Moving &dangerous parts of machinery ( fans, belts, couplings, gears etc ) should be guarded Equipment which get damage due to rough handling, should be marked with “ Handle with Care” Considering the safely requirements of the products and the possibility of risk of injury with the hazardous products, The manufacturer should adopt the following technique to ensure that their products are reasonably safe and chance of getting defective products is minimized. Use safety design criteria for a product to guard against all possible danger in the use, operation, transport &consumption Build safety into product during manufacturing stage Inspect the finished products to ensure for its all safety measures Instruct users for safe use of products Issue/ write adequate warning against possible danger in using product It is a legal responsibility of every manufacturer, seller, agent or supplier of supplier of each product to make it safe to use, otherwise if any harm is caused to consumer by the product, Their legal damages are payable to consumer as per statutory requirement.
- 393. MAJOR ACCIDENT HAZARDS(MAH) FACTORY MAJOR ACCIDENT As per “THE MAHARASHTRA FACTORIES (CONTROL OF INDUSTRIAL MAJOR ACCIDENT HAZARDS) RULES. 2003”, major accident means, an incident involving loss of life inside or outside the factory, ten or more injuries inside and/or one or more injuries outside or release of toxic chemicals or explosion or fire or spillage of hazardous chemicals resulting in on-site or off-site emergencies or damage to equipment leading to stoppage of process or adverse effects to the environment. MAJOR ACCIDENT HAZARDS (MAH) FACTORY MAH factory means an industrial activity ordinary handling hazardous chemical equal to or in excess of the threshold quantities specified in Column 3 of the Schedule 2 of “The Maharashtra Factories (Control of Industrial Major Accident Hazards) Rules, 2003. FOR EXAMPLE – If factory storing 50 ton of toxic chemical such as Ammonia then the factory comes under MAH unit. STATUTORY PROVISIONS When a factory declared as MAH unit then following provisions give in “The Maharashtra Factories (Control of Industrial Major Accident Hazards) Rules, 2003” are to be complied with: Notification of major Accidents – Occupier shall notify major accident to statutory authority within 4hrs in form (Sc3) Notification of Site – Occupier has o submit a written report to statutory authority as per the content given in Sc 4. Occupier shall prepare an “On-site Emergency Preparedness Plan” as per details given in Sc 6. Mock-drills are to be conducted every six month and record is to be maintained. Safety Report is to be submitted and also once in two-year safety is to be carried out. CONTROL MEASURES I. TOXIC CHEMICALS 1. Tanks are to be provided with dyke wall having proper slope and drain valve connected and drain valve connected to a pit (out side the dyke wall). 2. Anticorrosive paints to pipelines & tanks 3. Proper support to pipelines 4. Earthing to tanks 5. Level, pressure, temperature indication/alarm 6. Fire protection system (water hydrant & extinguisher) 7. Suitable personal protective equipments (respiratory & non-respiratory) 8. Vents are to be connected to scrubber system 9. Spill control procedure 10. Display of Doe’s & Dint’s 11. Suitable container to collect material if leaks. 12. Statutory inspection & testing of pipelines & tanks 13. Proper ventilation, illumination 14. Proper approach/access 15. Work place monitoring 16. Emergency action plan
- 394. 17. Training/education II. FLAMMABLECHEMICALS 1. Flameproof electrical fitting as per area classification 2. Level, pressure, temperature indication/alarm 3. Proper earthing to tanks 4. Bond wires (Al or Copper) to the flanges of pipelines 5. Proper support to pipelines 6. Proper fencing and tanks are to be provided with dyke wall having proper slope and drain valve connected to a pit (outside the dyke wall). 7. Anticorrosive paints to pipelines & tanks. 8. Fire protection system (water hydrant, sprinklers to tanks & extinguishers) 9. Suitable personal protective equipments (respiratory & non-respiratory) 10. PV valves 11. Vents are to be provided with flame arrestor 12. Spill control procedure 13. Display of Doe’s & Dint’s 14. Suitable container to collect material if leaks. 15. Statutory inspection & testing of pipelines & tanks. 16. Proper ventilation, illumination 17. Proper approach/access 18. Work place monitoring 19. Detectors 20. Emergency action plan. 21. Training/education. III. PRESSURE VESSELS 1. Safety valve, stop valve, excess flow valve, remotely operated isolation valve (as per SMPV rules) to vessel. 2. Detectors 3. Flameproof electrical fittings as per area classification 4. Level, pressure, temperature indication/alarm 5. Proper earthing to tanks 6. Bond wires (Al or Copper) to the flanges of pipelines 7. Proper support to pipelines 8. Proper fencing and tanks are to be provided with dyke wall having proper slope and drain valve connected to a pit (outside the dyke wall). 9. Anticorrosive paints to pipelines & tanks. 10. Fire protection system (water hydrant, sprinklers to tanks & extinguishers) 11. Suitable personal protective equipments (respiratory & non-respiratory) 12. Spill control procedure 13. Display of Doe’s & Dint’s 14. Suitable container to collect material if leaks. 15. Statutory inspection & testing of pipelines & tanks. 16. Proper ventilation, illumination
- 395. 17. Proper approach/access 18.Work place monitoring 19. Detectors 20. Emergency action plan. 21. Training/education. DAMAGE DUE TO SHOCK-WAYS (EXPLOSION) PRESSURE IN BAR DAMAGE TYPE 0.3 Heavy 0.1 Repairable 0.03 Damage of Glass 0.01 Crack of Windows TOXIC EFFECT EXPLOSURE TOXIC EFFECT IN AFFECTED ZONE IDLH ACUTE EFFECT – FATAL STEL CAN REMAIN IN AFFECTED ZONE FOR 15 MINUTES TLV CAN REMAIN IN AFFECTED ZONE FOR 8 HOURS THE CONCENTRATIONS CONSIDERED FOR CHLORINE GAS DIPURTION ARE : IDLH 25ppm STEL 3ppm LC50(rat) 293 THE CONCENTRATIONS CONSIDERED FOR AMMONIA GAS DISPURTION ARE : TLV 27mg/m3 LOC 54mg/m3 IDLH 360mg/m3
- 396. ILO code ofpractice for major accident control: The practical recommendations of this code of practice are intended for the use of all those who have responsibility for the prevention of major industrial accidents. The code is not intended to replace national laws, regulations or accepted standards. It has been drawn up with the object of providing guidance to those who may be engaged in the framing of provisions relating to the control of major hazards in industry: competent authorities; works managements; emergency services; and government inspectors. The code should also offer guidelines to employers' and workers' organisations. International Labour Organization (ILO): Establishment of a Major Accident Role of DGFASLI & DISH through ILO: (DGFASLI). Important achievements of the project are – Setting up a three-tier Major Accident Hazards Control Advisory Division in Central Labour Institute (CLI), Mumbai and its cells in Calcutta, Chennai and Kanpur. Identification of (MAH) Installations in different States and Union Territories & bringing them under a programme of intensive inspection. Establishing Computerized Data Bank at CLI for storage, retrieval and dissemination of information on hazardous chemicals, MAH installations, specialists on MAH Database on OSH etc. The Data Bank has two software’s WHAZAN and TNO for calculation of physical effects and con sequence of release of toxic and flammable chemicals. Expansion of the Factory Inspection Services and enhancing their capabilities through set ting up of laboratories and training of inspectors. Training of the inspection and advisory staff and key personnel from industry to develop their competence on HAZOP study, Risk Assessment, Safety Audit, etc. Extended the system of MAHC to the port sector. The project had succeeded in enhancing. ON-SITE EMERGENCY PLAN INTRODUCTION: Modern industry, characterized by complex process and technology is open to an ever increasing danger form disasters, which can seriously affect the safety, security and stability of the organisation. Some of these disasters are natural such as earthquakes, floods, tsunamis, cyclones, lightening, while others are man-made. The man-made disasters included dangerous spills & leak of chemicals, fires & explosions, hit by external objects, contamination & poisoning of food, terrorist attacks, etc. All of these have occurred several times in industries, when unprepared for such disasters creating panic, disorder and confusion. The result has been extensive damage to men and material. Major
- 397. accidents/disasters in afactory is one which has the potential to cause serious injury or loss of life. It may cause extensive damage to property, loss of life and serious disruption both within and outside the works. A number of chemicals produced and used in the chemical industry are one of hazardous nature. This hazard arises as a result of three properties, viz.: toxicity, flammability and corrosivity. Sudden and uncontrolled leak of contaminant will give rise to a disastrous condition, magnitude of which will depend on the type of chemicals as well as its inventory. An emergency plan is an informative document, which acquaints the occupants of a factory or an occupancy with procedures to be implemented, during an emergency. It details standard operational guidelines to emergency controllers and their personnel, who may be required to fulfil a key functional role, during the various stages of an emergency. In other words, it contains critical information, which can assist emergency services personnel to formulate appropriate incident management strategies and tactics, when attending on an emergency at a plant. Since it is a critical document in implementing appropriate management strategies, it is important that the plan is comprehensive and easy to read and use. Each works shall formulate an emergency/disaster management plan, detailing explicitly what action will be taken in the event of a major accident occurring on site, to prevent further escalation and to ensure rapid control. The emergency planning within the factory premises is known as On-Site Emergency Plan. This is to be dovetailed with Off-Site Emergency Plan. This article will deal with the details of On-Site Emergency Plan. LEGAL PROVISIONS: The On-Site Emergency Plan is a mandatory document under various statutes of India. By virtue of the provision under Section 41-B (4) of the Factories Act, 1948 and its amendments of 1987, the occupier is expected to draw up the On-Site Emergency Plan along with detailed control measures for his factory. The occupier should also make the plan known to the workers and general public in the vicinity of the factory, with safety measures required to be taken by them in case of an emergency. The various state Factories Rules made under the Factories Act, 1948, also prescribe the procedures to be followed in emergency planning, for example, Rule 73 (M), (N), (O), (P), (Q) and (R) of the Maharashtra Factories Rules, 1963, prescribe in details regarding the procedures to be followed in emergency planning, informing workers and the people in the neighborhood, district administration and Chief Inspector of Factories. Incidentally, under Rule 13 and 14 of the Manufacture, Storage and Import of Hazardous Chemicals (MSIHC) Rules, 1989, framed under the Environment (Protection) Act, 1986, it is the responsibility of District Collector or District Emergency Authority to prepare an Off-Site Emergency Plan. MANAGEMENT STRATEGIES: An On-Site Emergency Plan must be related to final assessment of the size and nature of events foreseen. It means that it should be specific. The effectiveness of response during emergencies depends on the
- 398. amount of planningand training. If management is not interested in employee protection and minimizing property loss, very little can be done to promote a safe workplace. It is therefore, management’s responsibility to see that a programme is instituted and that it is frequently reviewed and updated. The input and support of all employees must be obtained to ensure an effective on-site emergency programme. The emergency response plan should be developed locally and should be comprehensive enough to deal with all type of emergencies. SALIENT FEATURES OF EMERGENCY PLAN: An On-Site Emergency Plan must include the following features: Emergency escape procedures and emergency escape route assignments. Procedures to be followed by employees, who remain to perform critical plant operations before they evacuate. Procedures to account for all employees after emergency evacuations has been completed. Assigning Rescue and Medical duties for these employees who have to perform them. The procedures for reporting fire and other emergencies. Name and regular job titles of persons or departments to be contacted for further information or explanation of duties under the plan. The emergency action plan should address all potential emergencies, which can be expected in the workplace. It must list in detail the procedures to be taken by those employees who must remain behind to care for essential plant operations until their evacuation becomes absolutely necessary. This may include monitoring plant power supplies, water supplies and other essential services that cannot be shut down for every emergency alarm. For emergency evacuation, the use of floor plans or workplace maps, which clearly show the emergency escape routes and safe areas, should be included in the plan. All employees must be told, what actions they are to take in the emergency situation that may occur in the workplace. Above all, this plan should be reviewed with employees initially when the plan is developed, whenever the employees responsibilities under the plan change and whenever the plan is changed. COMPONENTS OF ON-SITE EMERGENCY PLAN: While preparing an On-Site Emergency Plan, the following components should be considered: Chain of Command Communications
- 399. Counting ofPersonnel Emergency Control Centre Training Personnel Protection Medical Assistance Security Mutual Aid Chain of Command: A chain of command should be established to minimize confusion, so that employees at the workplace will have no doubt, who has the authority for making decisions. Responsible employees should be selected to co-ordinate the work of emergency response teams. Emergency Response Coordinator is also known as Site Controller or Works Main Controller. The duties and functions of the team leaders can be written and included in the emergency plan document. The size of the team will vary from organisation to organisation. Some of the duties and functions of the Emergency Response Coordinator are given below: To assess the situation and determining whether an emergency exists which requires activating the emergency procedures. To direct all action in the areas including evacuation personnel and minimizing property loss. To ensure that outside emergency services such as police, medical aid and local fire brigade are called in when necessary. To direct the safe shutdowns of plant operations when necessary. To declare the withdrawal of emergency at the site. To look after the rehabilitation of affected persons after withdrawal of emergency at the site. To issue authorised statements to news media and ensure that evidence is preserved for enquires to be conducted by the statutory authorities. Communications: During an emergency involving a major fire or explosion, it may be necessary to evacuate offices in addition to manufacturing areas. During such emergencies, normal services such as electricity, water and telephones may not exist. Under these circumstances, an alternate area may be necessary, where employees can report or which can act as a focal point for incoming and outgoing calls. Since time is an essential element for adequate response, the person designated as being in charge should make this area, as the alternate headquarters, so that he can be easily reached. A method of communication also is needed to alert employees for evacuation or to take other actions as required in the emergency plan. An Alarm should be provided, which should be audible or seen by all people in the plant and should have an
- 400. auxiliary power supplyin the event of electricity failure. The alarm should be distinctive and recognizable by all employees. The employer should explain to each employee the means of reporting emergencies. Emergency phone numbers of Key Persons and Organisations should be posted on or near telephones and other conspicuous locations. It may be necessary to notify other key personnel such as Plant Managers, Shift In-Charges, or Physicians during off duty hours. An updated written list should be kept of Key Personnel listed in order of priority. Counting of Personnel: A responsible person in the Control Centre should be appointed to account for personnel and to inform police or emergency response team member of those persons believed missing. The person appointed should make a team and team members are physically capable of performing the duties assigned to them. The team members should be trained in the following areas: Use of various types of fire extinguishers. Use of Self Contained Breathing Apparatus (SCBA) First Aid, including cardiopulmonary resuscitation (CPS) kits Evacuation procedures Chemical spill control procedures Search and Emergency Rescue procedures Emergency response teams should be trained, in the types of possible emergencies and the emergency actions to be performed. They should be informed about special hazards, such as storage and usage of flammable materials, toxic chemicals, radioactive sources and water reactive substances to which they may be exposed during fire and other emergencies. Emergency Control Centre: The Emergency Control Centre is the place from which the operations to handle the emergency are directed and coordinated. It will be attended by the Emergency Response Coordinator or Incident Controller or Site Main Controller, Key Personnel and Senior Officers of the Fire Brigade, Police, Officials of the Factory Inspectorate, District Authorities, Emergency Services and Medical Personnel, etc. The Control Centre should be sited in an area of minimum risk and close to road to allow for ready access by a radio-equipped vehicle for use, if other system fail or extra communications facilities are required. For large sites or where toxic releases might be
- 401. anticipated, consideration shouldbe given for setting up two Control Centres to ensure, that at least one centre will be available for use, should the other be disabled. If necessary, the police will assist to set up an Emergency Control Centre. The Emergency Control Centre should consist of: Adequate number of external telephones, Internal telephones, and PA Systems Radio equipment, hot lines, walkie-talkie, mobiles, etc. Plans of the factory to show: o Areas of large inventories of hazardous materials, including chemical storage tanks, reactors, drums and compressed gas cylinders o Location of radio-active sources. o Location of sirens. o Location of safety equipment including fire, explosion, spill and gas control kits. o Location of firefighting installations. o The fire water system and additional source of water, site entrances and road system. o Assembly points, shelters, refuge areas, lunch rooms and canteens. Training: Training is important for the effectiveness of an emergency plan. Before implementing an emergency action plan, a sufficient number of persons must be trained to assist in the safe and orderly evacuation of employees or occupants. Training for each type of disaster response is necessary, so that employees or occupants know what actions are required to be taken. In addition to the specialized training imparted for emergency response team members, all employees or occupants should also be trained in: Evacuation plans Shutdown procedures Alarm System Reporting procedures for personnel Types of potential emergencies These training programmes should be provided: Initially when the plan is developed For all new employees or occupants
- 402. When newequipment, process, or materials are introduced When procedures have been updated or revised At least once in a year. The emergency control procedures should be written in concise terms and be made available to all employees or occupants. A mock drill should be held for all personnel at random at least once in a year. The emergency plan should be revised periodically and updated to maintain adequate response personnel and programme efficiency. Personal Protection: Effective personnel protection is essential for any person, who may be exposed to potentially hazardous substances. In an emergency, employees may be exposed to a wide variety of hazardous circumstances, including Chemical splash or contact with toxic materials Unknown atmosphere that may contain inadequate oxygen to sustain life or toxic gases, vapours or mist Falling objects and flying objects Fires and electrical hazards It is extremely important that employees be adequately protected in these situations. Some of the safety equipment that may be used include: Safety glasses, goggles or face shields for eye protection Helmets and safety shoes for head and foot protection Whole body coverings, gloves, hoods and boots for body protection from chemicals Whole body protection for abnormal environmental conditions such as extreme temperature Respirators for breathing protection Emergency situations may involve entering confined space to rescue employees overcome by toxic compounds or lack of oxygen. They include tanks, vaults, pits, sewers, pipelines, silos and vessels. Entry into confined spaces can expose the employees to a variety of hazards, including toxic gases, explosive atmospheres, oxygen deficiency, electrical hazards and hazards created by mixers and impellors that have not been deactivated and locked out.
- 403. Medical Assistance: Medical Assistanceplays an important role, during an emergency, especially when a major fire and explosion occurs. Thus a Medical Assistance Team should be formed and the team should have: Persons trained in First-Aid should be available. Eye washers or suitable equipment for quick drenching or flushing must be provided in the work area for immediate emergency use. First-Aid supplies should be provided for emergency use. Ambulance service should be available to handle any emergency. Security: During emergency, it is often necessary to secure the area to prevent unauthorised access and to protect vital records and equipment Mutual Aid: In major emergency situations, resources over and above these available at the works will be needed. In locations, where there are a number of industrial concerns, it may be beneficial to set up a mutual aid programme which will assist to secure additional supplies when needed. CONCLUSION: Every industry is exposed to threat of disasters, both man-made and natural due to variety of causes. Experience has shown that such disasters can strike at the most unexpected time. The impact of such disasters depends on how well the management copes with such a situation. A major accident/disaster may be defined as one or more emergencies, which can affect several or all departments and personnel working within a factory or an occupancy and can result in extensive damage to property, loss of life and disruption both inside and outside the works. An important element of mitigation is emergency planning, i.e., recognising that accidents are possible, assessing the consequences of such accidents, and deciding the emergency procedures both On-Site and Off-Site. Emergency planning is just one aspect of the safety, other being maintaining good safety standards of operating inside plants. The effectiveness of what we should do, if a disaster strike, will wholly depend upon how well we have prepared the On-Site Emergency Plan and train the people, who will have to
- 404. implement them. Thepreparation of an On-Site Emergency Plan is in itself an invaluable learning exercise and it should involve the manager, workforce, and the emergency services. The objective of an emergency plan will be to localise the emergency and, if possible, eliminate it. Minimising the effects may include rescue, first aid, evacuation, rehabilitation, and giving information properly to people living nearby. In other words, the disaster plan is in effect, an orderly assimilation of the consideration to the activities necessary for the co- ordination of rescue, firefighting, medical needs, welfare requirements and the preservation of life and property. OFF-SITE EMERGENCY PLANNING: Purpose To ensure that the local authority’1 (LA) adequately discharges its duty to prepare, test on an ongoing basis and review and revise the off-site emergency plan (OfSEP) for each COMAH toptier site within its area so as to minimize the consequences of major accidents to people and the environment. To ensure that operators of top tier COMAH sites supply to local authorities the information necessary for the purpose of enabling the authority to prepare the off-site emergency plan as required by COMAH Regulation 10, and provide information to the public as required by Regulation 14. Emergency response is a Competent Authority Strategic Management Group (CASMG) priority topic for 2010-2011. The results from the intervention will be recorded on COIN and reported to CASMG at the end of the work year. The results will be used to inform future interventions. Off-site Emergency Plan: The main objective of the plan are – To save lives and injuries. To prevent or reduce property losses and To provide for quick resumption of normal situation or operation.
- 405. Risk Assessment: Riskassessment is most essential before preparing any off site emergency plan. Hazardous factories and their hazard identification, other hazard prone areas, specific risks, transportation risk, storage risks, pollution risks by air and water pollution, catastrophic risks such as disasters, natural calamities, acts of god, earthquake, landslide, storm, high wind, cyclone, flood, scarcity, heavy rain, lightening, massive infection, heavy fire, heavy explosion, volcano, heavy spill, toxic exposure, environmental deterioration etc., risks from social disturbances, risks from the past accidents must be considered while carrying out risk assessment for a particular area(district) from which the offsite emergency plan is to be prepared. Central Control Committee: As the offsite plan is to be prepared by the Government, a Central Control Committee shall be formed under the Chairmanship of the District Collector. Other officers from Police, Fire Service, Factory Inspectorate, Medical Department shall be incorporated as members of the Central Control Committee. Under the Central Control Committee the following committees shall be constituted under the control of the District Collector. Incident and Environment Control Committee. Fire Control Committee. Traffic control, Law and order, Evacuation and Rehabilititation Committee. Medical help, Ambulance and Hospital Committee. Welfare, Restoration and Resumption Committee. Utility and Engineering Services Committee. Press, Publicity and Public Relations Committee. The Off-site Emergency Plan shall be prepared by the District Collector in consultation with the factory management and Govt. agencies. The plan contains up to date details of outside emergency services and resources such as Fire Services, Hospitals, Police etc. with telephone number. The district authorities are to be included in the plan area. Police Department. Revenue Department. Fire Brigade.
- 406. Medical Department. Municipality. Gram panchayat. Railway Department. Telephone Department. Factory Department. Electricity Department. Pollution Control Department. Explosive Department. Press and Media. Mock exercises on Off-site plan should be carried out at least once in a year to train the employees, up to date the plan, observe and rectify deficiencies. HAZOP Study: Before making the on-site and offsite plan hazop study has to be carried out to identify the potential hazardous situations and to find out possible control measures. Hazop study is to be carried out by a team of experts. The team should consist of – Mechanical Engineer. Chemical Engineer. R & D Chemist. Works Manager. Project Manager. Outside experts.
- 407. Safety Officer/Manager. Conclusion: To carry out mock exercises and rehearsal of the off site plan to ensure its efficiency, test and response, interaction and co-ordination of operators various service organizations evaluate the effectiveness and adequacy of the equipment’s and to gain experience and confidence to implement the plan. The finalized disaster plan shall be given to all concerned for implementation and rehearsal for preparedness. Objectives: The overall objective of the LP-MARG is to generate, develop and sustain a voluntary movement of Safety, Environment & Health at the Lote parshuram MIDC level. To prevent Human Injuries, consistent effective control and reduction of EHS risks-aspects, incidences & hazards through awareness among employees. To provide training to the employees of the MARG Members and concerned authorities etc., with sole intention of averting Industrial disasters. Essentially a mutual aid scheme, by which the resources held by MARG Members can be made available to a member company in an emergency at any time. To provide a rapid and co-ordinated response to minimize adverse effects to the workers, public, property and environment. Support small-scale industries by large scale industries to know the hazards, risks & requirement of emergency preparedness & response from the concern processes, Hazardous chemicals handling, storage & use of Chemicals. Sharing the information among employees for safe , environment friendly practices adopted in an industries. To voluntary scheme requires all MARG Members to play their part by promptly making available their resources in case of a major emergency in any Member company’s unit. How to sustain MARG: It is essential that: Each MARG Member maintains a list of equipment that can be spared which should be kept updated.
- 408. Each MARGMember has competent adviser. There should be an effective system of informing neighboring communities of any industrial emergency and what to do in case of the emergency. Meet regularly. Share Information. Discuss major accidents? Emergencies to learn lesson from them. Have regular joint drills based on Onsite emergency plans & on Off-site emergency plan. Communicate, share, and participate with other MARG Members. Communicate with emergency responders like city fire brigade, hospitals, Ambulance service& police etc. Standardize terminology used to identify the key emergency management groups and personnel, For example-Emergency co –coordinators, Site controller, etc. Ensure availability of services of competent advisor. Responsibilities of MARG Members related to Emergency Management: Each MARG Member to ensure that individual emergency response plans and procedures are developed and tested at frequent intervals. During the rehearsals, appoint 2-4 independent observers. After each rehearsal, have a review meeting and record the minutes/response time. Note down any feedback or suggestion for improvement of the plan. Periodically review and revise the on-site emergency plan. Update the same and Communicate to all stakeholders. Major accident control system at local state Many factories in India have been employed and implemented their risk Assessment System, such as safety management system, control of major accident hazards or other occupational safety and health – such as safety audit. Safety Management system (SMS) has various elements of safety and implementation of the Safety management system will ensure improved safety in Industries. This paper deals with various elements of Safety management systems in Major accident hazard (MAH) factories and the methodology to enhance safety in MAH industries by implementing proper, adequate and exhaustive SMS.
- 409. CONTROL OF MAJORACCIDENT HAZARDS Control of major accident hazards safety case study is to demonstrate the more ‘in depth’ auditing system is companies doing what they say they do? The representative of the company shall present what they want to do to prevent major accident/incident? What is their future improvement on safety, health and environment in the next three years? The company is requested to commission a registered competent person to assist the company to prepare a Control of major accident hazards safety report every three years. REQUIREMENT OF CONTROL OF MAJOR ACCIDENT HAZARDS SAFETY REPORT Indian Control of major accident hazards regulations require the main elements of the safety report shall include: Introduction of the hazardous substances, Major Hazards, Accidents which might be created major accident with in the Industry. Information relating to the installations: Location, process description, number of period on site and other population distribution etc. Information relating to the hazardous substances: Identification of the hazards by using risk assessment, Hazop, Fault tree analysis, event tree analysis etc. Information relationsto safety managementsystem: Safety policy, safety training, safety promotion, safety facility, safety rules and regulations, safety inspections, emergency preparedness etc. Information relating to public: action plan during accident, common names and dangerous characteri - stics etc. Information relating to potential major accident: Fire, Explosion, spillage, toxic gas/hazardous substances release, etc. SAFETY REPORT Safety report must contain Major Accident Prevention Policy. Safety Management System. Identification of Hazards. Adequate Prevention/Limitation Measures. Internal Emergency Plans. Information for External Emergency Plans. MAH System: National Control System Millions of chemicals are handled in industry cause harm to human beings, other living creatures, plants, micro-organisms, property or the environment referred to as hazardous chemicals. Industrial. Installations handling these chemicals have the potential to give rise to serious injury or damage beyond the immediate vicinity of the workplace. These are
- 410. known as majoraccident hazards. The Ministry of Labour, Government of India, responsible for administering the Factories Act, 1948 amended it in the year 1987. Important objectives of the amendment were, to regulate the location of hazardous process industries in such a manner that they do not cause adverse effects to the public in the vicinity and provide measures for safe handling of hazardous substances. Also, the Ministry of labour implemented through DGFASLI and Inspectorates of Factories an ILO Project: ‘Establishment and Initial Operation of a Major Accident Hazards Control System in India’ in the manufacturing sector in the later part of 1980s. A great deal of awareness was created through this project among all concerned about the prevention of major accidents and mitigation of adverse effects of such an accident. DIRECTORATE GENERAL FACTORY ADVICE SERVICE & LABOUR INSTITUTES (DGFASLI) : It is an attached office of the Ministry of Labour, Government of India was set up in 1945. It serves as a technical arm to assist the Ministry in formulating national policies on occupational safety and health in factories . It Implements ILO project on MAH Units. DGFASLI advise State Governments and factories on matters concerning safety, health, efficiency and wellbeing of the persons at workplace. It also enforces safety and health statutes in major ports of the country. Institute dealing with the scientific study of all aspects of industrial development relating to the human factors The Directorate General Factory Advice Service & Labour Institutes (DGFASLI) comprises: Headquarters situated in Mumbai Central Labour Institute in Mumbai Regional Labour Institutes in Calcutta, Chennai, Faridabad and Kanpur DGFASLI organization in CLI, Mumbai functions as a socio-economic lab. & is a national. International Occupational Safety and Health information centre (CIS) CIS (from the French name, Centre international Information security hygiene travail) i.e. International Occupational Safety and Health Information Centre, is a part of the International Labour Office, Geneva, Switzerland. The mission of CIS is to collect world literature that can contribute to the prevention of
- 411. occupational hazards andto disseminate this information at an international level. CIS imparts to its users the most comprehensive and up-to-date information in the field of occupational safety and health. The work of CIS is supported by a worldwide Safety and Health information exchange network which includes over 86 affiliated National Centers and 23 CIS collaborating Centers. CLI, Mumbai has been designated as the CIS National Centre of India. CIS can offer you rapid access to comprehensive information on occupational safety and health through: Microfiches on original documents abstracted in CIS DOC (CISILO) ILO CIS Bulletin “Safety and Health at Work” Annual and 5-year indexes The CIS Thesaurus The list of periodicals abstracted by CIS CIS ACCESSION NUMBER : ABSTRACT: Adverse occupational health and safety (OHS) effects associated with the use of Sub-contractors are identified and control OHS risks are described. Factors to be considered include: consideration of the costs and benefits of employing sub-contractors; senior management commitment; tender and contract requirements; OHS management policies; sub-contractor OHS management system; subcontractor behaviour.
- 412. CHAPTER- 6 OCCUPATIONALHEALTH AND SAFETY AUDITS IS-14489: Safety Audit Report: Safety audit with the help of an expert not associated with such industrial activities is to be submitted within 30 days after the completion of such audit. Looking to this need, BIS also published an Indian Standard - IS:14489 in 1998 as standard guideline for practice on occupational safety and health audit. This IS does not include rating (points) system like British Standard. Therefore, it gives qualitative analysis and not the quantitative. 1. Need of Safety Audit: (A) Safety Requirement: It is utmost necessary for the purpose of maintaining safety (accident free atmosphere) in industry that all systems of work should be thoroughly checked from safety point of view at regular interval and deficiencies identified should be removed by due compliance of safety recommendations. – (B) Legal Requirement: Rule 12-C & 68-0 of the Gujarat Factories Rules 1963 and Rule 10 & 12 of the Manufacture, Storage and Import of Hazardous Chemicals Rules 1989 need submission of safety audit reports to the concerned authorities within prescribed time. 2. Audit Procedure: Lead auditor along with his team may adopt following procedure: Constitution of Audit team (at least two members). Constitution of Auditee representatives. Recording identification and brief history of the auditee industry. Deciding audit goals, objectives and scope. Drawing audit plan with time schedule. Holding opening meeting with the auditee. Study of process and applicability of safely laws and standards. Taking plant round and noting observations. Examining records and documents. Filling checklists of audit points (e.g. filling of Annexure A, B & C of IS-.14489). Element wise (Annex. A) files will be useful. Holding of closing meeting and discussing findings.
- 413. Preparation andsubmission of Audit Report (with Executive summary in the beginning). Report distribution for compliance. Compliance audit if required by the audittee or client. Visit for compliance audit and its report. 3. Audit Frequency: Normally an external or third party safety audit should be conducted once in two years and an internal audit may be organized once in every year. 4. Audit Goals: Following goals can be decided while starting the audit: 1. Assessment of Auditee's OS&H system against existing standards and identification of areas for improvement. 2. Determination of conformity of the implemented OS&H system with specified requirements and identification of areas for improvement. 3. Checking of statutory requirements. 5. Audit Objectives: Following objectives can be decided for the audit: To carry out a systematic, critical appraisal of all potential hazards involving personnel, plant, services, methods etc. To ensure that company's OS&H system and safety policies, objectives etc. satisfy the legal requirements. 6. Audit Scope: The scope and depth of the audit should be decided as per auditor’s or client's requirements. This should include: Which plants or areas to be audited. Which OS&H system elements to be audited. With what legal and other safety standards, rules or documents, the auditee's OS&H systems should be compared. Benchmarking if any, should be considered. List of resources and evidences including workers and experts that will be available for
- 414. audit. Within whattime frame audit should be completed and with what other terms and conditions. A written agreement, if necessary, should be prepared and signed. 7. Audit Plan: Audit plan should be finalized after consultation with auditee and should be informed to auditors and auditee in the opening meeting. This plan should include: Audit goals, objectives and scope as stated earlier. Names of audit team members and management's representatives. List of documents to be checked. List of legal and other standards to be followed during audit. Auditee's OS&H policy and its other intentions. Time schedule of audit visits of each plant or location. Schedule of meetings to be held with auditee for the audit purpose. Expected date of issue of the audit report. Procedure or methodology of compliance of the report, and Whether compliance audit will be required by the auditee and if yes, it's probable time schedule, and method of communication. 8. Checking of Records & Registers: Statutory forms, records and registers under the Factories Act & Rules and other safety laws should be checked for relevant information and statutory compliance. This may include (for Gujarat): Form No. 1 a (GFR) i.e. structural stability certificate. Form No. 9, 10, II (GFR) for hoists, lifts, lifting machines and pressure vessels. Reports of Competent Persons regarding examination of dangerous machines, safety devices, dangerous operations etc. Form No. 29 (GFR) i.e. Accidents Register. Form No. 20, 32 & 33 (GFR) i.e. Health records for workers. Form No. 37 (GFR) i.e. work place monitoring record. Industrial Hygienist’s report regarding measured values of gas, vapor, noise, WBGT (Heat stress parameters), ventilation system etc.
- 415. Statutory cautionarynotices, safety policy and minutes of safety committee meetings. Certificate of safety, testing of pressure vessels and safety valves etc. under SMPV (U) Rules 1981 and Petroleum Act & Rules, if applicable. Forms under Gas Cylinder Rules if applicable. Testing certificates of effluents, air pollutants, solid wastes, ambient air quality etc. Under GPCB norms. Licenses under applicable Acts and Rules and their validity. Public liability insurance policy, if required. Records of storage quantities of hazardous chemicals for verification of threshold quantities and identification as MAH installation. Records and Registers (29) as suggested by Annexure - B of IS:14489. Other relevant records and registers as considered necessary by the auditors. 9. Checking Applicability of Safety Laws: From above records, registers, licenses etc. and physical verification of storage quantities, number of gas cylinders etc., act-wise applicability and validity of licenses etc. should be checked, discussed and narrated in audit report. 10. Points of Plant-visits: All safety points (audit points) seen during plant visits should be recorded plant-wise or location-wise so that plant-wise implementation will become easy. This should be separately reported in the audit report. Such points are to be seen as requirement of law and other standards. Their mention will include reference of relevant section, rule, standard (attributes) etc. 11. Audit Observations and Recommendations: Safety audit questionnaire sheet should be prepared in the following form: Sr. No. Items to be observed Observation seen/ found (Non conformities)
- 416. Recommendations i.e. safety suggestions. Observationsshould be clear and specific. Recommendations should also be clear, specific, easy to understand, brief and with reference of safety standard or reason as per auditor's opinion. Annexure - C of IS:14489 is a good guideline for safety audit which can be used for a chemical indstry also. It should be utilized as a whole or with necessary modification deem fit by the auditors. Points may be decreased or increased depending on the size, status, contents, materials, processes, procedures and systems of works and experience of the auditors. As Annexure - C includes many items of safety •inspection and audit including safety policy, organization, training, general working conditions, hazard identification and control, technical aspect, work permit system, PPE, fire protection, emergency preparedness, hazard area classification, static lectricity, vessels and equipments, storage safety, communication system, transport, pipelines etc., they are not separately discussed in this article. There is no end to such items. Only experience can specify and classify them. Therefore, audit by duly qualified and experienced auditors is more useful. 12. Closing Meeting: After recommendations are ready, prior to preparing the audit report, auditors should hold a closing meeting with auditee's senior managers to explain them the result of the audit. Audit observations and recommendations should be explained to them. Power point presentation is more effective. Querries of the audience should be replied forthwith. Reasons (legal requirements, standards etc.) of recommendations should be properly explained. It should also be clarified that the purpose of this effort (audit) is not to criticize but to try to find out the methods of further improvement. 13. Report Preparation & Submission: Audit report should be well documented by the auditors, audit certificate should be signed (with date) by the lead auditor and enclosed with the audit report and it should be sent to the auditee or client as soon as possible. If it cannot be sent within agreed time limit, reasons of delay should be communicated. The auditee should send acknowledgement of receipt of audit report to the auditors and client and final report of compliance when it is over. 14. Report Distribution and Compliance: Auditee will decide internal distribution (relevant copies) of audit report to the concerned departments or managers with its instructions of compliance within specified time limits assigned to each of them. The auditee will collect the reports of compliance, will verify and arrange in chronological order against each point of recommendation. 15. Report Retention: Auditee should retain the audit report alongwith its compliance report and should show them to the authorities on demand. Such retained audit reports will show the history of safety improvement of the
- 417. auditee. Minimum timeof retention is till full compliance of the audit report. Cost benefit ratio can also be determined based on this. If compliance or follow-up audit is required by the same auditors, auditee or client should inform them accordingly. Report as BIS 14489: Safety Report: Statutory information required in a safety report is given in Sch. 8, Rule 10(1) of the MSIHC Rules, 1989 Before 90 days of any modification (having material effect), an updated Safety Report shall be submitted to the authority. Integrated Management System (IMS) ISO (International Organization for Standardization) has a membership of 164 national standards bodies from countries large and small, industrialized, developing and in transition, in all regions of the world. ISO’s portfolio of over 19200 standards provides business, government and society with practical tools for all three dimensions of sustainable development: economic, environmental and social. ISO standards make a positive contribution to the world. They facilitate trade, spread knowledge, disseminate innovative advances in technology, and share good management and conformity assessment practices. Integrated management system combines all related components of a business into one system for easier management and operations. An Integrated Management System (IMS) integrates all of an organization's systems and process objectives to achieve its purpose and mission. Organizations often focus on management systems individually, often in silos and sometimes even in conflict. The integration of all the management systems into a single system and centrally managed is defined as Integrated Management System. On the part of the different structure of ISO standards, it is difficult to integrate the management systems into integrated management system. This is the reason why ISO published Annex SL. According to this Annex SL, the new published standards will have the common High-level structure (HLS) with the following 10 clauses. Class 1 Scope Class 2 Normative references Class 3 Term and definitions Class 4 Context of the organization Class 5 Leadership Class 6 Planning Class 7 Support Class 8 Operation
- 418. Class 9 Performanceevaluation Class 10 Improvement Integrated Management System comprises of: ISO 9001:2015 - Quality Management Systems (QMS); ISO 14001:2015 - Environmental Management Systems (EMS); OHSAS 45001- Occupational Health & Safety Management Systems (OHSMS); Integrated Management System ISO 9001:2015 ISO 14001:2015 OHSAS 45001 OHSAS 18001:2007 – Health And Safety Management System Managing health and safety (OH&S) issues in the workplace represents an enormous challenge due to varying human nature, skills set, process complexity & local culture and have implications for everyone at the workplace. Effectively managing these issues means taking account not only of legal requirements, but also the well-being of your personnel in the organization. Purpose of OHSAS 18001 Management of health & safety issues for an organization considering all interested parties concern is the main challenge of the business while working with significant hazardous process & risk. Achieving OHS performance with improved well-being is the need to assure the regulatory bodies, customers and other stack holders due to high premium cost for any incident. Certification to OHSAS 18001 show the commitment to the health and safety of employees, demonstrates your ability to manage risk & hazards associated with the activities and provide assurance to all concerned including customers and management that legal compliance is effectively managed. Implementation of OHSAS 18001 policies gives systematic approach to minimizing health and safety risks and provide a framework for an organization to manage its legal compliance and improve occupational health and safety performance, including risk and opportunity identification, analysis, target setting, and measurement. Organizations are improving the health & safety status by implementing the universally valid international standard along with best practices beside their own country specific health & safety legislations. OHSAS 18001 is basic and globally recognized standard for occupational health and safety management systems and is applicable to any organization in any business sector.
- 419. Benefits of OHSAS18001 Implementing an effective occupational health and safety management system reduces the risk of harm to your employees and other personnel and reduces overall liability. Effective Management of Health nd Safety risks will help: Demonstrate your commitment to the protection of employee, property and plant. Minimize the number of accidents and production time loss due to better control over hazards at the workplace Focus on employee safety results in a satisfied, motivated and highly productive work team. Increase control and reduction of hazards through the setting of objectives, targets and evolved responsibility. Maximize the well-being and productivity of all people working for the organization. Encourage better relationships with contractors and more effective contracted activities. Reduction in insurance premiums & workers compensation Demonstrates an innovative and forward thinking approach Ensuring legal compliance Improve safety culture & your reputation in the eyes of customers, competitors, suppliers, other stakeholders and the wider community. More about OHSAS 18001A certificate issued by third party registrar to demonstrates that your business system has been certified against requirements of OHSAS 18001 requirements. Implementation of OHSAS 18001 by setting up of internal processes gives confidence to management, employees & society at large about the protecting the health & safety and managing risk to human being. OHSAS 18001 is an international standard for environmental management, applicable to companies of all sizes and types; certification to OHSAS 18001 provides a dynamic mechanism for the development of effective health & safety management system. “Plan-Do-Check-Act” principle based cycle, OHSAS 18001: 2007 specifies the most important requirements to identify, control and monitor the risk & hazards of any organization, and also how to manage and improve the whole system. The OHSAS 18001 (Occupational Health and Safety Assessment Series) certification system is developed by an association of national standard bodies, group of certification bodies/registrars, and specialist of health & safety. Features of OHSAS 18001 OHSAS series is designed to help organizations formulate occupational health and safety policies and objectives containing two documents viz. OHSAS 18001 – OHS Requirements & OHSAS 18002 which generally known as guidance document for implementation of OHSAS 18001. It is applicable to any organization, large or small, and within any business sector. OHSAS 18001 is largely aligned with the structure of ISO 14001 and is based on the two concepts of continual improvement and regulatory compliance.
- 420. OHSAS 18001 auditcovers following: Policy statement (commitment of top management to improve OHS conditions) Hazard identification, assessment & control (evaluation of risk & its consequence on human being) Legal & other requirements (ensuring stringent compliance to the law of the land) Documented objectives & targets (continual improvement) Resources, Role, Responsibility & Authority (making responsible every one) Competence, awareness & training (ensures availability of right person all the time) Communication, participation & consultation (ensuring everyone has to become part of OHS management) Documentation, Control of documents & records (for ensuring compliance) Operational controls(established safe working conditions) Emergency preparedness & response (check your preparation to mitigate any emergency or abnormal situation) Performance measurement & monitoring (ensuring health & safety parameters) Incident, Nonconformity, corrective & preventive action (provides mechanism for improvement) Management review (ensuring organization system is compiled) OHSAS 18001 Accreditation Certification Europe is an accredited certification body which provides International Organisation for Standardization (ISO) management system certification and inspection services to organisations globally. We hold OHSAS 18001:2007 accreditation with both the Irish National Accreditation Bureau (INAB) and United Kingdom Accreditation Services (UKAS). Accreditation is the process by which a certification body is recognised to offer certification services. In order to become accredited, Certification Europe is required to implement ISO 17021 which is a set of requirements for certification bodies providing auditing and certification of management systems. Certification Europe is audited annually by our accreditation bodies to ensure our services meet the exact requirements of the relevant accreditation standards. What industries implement OHSAS 18001:2007? OHSAS 18001 is implemented by a wide variety of industries. The Health and Safety standard can benefit any organizations that choose to implement it. If you have a workforce of 5 or 500 then OHSAS 18001 will benefit you immediately. The purpose of the management system is to put the focus on the employees and ensure best practices are being implemented. Effectively implementing the standard results in a safer working environment for your workforce, plus reduce risk and liability exposure on the organisation.
- 421. OHSAS 18001:2007 Training CertificationEurope can provide in house training for your staff on implementation and auditing your systems internally to OHSAS 18001. Contact our team today to learn more. Eliminating risks and hazards: OHS hazards & its risk to human being are identified by a team of experts considering extent of application, nature of activity & conditions in which it operates. Identified risk are prioritized by making objective to reduce its significance level by giving a frame work of management programs which identify the resources & approach to achieve the desired goal. Timely review of achieved objective & new process area will direct the organization to set the next goal towards improvement in health & safety status. Certification Process for OHSAS 18001 DQS Certification India appoints a competent & suitable auditor or team of auditors to audit the organization against the standard & scope requested by the clients. Client has to file an application seeking standard for which to be certified. Gap analysis may be performed first to check readiness for the auditee organization which help organization to improve upon. Routine surveillance audits are carried out to evaluate continual improvement in the validity period. A re-certification audit is performed after every three years to maintain continuity of the certification. OHSAS 18001 Certification The most important asset of every organization would be their employees. Every company performs best when its employees are generating the best results and are optimizing on the quality being delivered. It should be the aim of every company to achieve the maximum returns for your employees. For this you would have to implement quality standards in the occupational health and safety management system. We at IRQS understand the need of such a certification in today’s world. Most employees in the world today would trust an employer with an OHSAS 18001 quality standard in place. The obvious reason being this is the high level of safety that is provided to the organization’s work force. When you have such a standard in place, it means that the company is taking a stronger step towards occupational health – a prime necessity of every employee. To have an OHSAS 18001 certification, you would have to implement different approaches toward the standard. You would have to discover the best ways to put certain processes and practices into place. Understanding the framework of your organization would not be easy, but you would have to detect weak links all across and optimize them for best performance. When you have an occupational health and safety management system in place, your employees would be more dedicated towards your business and would want to perform better. It would mean an increase in output for the company and thus result in higher profitability. There would be many factors to audit even after the certification is complete. This ensures that the level of quality is always maintained and kept at
- 422. its peak. Believeit or not, many employees choose companies that are OHSAS 18001 certified only. Mainly because it signifies a growing and responsible company, a trait that every employee looks for. If you were to point out your organizations most important asset, it would have to be your employees. They are the blocks of success for your company. Every company performs best when its employees are generating the best results and are optimizing on the quality being delivered. But how can this be ensured? By implementing an OHSAS 18001 Certification. We at IRQS understand the need of such a certification in today’s world. Most employees in the world today would trust an employer with an OHSAS 18001 quality standard in place. What is OHSAS 18001 Certification? An occupational health and safety management system will place the basic requirements for a safe and secure environment. This will ensure that your business practices the right methods and standards to give your employees a safe and secure time at work. To have an OHSAS 18001 certification, you would have to implement different approaches toward the standards. You would have to discover the best ways to put certain processes and practices into place. Benefits of OHSAS 18001 Certification When you have an occupational health and safety management system in place, your employees would be more dedicated towards your business and would want to perform better. It would mean an increase in output for the company and thus result in higher profitability. ISO 45001 The issue of work-related injuries and diseases is significant and growing, both for employers and the economy. To combat this problem, ISO is developing a new standard named ISO 45001 (Occupational health and safety management systems - Requirements) that will help organizations reduce this burden globally by providing a framework to improve employee safety, reduce workplace risks and create better, safer working conditions. The standard is currently being developed by a committee of occupational health and safety experts and will follow other standard management system protocols approaches such as ISO 14001 and ISO 9001. It will take into account other International Standards in this area such as OHSAS 18001, the International Labour Organization's ILO-OSH Guidelines, various national standards and the ILO's international labor standards and conventions. The standard is targeted to be published in March of 2018 If you have certification to OHSAS 18001 you need to migrate to ISO 45001 to maintain the validity of the certification. To correct the foregoing sentence: ISO and BSI are two different organizations, and certification to each is a separate process. Therefore a new application and certification will be required for ISO 45001. OHSAS 18001 will be withdrawn three years after the publication of ISO 45001. Moving forward, the committee established a plan for the development and publication of the standard: The new proposed publication date is now March 2018 The drafting committee published the second draft in March 2017 which passed the Ballot with 88% support. ISO/DIS Published January 2016, with ballot due May 2016. The ballot to approve the Draft failed by a few votes.
- 423. ISO/CD 45001a second Committee Draft was published in March 2015. ISO/DIS 45001 (first draft international standard) could not be published by February 2015 as planned, because the first committee draft failed to secure the necessary two-thirds majority vote in the international Organization for Standardization (ISO) committee developing it on 18 October. ISO/CD 45001 (first committee draft) was published in May 2014. Assuming timescales are accurate, the standard will be called ISO 45001:2018, per the usual naming convention for standards published by the International Organization for Standardization. It is hoped that ISO 45001 will attain more international recognition, aiding the response to published statistics showing poor health and safety management costs around 4% of global GDP. Similar to existing standards like OHSAS 18001, which will be withdrawn, and ILO-OSH, the new international standard's impact has the potential to save lives, reduce work-related ill-health and accidents and improve employee morale. Aim of an OH&S management system: The purpose of an OH&S management system is to provide a framework for managing the prevention of injury and ill-health. The implementation of an OH&S management system can be a strategic decision for an organization. An organization‘s activities can pose a risk of injury or ill-health, consequently it is critically important for the organization to eliminate or minimize OH&S risks by taking appropriate preventive measures. When these measures are applied by the organization through its OH&S management system (supported by the use of appropriate methods and tools, at all levels in the organization) they proactively improve its OH&S performance. The intended outcome for an organization's OH&S management system is to prevent injury and ill-health, to improve and enhance the safety and health of its workers and the others persons under its control. An OH&S management system can enable an organization to improve its OH&S performance by; a) Developing and implementing an OH&S policy and OH&S objectives; b) Establishing systematic processes which consider its "context" and which take into account its risks and its opportunities, its legal requirements and the other requirements to which it subscribes; c) Determining the hazards and OH&S risks associated with its activities; seeking to eliminate them, or putting in controls to minimize their potential effects; d) Establishing operational controls to manage its OH&S risks, and to comply with its applicable legal and the other requirements; e) Increasing awareness of its OH&S risks; f) Evaluating its OH&S performance and seeking to improve it; g) Establishing the necessary competencies;
- 424. h) Developing apositive health and safety culture in the organization; i) Ensuring the consultation and participation of the workers. Success factors The success of the OH&S management system depends on leadership, commitment and participation from all levels and functions of the organization. The implementation and sustainability of an OH&S management system, its effectiveness and its ability to achieve its objectives are dependent on a number of key factors which can include: a) Top management leadership and commitment; b) Promotion of a positive health and safety culture; c) Participation of workers (and, as applicable, their representatives); d) Consultation – two way communication; e) Allocation of the necessary resources for sustainability; f) Clear OH&S policies, which are in line with the overall strategic objectives of the organization; g) The integration of the OH&S management system into the organization's business processes; h) The continuous evaluation and monitoring of the OH&S management system to improve OH&S performance; i) OH&S objectives that align with the OH&S policy and reflect the organization's OH&S risks; j) Awareness of its applicable legal and other requirements; k) Identification of hazards and control of the OH&S risks. Demonstration of successful implementation of this International Standard can be used by an organization to give assurance to workers and other interested parties that an effective OH&S management system is in place. Adoption of this International Standard, however, will not in itself guarantee optimal outcomes. The level of detail, the complexity, the extent of documented information, and the resources needed for an organization's OH&S management system will depend on a number of factors, such as: The organization’s context (e.g. its number of workers, its size, its geography, its culture, its social conditions, its applicable legal and other requirements); The scope of its OH&S management system; The nature of its activities, its products, its services, and its OH&S risks. "Plan, Do, Check and Act" cycle
- 425. The basis ofthe OH&S management system approach applied in this International Standard is founded on the concept of ―Plan, Do, Check and Act‖ (PDCA), which requires leadership, commitment and participation from all levels and functions of the organization. The PDCA model demonstrates an iterative process used by organizations to achieve continual improvement. It can be applied to a management system and to each of its individual elements. It can be described as follows: Plan: establish objectives, programmers and processes necessary to deliver results in accordance with the organization‘s policy. Do: implement the processes as planned. Check: monitor and measure activities and processes with regard to the policy and, objectives, and report the results. Act: take actions to continually improve the OH&S performance to achieve the intended outcomes. Contents of this International Standard This International Standard has adopted the ―high-level structure‖ (i.e. clause sequence, common text and common terminology) developed by ISO to improve alignment among its International Standards for management systems. This International Standard does not include requirements specific to other management systems, such as those for quality, environmental, security, or financial management, though its elements can be aligned or integrated with those of other management systems. Clauses 4 to 10 contain requirements that can be used to assess conformity. Annex A provides informative explanations to assist in the interpretation of those requirements. Scope This International Standard specifies requirements for an occupational health and safety (OH&S) management system, with guidance for its use, to enable an organization to provide safe and healthy working conditions for the prevention of injury and ill-health and to proactively improve its OH&S performance. This International Standard is applicable to any organization that wishes to: establish, implement and maintain an OH&S management system to improve occupational health and safety, eliminate or minimize OH&S risks and address OH&S management system nonconformities associated with its activities. b) Continually improve its OH&S performance and the fulfilment of its OH&S objectives; c) Demonstrate conformity with the requirements of this International Standard. This International Standard is intended to be applicable to any organization regardless of its size, type and activity and applies to the OH&S risks that the organization determines it can manage, taking into account factors such as the context in which the organization operates and the needs and expectations of its workers and other interested parties.
- 426. This International Standarddoes not state specific criteria for OH&S performance, nor is it prescriptive about the design of an OH&S management system. This International Standard enables an organization, through its OH&S management system, to integrate other aspects of health and safety, such as worker wellness/ wellbeing. The organization can also be required by applicable legal requirements to address such issues. This International Standard does not address issues such as product safety, property damage or environmental impacts, beyond the risks they provide to workers.
- 427. Industrial Safety Management: Theorganization and coordination of the activities of a business in order to achieve defined objectives: Management is often included as a factor of production along with‚ machines, materials, and money. According to the management guru Peter Drucker (1909-2005), the basic task of management includes both marketing and innovation. Practice of modern management originates from the 16th century study of low-efficiency and failures of certain enterprises, conducted by the English statesman Sir Thomas More (1478-1535) General Principles of management:- The principles were developed under fundamental assumptions as follows: • Organization and individuals behave in conformity with rational economic principles. • One best way to organize production is through systematic and scientific investigations. • Organization is established to fulfill production-related and economic goals. Principles of management are statements that are based on a fundamental truth. These principles serve as a guideline for decision-making and management actions. They are drawn up by means of observations and analyses of events that managers encounter in practice. Henri Fayol was able to synthesize 14 principles of management after years of study, namely: 1. Division of Work:-In practice, employees are specialized in different areas and they have different skills. Different levels of expertise can be distinguished within the knowledge areas (from generalist to specialist). Personal and professional developments support this. According to Henri Fayol specialization promotes efficiency of the workforce and increases productivity. In addition, the specialization of the workforce increases their accuracy and speed. This management principle of the 14 principles of management is applicable to both technical and managerial activities. 2. Authority and Responsibility ;-In order to get things done in an organization, management has the authority to give orders to the employees. Of course with this authority comes responsibility. According to Henri Fayol, the accompanying power or authority gives the management the right to give orders to the subordinates. The responsibility can be traced back from performance and it is therefore necessary to
- 428. make agreements aboutthis. In other words, authority and responsibility go together and they are two sides of the same coin. 3. Discipline :-This third principle of the 14 principles of management is about obedience. It is often a part of the core values of a mission and vision in the form of good conduct and respectful interactions. This management principle is essential and is seen as the oil to make the engine of an organization run smoothly. 4. Unity of Command :-The management principle ‘Unity of command’ means that an individual employee should receive orders from one manager and that the employee is answerable to that manager. If tasks and related responsibilities are given to the employee by more than one manager, this may lead to confusion which may lead to possible conflicts for employees. By using this principle, the responsibility for mistakes can be established more easily. 5. Unity of Direction :-This management principle of the 14 principles of management is all about focus and unity. All employees deliver the same activities that can be linked to the same objectives. All activities must be carried out by one group that forms a team. These activities must be described in a plan of action. The manager is ultimately responsible for this plan and he monitors the progress of the defined and planned activities. Focus areas are the efforts made by the employees and coordination. 6. Subordination of Individual Interest :-There are always all kinds of interests in an organization. In order to have an organization function well, Henri Fayol indicated that personal interests are subordinate to the interests of the organization (ethics). The primary focus is on the organizational objectives and not on those of the individual. This applies to all levels of the entire organization, including the managers. 7. Remuneration :- Motivation and productivity are close to one another as far as the smooth running of an organization is concerned. This management principle of the 14 principles of management argues that the remuneration should be sufficient to keep employees motivated and productive. There are two types of remuneration namely non-monetary (a compliment, more responsibilities, credits) and monetary (compensation, bonus or other financial compensation). Ultimately, it is about rewarding the efforts that have been made. 8. The Degree of Centralization: - Management and authority for decision-making process must be properly balanced in an organization. This depends on the volume and size of an organization including its hierarchy. Centralization implies the concentration of decision making authority at the top management (executive board). Sharing of authorities for the decision-making process with lower levels (middle and lower
- 429. management), is referredto as decentralization by Fayol. Henri Fayol indicated that an organization should strive for a good balance in this. 9. Scalar Chain :- Hierarchy presents itself in any given organization. This varies from senior management (executive board) to the lowest levels in the organization. Henri Fayol ’s “hierarchy” management principle states that there should be a clear line in the area of authority (from top to bottom and all managers at all levels). This can be seen as a type of management structure. Each employee can contact a manager or a superior in an emergency situation without challenging the hierarchy. Especially, when it concerns reports about calamities to the immediate managers/superiors. 10. Order :- According to this principle of the 14 principles of management, employees in an organization must have the right resources at their disposal so that they can function properly in an organization. In addition to social order (responsibility of the managers) the work environment must be safe, clean and tidy. 11. Equity :-The management principle of equity often occurs in the core values of an organization. According to Henri Fayol, employees must be treated kindly and equally. Employees must be in the right place in the organization to do things right. Managers should supervise and monitor this process and they should treat employees fairly and impartially. 12. Stability of Tenure of Personnel :- This management principle of the 14 principles of management represents deployment and managing of personnel and this should be in balance with the service that is provided from the organization. Management strives to minimize employee turnover and to have the right staff in the right place. Focus areas such as frequent change of position and sufficient development must be managed well. 13. Initiative :- Henri Fayol argued that with this management principle employees should be allowed to express new ideas. This encourages interest and involvement and creates added value for the company. Employee initiatives are a source of strength for the organization according to Henri Fayol. This encourages the employees to be involved and interested. 14. Esprit de Corps:- The management principle ‘esprit de corps’ of the 14 principles of management stands for striving for the involvement and unity of the employees. Managers are responsible for the development of morale in the workplace; individually
- 430. and in thearea of communication. Esprit de corps contributes to the development of the culture and creates an atmosphere of mutual trust and understanding. MANAGEMENT AND TYPES OF MANAGEMENT Management in businesses and other organizations, including not-for-profit organizations and government bodies, refers to the individuals who set the strategy of the organization and coordinate the efforts of employees (or volunteers, in the case of some voluntary organizations) to accomplish objectives by using available human, financial and other resources efficiently and effectively. Management typically includes planning, organizing, selecting the staff, leading or directing, and controlling an organization to accomplish various goals. Resourcing encompasses the deployment and manipulation of human resources, financial resources, technological resources, natural resources and other resources. Management is also an academic discipline, a social science whose objective is to study social organization. Types of Management: Top-Level Management Top-level managers include boards of directors, presidents, vice-presidents, CEOs, general managers, and senior managers, etc.Top-level managers are responsible for controlling and overseeing the entire organization. Rather than direct the day-to-day activities of the firm, they develop goals, strategic plans, and company policies, as well as make decisions about the direction of the business.Top managers need to have more conceptual skill than technical skill. They understand how competition, world economies, politics, and social trends affect organizational effectiveness. Middle management: This management is the intermediate management level accountable to top management and responsible for leading lower level managers. 1. Recognize the specific responsibilities and job functions often assigned to middle-level management professionals 2. Middle management isatthecenterofahierarchical organization, subordinate to the senior management but above the lowest levels of operational staff. 3. Middle managers are accountable to top management for their department's function. They provide guidance to lower-level managers and inspire them to perform better. 4. Middle-management functions generally revolve around enabling teams of workers to perform effectively and efficiently and reporting these performance indicators to upper management.
- 431. 5. Middle managementmay be reduced in organizations as a result of reorganization. Such changes can take the form of downsizing, " and outsourcing. Middle Management :-Most organizations have three management levels: first middle-level, and top-level managers. These managers are classified according to a hierarchy of authorityand perform different tasks. In many organizations, the number of managers in each level gives the organization a pyramid structure. Middle management is the intermediate subordinate to the senior management but above the lowest levels of operational staff. For example, operational supervisors may be considered middle management; they may also be categorized as non particular organization. Frontline managers oversee primary production activities on a daily basis, so they need very high interpersonal and technical skills. Frontline management is the level of management that oversees a company's primary production activities. Frontline ensure quality and quantity production, make recommendations, channel employee problems to other managers, provide technical expertise, check quality, and deal with customers and clients. Frontline with the operating personnel need very high interpersonal and technical Frontline managers are actively involved in operations; examples of frontline management include a store man Frontline managers are managers who are responsible for a work group to a higher level of management. They are normally in the lower layers of the management Middle management may be reduced in organizations as a result of reorganization. Such changes can take the form of downsizing, " and outsourcing. Most organizations have three management levels: first level managers. These managers are classified according to and perform different tasks. In many organizations, the number of managers in each level gives the organization a pyramid structure. Middle management is the intermediate leadership level of a hierarchical organization, being subordinate to the senior management but above the lowest levels of operational staff. For example, operational supervisors may be considered middle management; they may also be categorized as non-management staff, depending upon the policy of the oversee primary production activities on a daily basis, so they need very high interpersonal and technical skills. Frontline management is the level of management that oversees a company's primary activities. Frontline managers assign employees tasks, supervise employees, ensure quality and quantity production, make recommendations, channel employee problems to other managers, provide technical expertise, check quality, and deal with lients. Frontline managers who are responsible for dealing directly with the operating personnel need very high interpersonal and technical managers are actively involved in operations; examples of frontline management include a store manager or manufacturing facility manager. Frontline managers are managers who are responsible for a work group to a higher level of management. They are normally in the lower layers of the management Middle management may be reduced in organizations as a result of reorganization. Such changes can take the form of downsizing, "de-layering," Most organizations have three management levels: first-level, level managers. These managers are classified according to and perform different tasks. In many organizations, the number of managers in each level gives the organization a pyramid structure. Middle level of a hierarchical organization, being subordinate to the senior management but above the lowest levels of operational staff. For example, operational supervisors may be considered middle management; they ment staff, depending upon the policy of the oversee primary production activities on a daily basis, so they Frontline management is the level of management that oversees a company's primary managers assign employees tasks, supervise employees, ensure quality and quantity production, make recommendations, channel employee problems to other managers, provide technical expertise, check quality, and deal with managers who are responsible for dealing directly with the operating personnel need very high interpersonal and technical skills. managers are actively involved in operations; examples of frontline ager or manufacturing facility manager. Frontline managers are managers who are responsible for a work group to a higher level of management. They are normally in the lower layers of the management
- 432. hierarchy, and theemployees who report to them do not themselves have any managerial or supervisory responsibility. Frontline management is the level of management that oversees a company's primary production activities. Frontline managers consist of supervisors, section leads, foremen, and so on. They focus on controlling and directing. They usually perform the following functions: 1. assign employees' tasks 2. guide and supervise employees on day-to-day activities 3. ensure quality and quantity production 4. make recommendations 5. channel or redirect employee problems 6. provide technical expertise 7. monitor work processes 8. deal with customers and clients 9. measure operational performance 10. Frontline managers also serve as role models for employees in providing basic supervision, motivation, career planning, and performance feedback. General management:-focuses on the entire business as a whole (a top-down organizational view).A functional manager is a person who has management authority over an organizational unit—such as a department—within a business, company, or other organization. Under functional management, direct reports reside in the same department. A general manager is responsible for all areas and oversees all of the firm's functions and day-to-day business operations. The general manager has to communicate with all departments to make sure the organization performs well. General management and functional management have many similarities; the primary difference is that a functional manager focuses on one facet of an organization, while the general manager must keep everything in view.
- 433. Functional Management:- Besides theheads of a firm's product and/or geographic units, the company's top management team typically consists of several functional heads (such as the chief financial officer, the chief operating officer, and the chief strategy officer). A functional manager is a person who has management authority over an organizational unit—such as a department—within a business, company, or other organization. Functional managers have ongoing responsibilities and are not usually directly affiliated with project teams, other than ensuring that goals and objectives are aligned with the organization's overall strategy and vision. General managers:-include owners and managers who head small-business establishments with duties that are primarily managerial. Most commonly, the term general manager refers to any executive who has overall responsibility for managing both the revenue and cost elements of a company's income statement. This means that a general manager usually oversees most or all of the firm's marketing and sales functions, as well as the day-to-day operations of the business. Frequently, the general manager is responsible for effective planning, delegating, coordinating, staffing, organizing, and decision making to attain profitable results for an organization. Line and Staff Function for safety, Health, Environment Line & Staff Organization :'Line & staff organization' is a combination of line and functional structures, line of authority flows in a vertical line, but staff specialists are attached to line positions to advise them on important matters and these specialists do not have power of command over subordinates in other departments, but they possess it over subordinates in their own department
- 434. E.g. Chief SafetyOfficer has command over safely officers in his department but he has no command over accounts officer in other department. He has only advisory relationship with other departments like production, personnel, HRD etc. A common model of line & staff organization Advantages Disadvantages 1. Relief to line managers 2. Expert advice (specialization) 3. Better decisions 4. Training of personnel 5. Flexibility – opportunity for advancement Line-staff conflicts Confusion in relationships Staff becomes ineffective or irresponsible Expensive for small units Line and Staff Function:-
- 435. Authority :- Authority means“legal” or delegated power or right to a person.Government official have powers vested in them by law and therefore they are called Government
- 436. authorities.Authority can bedelegated .it is also decentralisation of power downward. A safety officer can delegated his authority to permit some work to safety supervisor..Authority gives right to aamanagers and disobedience of his order injuries his right for which a penality is possible According to some scientist:- Henry fayal:-Authority is the right to give orders and the power to exact obedience. Herbert Simon:- It is the power to make dicisions which guide actions of others. Terry:- It is excersied by making decisions and seeing that they are carried out. Characteristics of Authority:- a. Legitimacy: -It determines the effectiveness of authority. Hence it is the hall mark of the concept of authority. According to Robert Dahl “A commands B and B feels A has perfect right to do so and to which he has complete obligation to obey. Power of this kind is often said to be legitimate………. Legitimate power is often called authority.” b. Dominance:--Authority is capacity of the individual to command others. An individual or a group which possesses authority exercises dominance over other individuals. Authority is a command of superior to an inferior. c. An informal power:--It is not a formal power as it lacks characteristics which are the main features of power. According to Fredrick “Authority is not a power but something that accompanies power.” It is the quality in men and things which adds to their power, something which creates power but it is not itself power. d. Rationality:--This is the main characteristic of authority. In the words of Fredrick, ‘The man who has authority possesses something that I would describe as the capacity for reasoned elaboration for giving convincing reasons for what he does or proposes to have others to do.” Evidently the basis of authority is logic or reason. e. Accountability:--The individual or a group of individuals who possess authority are responsible to some higher authority. In a democratic system accountability is the most significant characteristic of authority. Scope of Authority;- Biological and physical limitation Legal and social constrains Economics constrains Limited span
- 437. Organizational limitation Responsibility:-Being a good manager is a challenging job. You are not only responsible for supervising your employees and making sure the work they do is of high quality and completed on time. You must also be effective at interacting with your own supervisors in upper management. While the specific duties of a manager differ by the position and company, there are a few common responsibilities all managers must deal with. 1. Get the Job Done :-One of the most important functions of a manager is to ensure that the people in your department do the job that needs to be done on time and with the highest degree of quality possible. 2. Be a Leader :-As a manager, you set the tone for your department. If you're upbeat and positive, your employees will be as well. It is your responsibility to lead by example -- not only in regard to your own attitude but also your personal work ethic and how you interact with other people. Treat others with respect, whether they are other managers, subordinates, superiors, customers, suppliers or other stakeholders 3. Evaluate Performance and Processes :--To be an effective manager, you need to know that your employees are being as productive as possible and that the processes in place to facilitate completion of their tasks are working optimally. For this reason, it's important to not only evaluate your workers' performance, but also the processes they're using during the course of each workday. 4. Traits of a Good Manager :-No matter what industry you work in, there are several characteristics that good managers have in common. Don't be afraid to praise employees for good performance. If you need to reprimand a worker, don't do it in front of other employees. Instead, talk to the worker one-on-one in your office to discuss the problem. Communicate with your employees openly and often. Keep them informed of what's happening in the company at weekly staff meetings Power of management :-means ability to do or capacity to do something to act. To control, to exercise force or enforcement etc. Power also comes with authority because authority gives right and that right gives power. Powerless person cannot manage or do anything. Subordinate do not follow his orders and goals of management can never be achieved .Therefore power should be vested by giving authority to managers Span of control:- It is a very important concept of organizing function of management. It refers to the number of subordinates that can be handled effectively by a superior in an organization. Span of control or span of management is a dimension of
- 438. organizational design measuredby the number of subordinates that report directly to a given manager. It represents a numerical limit of subordinates to be supervised & controlled by a manager. ACCOUNTABILITYANDRESPONSIBILITY: The main difference between responsibility and accountability is that responsibility can be shared while accountability cannot. Being accountable not only means being responsible for something but also ultimately being answerable for your actions. Also, accountability is something you hold a person to only after a task is done or not done. Responsibility can be before and/or after a task. ACCOUNTABILITY: In ethics and governance, accountability is answerability, blameworthiness, liability, and the expectation of account-giving. RESPONSIBILITY: Responsibility may refer to: being in charge, being the owner of a task or event. Ex. It is Tom's responsibility to make sure there are supplies in the office room. So Tom will be aware of this task and keep bringing in more supplies before they run out. At this point, you cannot say Tom has been held accountable (answerable) for performing this task. Tom is responsible for the office supplies, but he is only held accountable — owes an explanation for his actions — if the supplies ever run out. SPANOFMANAGEMENT Definition: The Span of Management refers to the number of subordinates who can be managed efficiently by a superior. Simply, the manager having the group of subordinates who report him directly is called as the span of management. The Span of Management has two implications: 1. Influences the complexities of the individual manager’s job 2. Determine the shape or configuration of the Organization The span of management is related to the horizontal levels of the organization structure. There is a wide and a narrow span of management. With the wider span, there will be less hierarchical levels, and thus, the organizational structure would be
- 439. flatter. Whereas, withthe narrow span, the hierarchical levels increases, hence the organizational structure would be tall. Both these organizational structures have their advantages and the disadvantages. But however the tall organizational structure imposes m Since the span is narrow, which means less number of subordinates under one superior, requires more managers to be employed in the organization. Thus, it would be very expensive in terms of the salaries to be paid to each senior. With more levels in the hierarchy, the communication suffers drastically. It takes a lot of time to reach the appropriate points, and hence the actions get delayed. Lack of coordination and control because the operating staff is far away from the top management. DELEGATION AND DECENTRALIZATION OF AUTHORITY: Delegation of Authority : All activities are not performed by one person. Authority should be provided to the subordinates too. Process of transferring authority and creation of responsibility between superior and subordinates to accomplish a certain task is called delegation of authority. Some of the main principle of delegation are mentioned below: Whereas, with the narrow span, the hierarchical levels increases, hence the organizational structure would be tall. Both these organizational structures have their advantages and the disadvantages. But however the tall organizational structure imposes more challenges: Since the span is narrow, which means less number of subordinates under one superior, requires more managers to be employed in the organization. Thus, it would be very expensive in terms of the salaries to be paid to each senior. levels in the hierarchy, the communication suffers drastically. It takes a lot of time to reach the appropriate points, and hence the actions get delayed. Lack of coordination and control because the operating staff is far away from the DELEGATION AND DECENTRALIZATION OF AUTHORITY: of Authority :- All activities are not performed by one person. Authority should be provided to the subordinates too. Process of transferring authority and creation of responsibility superior and subordinates to accomplish a certain task is called delegation of Some of the main principle of delegation are mentioned below: Whereas, with the narrow span, the hierarchical levels increases, hence the Both these organizational structures have their advantages and the disadvantages. ore challenges: Since the span is narrow, which means less number of subordinates under one superior, requires more managers to be employed in the organization. Thus, it would be very expensive in terms of the salaries to be paid to each senior. levels in the hierarchy, the communication suffers drastically. It takes a lot of time to reach the appropriate points, and hence the actions get delayed. Lack of coordination and control because the operating staff is far away from the All activities are not performed by one person. Authority should be provided to the subordinates too. Process of transferring authority and creation of responsibility superior and subordinates to accomplish a certain task is called delegation of Some of the main principle of delegation are mentioned below:
- 440. Principle ofabsoluteness of responsibility– according to it, responsibility can’t be delegated. Only authority can be delegated. The person who delegates authority is himself responsible for his seniors. Principle of unity of command– according to it, subordinates must be commanded by one superior, they should take their task from one superior and should be accountable fro their responsibility toward the superior level of operation Principle of functional definition of authority and responsibility– as per this principle. Duties and task assigned by the superior and the authority given to fulfill the task should be clearly explained and decided. Bt this subordinates can know about the limit of one’s right, duties and responsibility. The scalar chain– according to it, authority flows from top to bottom. So that scalar chain is the basis of relationship between the superior and subordinates. It emphasizes the relation between superior and subordinates by which delegation will be easier. Principle of parity of authority and responsibility– parity of authority and responsibility is one of the important principles of delegation of authority. There is equality in assigned task and power to do the work. Authority to the subordinates is given by the superior on the basis of assigned task. So Authority to the subordinates is given nether more or less than the task otherwise their can be improper utilization of authority and mismanagement of task. Decentralization:-Decentralization is the process of redistributing or dispersing functions, powers, people or things away from a central location or authority A few definitions are given below: 1. “Decentralisation refers to tire systematic effort to delegate to the lowest levels all authority except that which can only be exercised at central points.” —Louis A. Allen 2. “Decentralisation means the division of a group of functions and activities into relatively autonomous units with overall authority and responsibility for their operation delegate to timd of cacti unit.’—Earl. P. Strong 3. “Decentralisation is simply a matter of dividing up the managerial work and assigning specific duties to the various executive skills.” Degree of Decentralisation:-The degree of decentralisation is determined by: Nature of the authority delegated, How far down in the organisation it is delegated,
- 441. How consistentlyit is delegated. Factor determining decentralizing:- Size of Organization: - Decentralization depends upon size of organization. Larger the size of organization more the number of decision making areas will be there. So it will not be possible for single head to make all the decisions alone. Also the decision making process will be slow as communication process will be very long. Therefore need of decentralization would be more important. History of organization:- Decentralization depends upon how the organization developed over the period of time. Normally those organizations which expand under the direction of owner-founder show resistance to decentralization. Management philosophy: The character of top leader of organization influence the extent of authority is centralized or decentralized. Availability of mangers: - The shortage of quality manager also influences the extent of authority to be decentralized. If good managers are available then there is more possibility of decentralization of work. Costliness of decision: - The costliness of decisions in most important factor that effect the decentralization process. Decisions involving heavy costs or investment will be with top management like decision making for purchasing capital goods, land or machinery will be with top management and purchase of normal routine goods like daily stationary furniture will be made by department. Rate of change in organization: - The rate of change in organization also affects the decentralization decision. If the organization is fast developing and it is facing problems of expansion there is more chances of decentralization of authority for reducing burden from top management. Nature of activities: - The nature of operation s also determine the extent of decentralization i.e. whether the operation of organization are concentrated at one place or region or dispersed over different areas. If activities are dispersed in different territories then decentralization is must. Major Differences betweenDelegation and Decentralization Responsibility:-In delegation, a superior delegates or transfers some rights and duties to a subordinate but his responsibility in respect of that work does not end. On the other hand, decentralization relieves him from responsibility and the subordinate becomes liable for that work. Process:-Delegation is process while decentralization is the end result of a deliberate policy of making delegation of authority to the lowest levels in managerial hierarchy.
- 442. Need.:-Delegation isalmost essential for the management to get things done in the organization i.e., delegating requisite authority for performance of work assigned. Decentralization may or may not be practiced as a systematic policy in the organization. Control:-In delegation the final control over the activities of organization lies with the top executive while in decentralization the power of control is exercised by the unit head to which the authority has been delegated. Authority:-Delegation represents selecting dispersal of authority whereas decentralization signifies the creation of autonomous and self-sufficient units or divisions. Scope:-Delegation hardly poses any problem of co- ordination to the delegator of authority. While decentralization poses a great problem in this regard since extreme freedom of action is given to the people by creating self-sufficient or autonomous units. Good Results:-Decentralization is effective only in big organizations whereas delegation is required and gives good results in all types of organizations irrespective of their size. Nature:-Delegation is the result of human limitation to the span of management. Decentralization is the other hand, is the result of the big size and multi-furious functions of the enterprise. 1.4Role of management in industrial safety:- Planning Definition: Planning is the function of management that involves setting objectives and determining a course of action for achieving those objectives. Planning requires that managers be aware of environmental conditions facing their organization and forecast future conditions. It also requires that managers be good decision makers.
- 443. Planning is aprocess consisting of several steps. The process begins with environmental scanning which simply means that planners must be aware of the critical contingencies facing their organization in terms of economic conditions, their competitors, and their customers. Planners must then attempt to forecast future conditions. These forecasts form the basis for planning. Planners must establish objectives, which are statements of what needs to be achieved and when. Planners must then identify alternative courses of action for achieving objectives. After evaluating the various alternatives, planners must make decisions about the best courses of action for achieving objectives. They must then formulate necessary steps and ensure effective implementation of plans. Finally, planners must constantly evaluate the success of their plans and take corrective action when necessary. There are many different types of plans and planning. Strategic planning :-involves analyzing competitive opportunities and threats, as well as the strengths and weaknesses of the organization, and then determining how to position the organization to compete effectively in their environment. Strategic planning has a long time frame, often three years or more. Strategic planning generally includes the entire organization and includes formulation of objectives. Strategic planning is often based on the organization’s mission, which is its fundamental reason for existence. An organization’s top management most often conducts strategic planning. Tactical planning :-is intermediate-range (one to three years) planning that is designed to develop relatively concrete and specific means to implement the strategic plan. Middle-level managers often engage in tactical planning. Operational planning :-generally assumes the existence of organization-wide or subunit goals and objectives and specifies ways to achieve them. Operational planning is short-range (less than a year) planning that is designed to develop specific action steps that support the strategic and tactical plans. Definition of Planning by Planning refers to a preview of future activities.by Henry fayal It is fundamentally a mental predispositions to do thing in an orderly way, to think before acting and to act in the light of react rather than guesses. by Urwick Nature of planning It is a primary and important function of management.
- 444. It goaloriented. And an intellectual or rational process. It is a pervasive, flexible,continuous process and conscious process. Accuracy is essential to planning and is a choice of alternatives. Scope of planning In accuracy,rigidity,cost,incertainty,Timeconsumption,attitude of management,lack of orientation,Training for managers,false sense of security,Faults in planning system,Ressistance to change,Environmentlon strains. Procedure of planning:--Basic steps in planning are as under:- Identify problems Establish objectives or goals Develop planning premises e.g. land ,labor,capital,kmarket,money,time, procedure,publicrelation,reputation,morals,policy Determine alternatives course of action Evaluate the alternate Select a course of action Formulate derivatives plan ans sub-plan as per need. Range of planning Based on time schedule three types of plans can be prepared as under Short term:-For a period up to one years.they are specific and detaile and cover forms and contents of long term plan.they are prepared on the basis of stretigic and tactical plan e.g.:-daily operation,repairs,maintainance Medium term:-for a more than one year or less than 5 years they are coordinative and tactical in nature.they less detiled than short term, e.g. proposed product and its safety aspects, emergency planning, ,inspection, individual training. Long Term:-For a period of 5,10,15 or more years.it consider future changes in environment and provide overall target towards which all activitiy of all organisationae to be directed Variety of planning Bases on objective:-production plan ,sale plan, financial investment, expansion, r&d,training existing business, reform oriented plans Based on Time:-short,medium,long term plans are explained earlier Single use plan:- programs ,projects, budgets etc.
- 445. Repeated useplan:- they consider objective ,policies, procedure rules and strategies. Strategic planning:- Is a type of plan to meet challenges ,comptitions,emergencies and other environmental forces. On-site and off-sites emergencies plan are a best example. Management by Objectives (MBO) This concept was given by Alfred Slown in 1950 but popularized in 1954. MBOis a personnel management technique where managers and employees work together to set, record and monitor goals for a specific period of time. Organizational goals and planning flow top-down through the organization and are translated into personal goals for organizational members. The technique was first championed by management expert Peter Drucker and became commonly used in the 1960s. The core concept of MBO is planning, which means that an organization and its members are not merely reacting to events and problems but are instead being proactive. MBO requires that employees set measurable personal goals based upon the organizational goals. For example, a goal for a civil engineer may be to complete the infrastructure of a housing division within the next twelve months. The personal goal aligns with the organizational goal of completing the subdivision. MBO is a supervised and managed activity so that all of the individual goals can be coordinated to work towards the overall organizational goal. You can think of an individual, personal goal as one piece of a puzzle that must fit together with all of the other pieces to form the complete puzzle: the organizational goal. Goals are set down in writing annually and are continually monitored by managers to check progress. Rewards are based upon goal achievement. Process (steps) of MBO : Steps in sequence are: 1. Set objectives of the organisation. 2. Set objectives of the departments. 3. Set objectives of the individuals. 4. Develop action plans. 5. Implement plans.
- 446. 6. Take periodicreviews. 7. Appraise results. 8. Take corrective action for improvement. Advantages of MBO : They are : 1. Better management. 2. Clarifies organisation. 3. Harmony of objectives. 4. Motivation. 5. Evaluation of results. 6. Development of managers. 7. Improvement in superior - subordinate relations. Scope (limitations) of MBO: 1. Difficulty of introducing for reaching changes. 2. Difficulty in setting goals. 3. Too much emphasis on results. 4. Pressure on employees. 5. Too high expectations. 6. Neglect of some important goals. 7. Not useful for all. 8. Rigidity. Requisites (preconditions) of MBO : 1. Setting real objectives. 2. Ends - means distinction. 3. Clarity of objectives. 4. Active support from all participants 5. Active support of top management. 6. Three elements that objectives should be - helpful in evaluating performance, measurable and 1. Convertible into targets. 7. Multiple objectives and sub-optimization. 8. Displacement of objectives. 9. Quantitative cum qualitative objectives. 10.Receptivity. 11.Training for fulfillment of objectives. 12.The 'why' spirit (why cannot be obtained?) 13.Individual growth. 14.Study of environment and flexibility. 15.Provision of performance.
- 447. Role of MBOin Safety: The concept of MBO is much more useful in setting and achieving safety goals because it is a participative approach and safety being everybody's duty and everybody's target (goal) this approach is best fitting for safety management. First safety goals for the whole organization should be decided by the safety department. They may be: 1. Safety policy. 2. Some million man-hours work without accident. 3. Clean environment at all workplaces. 4. Productivity with safety. 5. Hazards detection and removal. 6. Maintenance of guards and safety devices. 7. Use of safety equipment. 8. Accident reporting, detailed investigation and record for cost and lesson. 9. Safety inspections and control techniques. 10.Safety committee, its objectives and functions. 11.Ergonomic improvements. 12.Occupational health & hygiene. 13.Compliance of statutory provisions. 14.Formation of other safety rules for specific works, SOPs and safety permit systems. 15.Induction, on-going and periodical safety programmes. Definitions of Policy: Koontz and O'Donnell - Policies are general statements of understandings which guide or channel thinking in decision making of subordinates. Dalton McFarland- Policies are planned expressions of the company's official attitudes towards the range of behaviour within which it will permit or desire its employees to act. Policy may be express or implied, verbal or written. Mostly it is in a short document form in writing. Objectives indicate destination and policy provides its route. Policy is the basic guidelines of attitudes, intentions, commitments or determination of the top management telling employees and the public its broad objectives and means to achieve them. Types of Policies: They are classified as basic, general or departmental policies, production policy, sales policy, purchasing policy, accounting policy, marketing policy, finance policy, personnel policy, safety/health or environment policy, imposed
- 448. policy, appealed policy,originated policy, opportunism policy (in politics and military), restrictive or permissive policy '(nature), written or implied policy etc. Safety Policy is statutorily required u/s 7A(3) and 41B(2) of the Factories Act, 1948 and its details arc prescribed u/r 12-C and 68-0 of the Gujarat Factories Rules, 1963. Steps in Policy Formulation : 1. Define policy area. 2. Identify policy alternatives. 3. Evaluate policy alternatives. 4. Select the best alternative. 5. Make policy document (if more details are required then policy manual). Follow statutory guidelines. a. Communicate for implementation. b. See its application into operational plans and all activities. c. Review and revise to keep it up-to-date. ORGANISING FOR SAFETY: Definition:- It refers an activity, process or function of management i.e. organizing. It is used in a dynamic way referring to process by which the structure is created, maintained and used. Chester Barnard-It is a system of co-operative activities McFarland-It is an identifiable group of people contributing their efforts towards the attainment of goals. of two or more persons.
- 449. Joseph L.Massie- Organization is defined as the structure and process by which co-operative group of human beings allocates its tasks among its members, identifies relationship and integrates its activities towards common objectives. John Pfeiffer- It is essentially a matter of relationship of man to man, job to job and departmentto department. Need of Organization:Organization is the foundation or framework of the whole structure of management and contributes greatly to success and continuity of an enterprise in the following ways 1. Facilitates administration and other functions of management process. 2. Facilitates growth and diversification. 3. Permits optimum use of technological improvements. 4. Encourages use of human beings. 5. Stimulates creativity. 6. Attains maximum efficiency with minimum costs. Planning is the brain of a business unit while organization is its physical structure. All managerial Functions like planning, directing, co-ordinating, controlling, budgeting, staffing etc. are performed· through the medium of organisation. Nature and Principle: Briefly they can be stated as under 1. It is a set up to realise the objectives (common purpose). 2. It is a co-operative activity. 3. It is a process (function) and structure both. 4. Division into Departments or groups. Division of labour. 5. Delegation of authority and responsibility. The chain of superior - subordinate relationship isknown as 'chain of command'. (Authority structure). 6. Importance of human element (people). 7. Vertical and horizontal relationship between man to man, job to job .and department to department. 8. It is closely linked with planning. Other functions of management are not possible withoutorganisation. 9. It is flexible and accommodates environmental changes. 10.It is stable and resists challenges. 11.Provides supervision, control and review. 12.Provides mechanism of co-ordination.
- 450. 13.Provides channels ofcommunication. 14.Provides policies, procedures, rules and regulations for systematic functioning. 15.Backbone of management and regenerates everything from beginning. Principles of Organisation (Features of a good Organisation Structure) : They aresummarised as under a. Unity of objective - all are geared to common objectives. b. Span of control - each superior has limited subordinates to report him. c. Unity of command - each subordinate has only one superior to get command. d. Scalar principle - clear chain of command from top to bottom. e. Co-ordination - should exist among all individuals and groups. f. Communication - should be open and clear. g. Facilitates leadership. 2. Parity of authority and responsibility - exist by way of delegation. 3. Exception principle - only matters beyond control may be referred to higher levels. 4. Functional definition - Functions (duties), authority and responsibility of every position should beclearly defined so as to avoid duplication or overlapping. 5. Efficiency - optimum use of resources at minimum possible costs. 6. Flexibility - should accommodate changes. 7. Stability - should resist challenges. 8. Continuity - by training and development of executives and employees. 9. Balance - between centralisation and decentralisation. 10. Division of work - one member one function. 11.Unity of direction - clear-cut direction at all levels. Directions should be simple, easy to understand and unambiguous. 12.Simplicity and clarity - they add to efficacy of organisation. Organizing for safety, Health, Environment. Planning:It includes setting safety objectives, formulating safety policy, safety programming,budgeting and determining safe or standard procedures. Good planting at the design stage always helps. Planning for site, effluent disposal, facilities for storing and handling raw materials, intermediates andproducts, types of floor, roof, construction, lighting,
- 451. ventilation, layout ofmachinery, pressure vessels,lifting machines, hazardous processes, boilers, storage tanks, repair services, auxiliaries, utilities, fireprotection, training, welfare and sanitary facilities etc., must consider safety points at this initial stage sothat the planning and design defects can be eliminated or minimised from the beginning. Previous plansapproval and correction after operation are also necessary. 2. Organising:It includes establishment of the formal structure of authority through which worksubdivisions are defined, arranged, and co-ordinated for the planned safety objectives.An organisational set-up describes four classes of management - Top or Executive, Intermediate,Middle and Supervisory management. The set-up may vary according to the size and nature ofestablishment. A model safety organization. The Company Board decides the safety policy and objectives and monitors its implementation. Managing Director is reportable to the Board for implementation of safety policy. Safety executive or safety department reports to MD. Managers are answerable to the Safety Department or Executive for application of the safety arrangements. Supervisors are reportable to the Managers for shop floor extension and application of safety policy, rules and procedures. Workers are responsible to their supervisors for effectively carrying out the safety rules and precautions. Safety Representatives selected from workers and supervisors advise and assist to Safety Committee for promoting health and safety.
- 452. Safety Committee adviseson all matters of safety and health to the Managers and the Managing Director. Staffing : It includes personnel function of recruitment and training the staff and maintainingsafe and favourable conditions of work through personnel. Directing : It is a continuous task of taking decisions, ordering, instructing, guiding and advisingon all maters of safety. Controlling : It includes performing, evaluating and correcting the performance according to objectives, procedures and plans. It is concerned with quality, times, uses and cost in safety matters.
- 453. Co-ordinating :It includes interrelating and synchronising the different activities for achievingsafety goals Organization structure, Function and responsibility The main points that follow from above definitions of organization are : 1. A business unit is divided into different sections or departments. 2. Each section or department is assigned a definite function or duty. 3. The authority and responsibility of each section or department or a group of people are clearlydefined. 4. The interrelationship among various departments and among the groups of people working inthem is clearly specified. See Fig.for a general organization structure. Safety Organization defined:Inferring from above general definitions. Safety organisation canbe defined as the structure and process by which groups of people (employees) are divided into sectionsor departments, each section or department is assigned specific safety function or duty. Authority andresponsibility of everybody is clearly defined and interrelationship between them is specified for theaccomplishment of organisational safely goals. A large unit may have safely department which may have groups of people for division of suchsafety function and responsibilities. But in a small unit (majority) if such division is not possible and onlya few persons are available for safety work, they will be assigned specific duty and other departmentalheads (production, purchase, personnel etc.) will be explained their role and responsibility towards safetygoals. All supervisors shall be integrated with safety as part of their duty. 'Safety is everybody's duty' willbe explained to all with their safety duty given in writing or by displaying at their workplaces.
- 454. Directing for Safety Directing: It is a continuous task of taking decisions, ordering, instructing, guiding and advising on all maters of safety. Definition:- Urwick and Brech - Directing is the guidance, the inspiration, the leadership of those men andwomen that constitute the real core of the responsibility of management. J. L. Massie - Directing concerns the total manner in which a manager influences the actions ofsubordinates. It is the final action of a manager in getting others to act after all preparations havebeen completed. Process : The process of directing consists of , the following steps : Issue orders and instructions. They should be clear, complete and within capabilities of thefollowers. Provide and continue guidance and supervision to ensure that the assigned tasks are carried outeffectively and efficiently. Maintain discipline and reward for good work. Inspire and motivate to work hard to achieve the goals. Principle and technique Principles of Direction : They are : 1. Harmony of objectives -Management should take care of personal goals of employees with the organizational goals. 2. Unity of command. -One subordinate should get orders/instructions from one superior only. 3. Direct supervision -There should be personal or direct supervision. 4. Good communication - Helps to improve understanding and speed of work. 5. Maximum contribution - Managers should try to get maximum possible contribution from eachsubordinate. 6. Appropriate techniques - The techniques should be suitable to superior, subordinates and situationto get efficiency. 7. Strategic use of informal organization- Some informal groups should be contacted to decidedirection. 8. Comprehension - Orders should be clear, complete and understandable. 9. Good Leadership - Managers should guide and counsel subordinates to win their confidence andtrust.
- 455. 10.Follow-up - Managersshould follow-up their orders and modify if necessary. Techniques of Direction: Generally four techniques are available for directing. They are Delegation of authority, supervision, orders and instructions. By delegation of authority a superior entrusts his subordinates with certain rights or powers. Heassigns a part of his work and authorises him to do work. Supervision means expert overseeing of subordinates at work to ensure compliance of plans andProcedures. At operating level it is most useful and effective. The terms order, instruction, directive and command are used interchangeably in managementliterature. They mean to initiate , modify or stop an activity. It is a primary tool by which activities arestarted, altered, guided and terminated. Leadership:- It is an indivisible part of the process of directing as explained in earlier part. It is a tool or meanswhich makes direction effective. Dr. Terry says that managers have to manage business which means thatthey have to provide leadership. They have to instil in them desire to achieve the goals, a desire toimprove their performance and a sense of co-operation. If the managers fail to provide such 'leadershipthe employees will search the leadership outside which may lead to conflict or distraction. Koontz and. O'Donnell - Leadership is influencing people to follow in the achievement ofcommon goal. Terry - It is the ability of influencing people to strive willingly for natural objectives. R. T. Livingston - It is the ability to awaken in others the desire to follow a common objective. Role and Functions of a Leader : 1. He should be clear about common objectives (goals) and should communicate them clearly. 2. He has to influence, guide, instruct, inspire and supervise his subordinates to work efficiently andeffectively. 3. He has to generate (awaken) desire in followers to achieve the common goal. 4. He works along with his followers, shows them how to work and gets their co- operation in return.
- 456. 5. He shouldconvince the followers that in protection of organisational (group) goals, lies theprotection of their personal goals. 6. He has to provide continuous guidance till the achievement of goals. 7. Depending on situation he should alter, modify or stop order and should not be rigid in hisdecision. 8. He has to set an example by his own behaviour. Urwick has rightly said that It is not what a leadersays, still less what he writes, that influences subordinates. It is what he is. And they judge whathe is by what he does and how he behaves'. An Attribute of leader:- 1. Attributes of a Leader : Certain qualities are necessary for leadership but they must be applied atthe correct place and time. Dr. Terry mentioned following qualities of a leader - 2. Energy - Physical and mental fitness to work by self and to guide for a longer time. 3. Teaching ability - He should be a good teacher. 4. Emotional stability- should be free from bias and anger and not emotional. 5. Empathy - It means the ability to understand other's viewpoint. He should have respect for othersand their beliefs. 6. Objectivity -He should be objective to others and should find out reasons for requests or refusal byhis subordinates. 7. Enthusiasm - is required in leader. He should be self motivated and capable of motivating others. 8. Knowledge of HR - Leader has to deal with human beings and therefore he should possesknowledge of human resources. 9. Communicative skill - He should be effective in his speech, talk and forceful impression. 10.Social skill - He should mix with his followers freely and socially. He should appreciate others'opinion and work with close co-operation. 11.Technical competence - Doubtlessly he must be technically more competent so that he cansuccessfully teach technical aspects. Leadership Styles (Techniques) : They are of three types - o Autocratic or Dictatorial leadership. o Democratic or Consultative or Participative leadership. o Free .Rein or Laissez Faire leadership. Autocratic leadership is useful when subordinates are illiterate, unskilled, untrained and secrecyin decision making is required. It can be applied when
- 457. there is aclear chain of command or clear-cutdivision of authority. Its features are retention of power, relying on orders only and close supervision. In democratic or consultative leadership method, the manager consults his subordinates andinvites their suggestions before making decision. Formal or informal meetings are also held. Heresubordinates work heartily because their views and opinions are respected. Close personal contacts andclear understanding of problems are ensured. It develops trust, co-operation and leadership amongemployees. This stage is useful when subordinates are literate, have sense of responsibility and organised. bIt requires much time in decision making. In free - rein leadership technique, the manager delegate authority to his subordinates and theyare encouraged to develop and contribute independent thought and action. This method is preferredmostly by highly educated and independent (free minded) persons. Here details are prepared by thesubordinates. There is a free communication between superior and his subordinates. They don't feeldifficulty in consulting each other. It is more creative and develops latent abilities of subordinates.Selection of leadership style depends on (1) force in Manager (2) force in Subordinates and (3)force in Situation. Communication :- It is a process involving the transmissionand-reception of message, eliciting meaning in the mind of the receiver and resulting in appropriateaction which is desired. Motivation cannot succeed without communication Haimann - Communication means the process of passing information and understanding fromone person to another. It is the process of imparting ideas and making oneself understand byothers. It is fundamental and vital to all managerial functions. Newman and Summer -It is an exchange of facts, ideas, opinions or emotions by two or morepersons. Koontz and O'Donnell -It is an intercourse by words, letters, symbols or messages, and is a waythat one organisation member shares meaning and understanding with another. Chester Bernard has stated "'The first executive function is to develop and maintain a system ofcommunication".
- 458. Purpose of communication:- It is utmost necessary for planning, decision making, organising, directing and controlling. Plans cannot be implemented without effective communication. Its basic purpose is to create mutual understanding and to secure desired response. Motivation and morale can be boost up. Human relations can be improved. Training and development is not possible without communication. Co-ordination can be bridged by communication. Public relations can be maintained and strengthened. It increases productivity and performance. It assists other functions. It gives job satisfaction. It is a basis of leadership. It gives success to enterprise. Process of communication:- According to Shannon and Weaver, it consists of followingcomponents or elements: Sender - One who sends a message. Message - What is conveyed by the sender. Encoding - Words, symbols, gestures etc. by which the message is transmitted. Channel -Medium or route through which, the message is passed" i.e. face to face, talk, phone,pager, radio, TV, letter etc. Receiver- Who receives the message. He may be a listener, reader or observer. Decoding - The process of understanding or interpreting by the receiver. Feedback - Means reply, response or acknowledgement of the receiver that he has understoodthe message. It may be by words, actions or expressions. When the sender receives such feedback,the process of communication becomes complete. See Fig.
- 459. Types and Channel Typesof Channels and Media of Communication: Communication Channels Media Formal Informal (Grapevine, inall directions) OralWritten Electronic Gesture Downward Upward Horizontal Diagonal A communication channel is a route through which messages flow from the sender to the receiver. It is either formal or informal. Formal (planned or systematic) communication may flow in downward, upward, horizontal or diagonal direction and creates communication networks. Informal i.e. unofficial or inter-personal (unplanned and need base) communication flows in all directions and therefore it is called structure less or grapevine. Essential tools in communication Tools of Communication:They are the means through which information is communicated. They canbe classified as under:
- 460. Oral (Verbal): Personal contact, talk, phone, meetings, audio, video etc. Written:Letters, circulars, memos, reports, notices, handbooks, manuals, booklets, magazines,Bulletins. Email etc. Visual: Newsreel, film, video, play, posters, pictures, boards etc. Informal : Casual or incidental talk, meetings etc. Barriers to Communication: Despite of growth in communication system and modern electronic media, it may fail due tofollowing barriers or obstacles. Incomplete, ambiguous or badly expressed message. Absence of clarity of thought. Absence of brevity and exactness, unwanted length, words, repetitions, over- elaboration etc. Timeliness i.e. the message does not reach in time. Lack of attention by the receivers. Organisational barrier - Scalar chain of command, filtering of message, discouragement to informal communication, excessive control etc. Status barrier - Subordinate has fear to report everything to superior and may hide unpleasantfacts. Perceptual barrier - Receiver may pay attention only on that part where he has interest or likingand may underrate or filter the message. Information overload - Due to overload work, managers may ignore some message, may forget toinform some people or may send incomplete message Premature evaluation - The receiver evaluates the message before getting complete information i.e.he derives premature conclusion. Channel distortion - Physical, Mechanical or electronic disturbance or mistransmission due to channel distortion. Improper order of information. Improper selection of medium. Emotional or sentimental messages. Change of meaning during transmission. Unwanted assumptions either by sender or receiver of both.
- 461. Essentials of EffectiveCommunication : Rules, principles or guidelines of effective communication or the measures to overcome its barriers are as under: Message should be clear, complete, and unambiguous and expressed properly. Information should be in proper order/sequence. Medium should be proper and effective. Channel should be sound and undistorted. Clarity - There should be clarity of thought. Brevity - Message should be brief, precise and perfect. Meaningless words, repetitions, and Excessive details should be avoided. Timeliness - Message should reach in time. Integrity - Message must be consistent with objectives, policies and programmes. Action and behaviour of the sender should support his message. Feedback - There should be follow up action (if necessary) to get feedback. Careful listening by the receiver is necessary. Strategic use of grapevine - The sender should try to fill up gaps in formal communication by strategic use of informal channel. Create a climate of faith, trust and good human relations to make the communication effective and respectful. Communication should be purposeful, at propel speed, sound and with synchronising. Line of communication (reporting) should be clear. Evaluation of communication system is useful for improvement. Two way communication Information Feedback Sender Receiver Adjusted Information Understanding Communication and group dynamics.
- 462. Keith Davisdefines "GroupDynamics" as the social process by which people interact face toface in small groups. Group dynamics is the study of forces operating within a group. It is the study of field that dealswith (1) Interactions and forces between group members in a social situation (2) The nature and development of small groups (3) Interactions among members and inter group behavior (4) How a group should be organized and operated and (5) Nature, Structure and processes of a group, and their influence on the behavior and performance of group members. The assumptions underlying the study of group dynamics are as under: 1. Groups are inevitable and ubiquitous. 2. Groups can produce both good and bad consequences. 3. Desirable consequences from groups can be obtained through correct understanding of groups andtheir functioning. 4. Groups mobilise powerful sources that produce effects of utmost importance to individuals. Team building The groups perform four functions of (1) Socialising the new employees (2) Getting the work Done (3) Decision making and (4) Control measures. Group dynamics states following characteristics of a group : 1. Structure - Each member occupies a position in the group depending on his status, power,experience, aggressiveness etc. Leadership is a special status. 2. Roles - Depending on position, the members perform three types of roles : expected role,perceived role and enacted role. 3. Norms - mean prescriptions for acceptable behaviour determined by the group. 4. Informal managerial roles - Managers can perform three types of roles (1) Interpersonal 'roles as a figurehead, leader and liaison officer. (2) Informational roles as disseminator, monitorand spokesperson. (3) Decisional roles as entrepreneur, disturbance handler, resource allocator and negotiator (Henry Mintzberg). 5. Informal communication system - or grapevine communications in all directions should beutilised to attain objectives.
- 463. Supervisors' good behaviourwith their workers, informal relations and taking interest in theirpersonal matters and paying constant attention for their individual growth, give desired results. Such behaviour is much more useful to make the workers safety Oriented. Sympathetic and fatherly behavior is the best form of communication. Group dynamics should not disintegrate the organisation, rather it should strengthen integration. Art of communication should be developed for this purpose by giving special training to the superiors. NATIONAL POLICY ON SAFETY, HEALTH AND ENVIRONMENT AT WORK PLACE The Constitution of India provide detailed provisions for the rights of the citizens and also lays down the Directive Principles of State Policy which set an aim to which the activities of the state are to be guided. OBJECTIVES: The policy seeks to bring the national objectives into focus as a step towards improvement in safety, health and environment at workplace. The objectives are to achieve:- a) Continuous reduction in the incidence of work related injuries, fatalities, diseases, disasters and loss of national assets. b) Improved coverage of work related injuries, fatalities and diseases and provide for a more comprehensive data base for facilitating better performance and monitoring. c) Continuous enhancement of community awareness regarding safety, health and environment at workplace related areas. d) Continually increasing community expectation of workplace health and safety standards. e) Improving safety, health and environment at workplace by creation of “green jobs” contributing to sustainable enterprise development. ACTION PROGRAMME: Enforcement: 1 by providing an effective enforcement machinery as well as suitable provisions for compensation and rehabilitation of affected persons; 2 by effectively enforcing all applicable laws and regulations concerning safety, health and environment at workplaces in all economic activities through an adequate and effective labour inspection system; 3 By establishing suitable schemes for subsidy and provision of loans to enable effective implementation of the policy;
- 464. 4 by ensuringthat employers, employees and others have separate but complementary responsibilities and rights with respect to achieving safe and healthy working conditions. National Standards: 1 by developing appropriate standards, codes of practices and manuals on safety, health and environment for uniformity at the national level in all economic activities consistent with international standards and implementation by the stake holders in true spirit 2 by ensuring stakeholders awareness of and accessibility to applicable policy, documents, codes, regulations and standards Compliance: 1. by encouraging the appropriate Government to assume the fullest responsibility for the administration and enforcement of occupational safety, health and environment at workplace, provide assistance in identifying their needs and responsibilities in the area of safety, health and environment at workplace, to develop plans and programmer in accordance with the provisions of the applicable Acts and to conduct experimental and demonstration projects in connection therewith; 2. by calling upon the co-operation of social partners in the supervision of application of legislations and regulations relating to safety, health and environment at work place. 3 by continuous improvement of Occupational Safety and Health by systems approach to the management of Occupational Safety and Health including developing guidance on Occupational Safety and Health management systems, strengthening voluntary actions, including mechanisms for self-regulatory concept and establishing auditing mechanisms which can test and authenticate occupational safety and health management systems; 4 by providing specific measures to prevent catastrophes, and to co-ordinate and specify the actions to be taken at different levels, particularly in the industrial zones with high potential risks. 5 by recognizing the best safety and health practices and providing facilitation for their adoption. Awareness: 1. by increasing awareness on safety, health and environment at workplace through appropriate means.
- 465. 2. by providingforums for consultations with employers’ representatives, employees representatives and community on matters of national concern relating to safety, health and environment at work place with the overall objective of creating awareness and enhancing national productivity 3. by encouraging joint labor-management efforts to preserve, protect and promote national assets and to eliminate injuries and diseases arising out of employment 4. by raising community awareness through structured, audience specific approach 5. by continuously evaluating the impact of such awareness and information initiatives Research and Development: 1. by providing for research in the field of safety, health and environment at workplace, including the social and psychological factors involved, and by developing innovative methods, techniques including computer aided Risk Assessment Tools, and approaches for dealing with safety, health and environment at workplace problems which will help in establishing standards; 2. by exploring ways to discover latent diseases, establishing causal connections between diseases and work environmental conditions, updating list of occupational diseases and conducting other research relating to safety, health and environmental problems at workplace 3. by establishing research priorities as per national requirements; exploring partnerships and improving communications with various national and international research bodies 4. by ensuring a coordinated research approach and an optimal allocation of resources in Occupational Safety and Health sector for such purposes. CHAPTER 2.SAFETY- EDUCATION AND TRAINING: Elements of Training Cycle : As per OSHA (Occupational Safety & Health Act)’s training guidelines, seven chronological steps are suggested to complete a training cycle. These are the basic elements of any safety training programmed. Fig. shows them in a cyclic order. ( 1) Determine whether training is needed or start up of improved programmed from step (7) 7) Improve the programmed (2) Identify training needs
- 466. (3) Identify goalsand objectives (6) Evaluate Programmed effectiveness (4) Design and Develop Training Programme (activities) (5) Conduct the training (methods &types3333) Fig 6.14 Training cycle These steps are explained as under: 1. Determine if training is needed - The first step is to determine whether a problem can be solved by training. All skill deficiencies are not solvable through training and some other tool may be required. This step includes need of any improved (revised) training programme. 2. Identify training needs - Analyse the worker's duties and what he or she needs to perform the job more skillfully and safely. 3.Identify goals and objectives -A list of specific job knowledge and skill deficiency derived from Step-2, will fell employers what workers should do, do better or stop doing. 4. Design & Develop training programme- After listing precise objectives and goals, learning (training) activities must be identified and described. Type of training will be decided based on the training resources available to the employer, the kind of knowledge or skills to be learned and whether the learning should be oriented towards physical skill or mental attitudes. 5. Conduct the training - Now the training programme should be conducted by (a) providing overviews of the material to be learned and (b) relating each specific item of knowledge or skill to the worker's goals, interests or experience to be learned. 6. Evaluate programme effectiveness - By knowing trainee's opinion, supervisor's observation, work place improvement, hazard reduction, performance improvement etc., it should be checked whether the training has accomplished its goals. 7. Improve the programme- Based on feedback from the workers, supervisors etc., and from evaluation and observing the gap, the training programme should be improved (revised) as per need. Assessment of Training Needs :
- 467. The first stepof any training process (cycle) is to be sure about the needs. Following four questions (approaches) should be considered: 1. Does an actual or potential performance discrepancy exist ? (viz. unsafe conditions, actions, efficiency). 2. Is it important to the organisation ? (viz. in reduction of cost of accident, hazards, losses etc.). 3. Is it important to the employees ? (viz. basic training to new employees, refresher course for old employees, more mistakes by workers, more accidents to them). 4. Is it correctable through training? (If yes, then only the training becomes useful and cost effective. General training needs are assessed from following grounds: 1. New employees are not very clear about job description. Therefore training is essentially required for them. 2. Old employees require knowledge of new topics, new technology, process revision, new methods and forgotten old items. Training for emergency preparedness, safety audit, fire fighting, hazard detection etc. are also necessary for them. 3. Change of position due to promotion or transfer. New position may require training. 4. Technological changes in the organisation. Addition of new material, machine, method, process, equipment etc. create need of training. 5. To make a person more versatile to do more than one job (safety supervision, accident analysis and computer data feeding). 6. When performance, productivity and efficiency fall down at any level, training may improve them. 7. Supervisors/foremen feel need of training for workers working under them. 8. Records of production, turnover, accidents, absenteeism, rejects, errors, wastes point out areas of training. The safety training programme is generally needed for all the times as an induction or introductory course or a refresher or ongoing course but is specifically needed when New employees are recruited New plant, material, process or equipment are introduced When safety procedures are evolved or updated New information of hazard is received Safety performance needs to be improved The accident rates are increased Labour turnover is increased and Excessive waste, rejects and scrap are noticed.
- 468. Objectives of Training: Trainingcannot and should not be started without any pre-decided objective. Training without objective (purpose) or for the sake of training is of no use and becomes wasteful activity. Training need must be assessed first and from that the objective(s) should be specified as under : 1. Transmitting information about policy, product, services, accident causes and remedial measures,new process, methods and technology or the company itself. 2. Developing skill for safe behaviour and to work efficiently. 3. Modifying attitudes more favourable to safety, production, co-operation, discipline etc. 4. To give a worker a new, necessary and broader view point of his safety responsibility 5. To explain him potential hazards of unsafe working conditions, actions, environment and safe views to prevent them and 6. To increase his safety consciousness, perception of danger, knowledge, experience, confidence, responsibility and ability in safe performance. Techniques (Procedure) of Training: Competence Building Technique (CBT) The concept or basic object of any training is to generate or build competence in participants (workers). Only knowledge is not sufficient. Knowledge alone cannot give competence or confidence of safe or successful working. Knowledge should be put into practice by necessary training. Training shows the practical part of knowledge and generates competence of work gradually. Competence in safe working is necessary. Due to advancement in technology, new processes, new equipment, modification or changes, training is always required to become familiar with tins. Therefore, safety is an online function. It should not end with any slogan, suggestion, award or safety day Celebration. It should be considered as' a part of continuous or ongoing activities. For this purpose, induction training and refresher training are organized. Effective communication system should be utilized. Role of multimedia and computers should be utilized. Safety films, pictures, hazard points, accident case studies etc should be shown and explained during training. A good safety training programme contains following steps: 1. Determine safety training needs and priorities .
- 469. 2. Design trainingto meet the needs. The steps are: (a) Assess training requirements (b) Determine training contents (c) Decide training methods and aids (d) Organise training content (e) Formulate training plan and (f) Decide evaluations measures. 3. Implement training process. The steps are: (a) Discuss with company officials (b) Decide administrative aspects and time schedule of training (c) Execute (give) training to the decided trainees (d) Monitor the programme (e) Conduct review of safety training and (f) Have follow up of trainees. (A) Off-the-job training techniques : No. Category Techniques (methods) 1 1. Information presentation techniques (less involvement of trainee). Reading list, Correspondence course, Films, Lecture, Panel discussion, Programmed or Computer based instruction. 2 2. Information processing techniques (trainees are involved). Conference or discussion group, T (training) group. 3 3. Simulation techniques (experiment or practice). Incident / case, role playing, In-basket, Vestibule, Mock-up, Business game. (B) On-the job training techniques : No Category Techniques(methods) 1 Actual job assignment Coaching, Job instruction training (JIT). 2 Temporary job assignment Special assignment on job, committee, project etc. job rotation through
- 470. predetermined set ofjobs to provide exposure to different part . Design and development of training program. Any training programme should be designed for its specific purpose. Design and development of safety training programme need systematic job safety or risk analysis. For steps (detail) of such analysis Following general points are useful in designing and developing any training programme. 1. Motivation should be the first condition of any type of training. 2. Number of lessons and content to teach should be well designed beforehand. Steps or sequence of topics should be decided. 3. The amount to be taught in an unit (period) should not be too large or too small. 4. An objective of the training should be decided and the training process should move toward it. The training procedure should be developed.' A list of training aids should be prepared. 5. The task to be performed should not be described only but it should be demonstrated in actual or simulated conditions. "Doing" is important than mere "Hearing" or "Seeing". Practice makes man perfect. 6. The demonstration (by teacher) should be followed by the learner (trainee) as soon as possible before' he forgets it. The teacher should be given feedback or knowledge of results. 7. Questions of learners should be properly replied and discussed at all stages (steps). 8. Ample practice opportunity should be provided and practice encouraged. 9. Frequent and accurate knowledge with examples, pictures, practical etc., speeds up learning rate and motivation. 10. The training should be taken to the point of goal and not be left unfinished. 11. Effectiveness of the training should be evaluated and conclusion be drawn to revise (improve) the training programme and it should be followed in the next cycle. The basic design of any training should consist: 1. Identifying the component tasks of a final performance. 2. Ensuring (in training) that each of these tasks is fully achieved or mastered by the learner. 3. Arranging the training of the task components in such a way that there will be positive transfer from learning of one to another. The design work may be done by specially designated training professionals, especially for programs to be offered several times or left to individual instructors.
- 471. Main design stepsinclude (1) Setting instructional objectives (2) Determining programme content.. and (3) Selecting instructional techniques for off-the-job and on-the-job training. Training Methods and Strategies : Aspects and Goals : The training methods have two aspects: 1. Theoretical or formal in the classroom and 2. Practical or informal in the job place. There are two basic goals : 1. To explain the worker to know the job and to do it correctly and 2. To be certain that he knows how to do it ' correctly. Steps: Any training method should have following steps: 1. Lay down the objective of the training programme. 2. Prepare the training programme. 3. Brief the trainee. 4. Use audio visual aids where appropriate. 5. Review the contents and 6. Follow up with trainees when the programme is completed. Effects of Methods : Effectiveness of different training methods is given by Bird as follows: A trainee tends to remember 1-10% of what he reads, 20% of what he hears, 30% of what he sees,50% of what he sees and hears, 70% of what he sees as he talks and 90% of what he says as he does a thing. This percentage is variable depending upon one's memory power, intelligence, grasping,understanding, susceptibility and interest in the subject. It also depends upon the explanation power.These factors can be developed by education and training. Speaking, writing, involving and doing are the most effective exercises to digest any subject. Types of Methods : Some usual methods are: Lecture method, discussion method, case study, role play, project work, programmed instruction, on-the-job instruction, training aids, fault analysis, algorithm as an aid to fault analysis, fault tree analysis, drill, demonstration, panel or group discussion, meeting, simulation, pictures and posters, films and closed circuit television, filmstrips and slides, projectors and microphones, charts, boards, and working models, checklists, exercise, rehearsal and use of press and other mass media. Thus methods are many from old to the ultramodern. Which method is the best? No one method can be named. Appropriate method should be selected depending upon the size, age and experience of the group, the amount of material, type of presentation necessary and time and money available. Selection of method requires skill and
- 472. experience. Result ofeffectiveness depends upon it. Therefore make the best choice of the method and apply it successfully. Display of relevant safety posters at workplaces contribute much without saying. Some common methods in use are mentioned below: 1. Lecture Method : Oldest and most basic method. Well planned lectures can cover a large amount of information in a short time. More useful when participants are more, or their involvement is less required. 2. Discussion Method : Useful with small number of people in a group. The trainer acts in a limited way as a scene setter or referee encouraging participants to speak out. The two way communication moves toward objectives. Participants are more attentive, active and don't feel boredom. 3. Case-study Method : Accident case study is presented explaining how an actual accident happened or an imaginary accident can happen. Causation analysis and remedial measures can be discussed by questions and answers. Good pictures are more useful to explain the situation effectively. 4.Role playing method : It is a form of learning by doing but in a simulated situation. Trainees are given 'a situation like in case-study method but instead of just discussing it they resolve the problem by acting out the roles of the people involved. Here extrovert trainees show their skill but introvert or shy trainees unused to such situation get embarrassed. 5. Business Games Method: More useful for business people and skill required for safety attitude or inspection in buying/selling items which are more safe or with the details of safety. 6. Sending at training Centres : Institutes, seminars, workshops, special courses etc. utilizes external resources for required training. 7. Job instruction training: Useful to train supervisors who in turn train the employees. Job instruction training (JTT) involves four steps. (1) Preparing the trainee. (2) Demonstrating the job. (3) Having the trainee performed the job. (4) Checking frequently the trainee's performance.All new job assignments should be preceded by on-the-job training. Each step of job safety analysis (JSA) is explained with hazard, safe procedure and use of safety equipment. Use of guards and controls are also explained. 8. Programmed instructions : Programmed instructions are given in a book form. A trainee learns it, answers the question or solves the problem. The system has mechanism of learning-checking and relearning.
- 473. 9. Project work: Project writing is given to trainees. They apply their knowledge to practical situations. 10. Other methods : Job rotation, committed assignments, HRD training, sensitivity training, creativity training, in-basket training etc. are other specific methods. Types of Safety Training: Types of safety training are formal and informal. Formal training may be general or specific. General Training includes - 1. Induction courses for new employees. 2. On-going safety training. 3. Safety representative training. 4. Supervisory training. 5. Senior/ middle management training and 6. Directors training. Specific Training includes - 1. Safety system of work for particular operations where the potential hazard is high and guarding is not feasible. 2. First aid training. 3. Specific items of plant or equipment. 4. Use of protective equipment. 5. Fire precautions. 6. Safety inspections. 7. Change of job for which a worker is not trained. 8. Role of workers in emergency planning. 9. Techniques of safety audit, Hazop, Hazan, FTA, ETA etc. 10. Safety permits system. Some details are given below: 1. Orientation or Induction Training : It is obvious that new employees may not be knowing much about the factory they joined, its safety policy, specific raw-materials, their characteristics, processes, methods, pollution control, health check-ups, role in emergency planning, first-aid, fire fighting, use of personal protective equipment, accident record, hazards of their work, remedial measures and workplace monitoring etc. Therefore it is always useful to design training on such subjects for the new employees. This basic knowledge builds their confidence, skill and interest towards the work and the company both. 2. Apprenticeship Training : A learner who has just completed his school or college education or is still undergoing it and agrees to work as a trainee or apprentice or
- 474. employed under theApprenticeship Act as an statutory requirement, is given this type of training. It is a combination of on the job and off-the-job training taking the strengths of both. Intention is to show him the practical or applied part fitting to his type of education. 3. On-the-job trainingis practical in nature and generally takes place on the job. Such job contact sessions may involve individual on one to one basis with the supervisor training an operator for the work he has to carry out. First the supervisors are trained for this purpose showing them the job safety or risk analysis. Then in turn they train the employees mostly new. It imparts necessary skill for the job involving worker to do the job systematically and safely. Injury to the trainee or the job is possible due to normal mistake of the trainee. Therefore its usage is limited to situations where mistakes can be tolerated. Airline pilots and Surgeons are allowed on the job practice only after their skills have been sharply honed using off the job simulation techniques. Some methods used in this type of training are coaching (personal attention), job instruction training (JIT), special assignment and job rotation. It is supervisor's or training instructor's responsibility to train the employees under him for safe methods, machine guarding, identification of hazards in each step and its remedial measure, need and use of safety equipment, avoidance of shortcuts, hasty actions, overconfidence etc. 4. Off-the-job training: All types except on-the-job are called off-the-job training. It includes classroom or lecture method, audio-visual, film, reading list, books, correspondence course, panel discussion, conference or discussion group, T-(training) group, computer based instruction, case study, role playing, in-basket, vestibule, mock- up, business game etc. and explained as "training methods" earlier. 5. Vestibule Training: It is an approach between on-the-job and off-the-job training and used when the job is dangerous and can harm the trainee if taught on the job. The training takes place away from the actual work place but the equipment and procedure to be followed are similar to be used on-the-job. 6. Individual and Team Simulations: Equipment and procedures that duplicate actual equipment and work conditions as closely as possible are known as "simulators" e.g. set up for training pilotsand astronauts. When economic or human costs of error are very high, this type of training is safeand cost effective. 7.Team Training: It is required to increase coordination and co-operation amongst team members and make them realise that their behaviour may help or hinder co- workers from performing effectively. 8. Individualised or Programmed Instructions:This is a technique to supply instruction through printed material or machines. Safety instructions by placard, slides, banners, notices, boards, film, transparencies, check list etc. are useful. It eliminates need for an instructor and trainees can learn when and where they choose. They do not
- 475. have to beassembled at one place and one time. This type is useful where a number of trainees cannot be spared from their duties simultaneously. 9. Modern methods of Training: It is a derivative of programmed instruction and utilises computer as medium of instructions. A computer is fed with the entire programme of presenting material asking questions and evaluating responses. The computer adjusts instructions according to the learner's abilities, prior'knowledge and his replies to computer's questions. It is like a private tuition by a computer as teacher who has full command of the subject and who never gets tired of repeating replies. It gives immediate feedback without sarcasm, anger or error. The disadvantage is the cost of computers and programs if they are need in bulk to supply individually. 10.Other types: Types are also classified as technical training, HRD training, safety training, productivity or creativity training, voice training, ISO training, computer training, customer training, supervisor's training, training for training etc. Now-a-days importance of training is widely accepted at all levels. Type should be selected best fitting to our need and budget. Training of Workers and Supervisors : Safety training should begin with every new worker and continue till he is in the service. Successive steps may be increased. Japanese system of weekly training (one day .in each week for training) is the best example of such training. The type of training, frequency, content and trainer may vary according to the need and type of industry. Training to New Workers : Safety training should be given to all new workers, irrespective of previous experience. He should be taught: 1. Safety Policy, rules and practices of the company. Provisions for safety committee. 2. Worker's duties and rights under the Factories Act and other safety statutes. 3. Emergency signals and their meanings. 4. Observance of warning signs and symbols. 5. Location of means of access, phones, fire alarm and extinguishers, emergency exits and procedure, first-aid and ambulance room, safety office, assembly points etc. 6. Types of protective equipment, their need and practice to wear them. 7. Types of hazards of his job and safeguards provided and to be maintained. 8. Safe practice and full job instruction for his job. 9. Codes and standards to be followed. 10. Records to be filled in. 11. Means of reporting hazards, absence of guard or defective equipment. 12. Need for good housekeeping. 13. Types of frequent accidents in his plant and means to avoid them. 14. Not performing any new job or machine without first learning from the supervisor.
- 476. 15. Seeking medicalassistance in case of any type of injury and reporting it to the supervisor. Even older and experienced workers need periodical job safety training and new knowledge to them. Safety meetings and .various types of safety refresher courses should be arranged to increase their job-training and safety performance. Training to Supervisors: Training to supervisors is most important because safety and production control are associated with supervisory functions and it is their main duty to prevent accidents. Objectives of safety training to supervisors include 1. To explain them their principal responsibilities of establishing work methods, giving job instruction, assigning people to job, supervising people at work and maintaining good housekeeping, plant and equipment. 2. To acquaint them with the company's safety policy, rules and practices. 3. To emphasise that accident investigation work is solely for prevention purpose and not for fixing blame. 4. To establish their status of a key-man for safety and production. 5. Ways and means to maintain safe conditions and actions. 6. Special information on accident causes and methods of prevention, particularly in their areas "of work. Case studies of actual accidents. 7. Job instructions for safely, supervising for safety, accident reporting, investigation and. Record writing, job safety and risk analysis and group meetings for safety etc. 8. Ways and means of job training to workers and training aids. 9. How to participate in planning of safety programme and safety committee. 10. Solving of supervisory problems. The steps are : (a) Identify the problems. (b) Find and verify the reason for the existence of the problem. (c) Select the appropriate remedy and apply the remedy. Kinds of Supervisory Problems: 1. Work Problems: (1) Error of commission or omission (2) Insufficient work (3) Poor work quality (4) Breakage, wastage, spoilage etc. (5) Improper methods, tools, equipment etc. 2. Procedure, Rules etc.: (6) Violation of rules (7) Failure to report facts
- 477. (8) Abuse ofprivileges (9) Failure to maintain premises, tools etc. (10) Play, gossip, loafing etc. 3. Additional Problems: 1. Direct refusal or insubordination 2. Assumption of unwanted authority 3. Loose talk 4. Ridicule of criticism of the company 5. Creating disturbance, noise etc. 4. Personal Problems: 1. Dissatisfaction, wages, treatment, unhappiness 2. Chronic tardiness –or absence 3. Outside, home, social situations 4. Demands for premature promotion 5. Trivial tale bearing. Reasons and Remedies of Supervisory Problems: Reasons for existence of problems: (1) Lack of skill (2) Insufficiently informed, misunderstands (3) Not convinced-indecision (4) Finds standard procedure difficult, awkward etc. (5) Spare, light, tools etc. inadequate, unsafe etc. (6) physically unsuited (7) Personal characteristics unsuited. Remedies: (1) Engineering or process revision (2) Persuasion and appeal (3) Personnel adjustment (Placing and medical treatment (4) Psychological treatment and (5) Discipline. Evaluation & Reviewing of Training Programme : An evaluation i.e. measurement of effectiveness or result of the training programme conducted, is useful in reviewing .the programme content, method, aid and redesigning the programme as per feedback for improvement. An effective training programme should show;
- 478. 1. Increase inquantity and quality of production. 2. Increase in production rate. 3. Increase in knowledge, skill and ability about job performance. 4. Increase in job satisfaction and motivation. 5. Decrease in accident rate. 6. Decrease in production time, breakage or use of consumable items. 7. Decrease in absenteeism. 8. Decrease in labour turnover. 9. Decrease in job turnover. 10. Decrease in operational cost. 11. Refinement of human behaviour towards intended objective or goal viz. safety outlook, interest and safety mindedness, production and quality orientation etc. The benefits of value measurement of safety training programme are: 1. The top management understands usefulness and cost effectiveness (in relation to accident costs) of the training programme. 2. Confidence, morale, skill, status, prestige etc. of the employees and the company itself are seen improved. 3.Most effective loss prevention measures can be segregated for repetition. 4. Strengths and weakness are highlighted and suggest the steps for next programme. 5. Safety professional can find out and promote most effective programmes. 6. It can be determined whether objectives/goals are met and reason of gap if any. This is useful in reviewing the programme. For evaluation participant and/or supervisors reaction should be assessed through interviews or questionnaires. Following questions are useful in such assessment. 1. How much change occurred ? The criteria include knowledge, attitudes, skills, behavioural change on the job and/or improvements or decrements in organisational results. These criteria can be measured by paper and pencil tests, questionnaires, work sample tests, timings of performance etc. 2.Can the change attributed to the training programme ?
- 479. 3. Was thetraining worth the effort ? Here cost of training is justified against gain to the organisation. Whether employee development needs are fulfilled ? TYPES OF TRAINING AIDS Following aids are useful in training : 1. Black boards, magnetic boards and flannel boards. 2. Charts, drawings and posters. 3. Slides, filmstrips, transparencies and overhead projector. 4. Printed material like books, manuals, handouts etc. 5. TV and Movies. 6. Scale, models, mock-ups, training devices and simulators. 7. Computers, Software (e.g. power point, page maker, graphic design and display etc.), CDs, LCD projector etc. Training or teaching aid should be selected judiciously to make learning interesting, meaningful and without boredom or monotony. Just after lunch interval in the afternoon, film may be more effective than mere lecture. Where machines and equipment are used as aid, they should be safe and clean and their safety and ergonomic aspect should also be explained. CHAPTER: 3 EMPLOYEE PARTICIPATION IN SAFETY Employees are the major work force working under hazards. Some know the hazards and some do not It is of great importance that they must realise that they would be the first victim of any accident, their safety awareness and all accident prevention work is in their interest and therefore their active participation in showing hazards and helping in removing them by the joint efforts of management and all employees is most desirable.
- 480. Section 41G ofthe Factories Act speaks worker's participation in safety management. A method of safety committee is suggested. Right of workers to warn about imminent danger is also created by sections 41 H 111A of the Act. Display of the Extract of the Act and Rules (Section 108(1), Rule 106 and Form No. 23) is for the same purpose of making workers aware and to call for their participation. Some areas and methods of participation are discussed below: Areas of Participation : General areas of participation are as under : 1. To set safety goals and training programmes. 2. To design and improve standard operating procedures (SOPs) and methods of operation. 3. Appraisal of progress towards goals. 4. To give, collect and discuss safety suggestions and to implement which are necessary. Rewards for good suggestions boost up motivation for participation. ' McGregor's theory states that participation management has a basic belief in the competence and abilities of individual employees regardless their status in organisation. Employees' and supervisory participation is essential for success of any safety programme. When workers are taken into confidence in designing any .safety programme or goal they feel themselves responsible for its success. This element of involvement and joint responsibility is most fundamental to employee participation. Workers' and Trade Union's Participation: Equal number of safety representatives from workers (or their union) and management should constitute their joint safety committee. This may be a central one or different in different plants. All must be sincere in their desire to co-operate in the matters of safety. Scope of the activities and agreement should be limited to Safety. Union representatives should be selected from the basis of their safety knowledge, interest and experience and should be cooperative and sincere. They should not bring other union demands like bargaining, grievance setting etc. in the meeting of safety committee. Union must recognize management's right of leadership in a joint safety programmed. Accident prevention is an area of mutual interest and not of dispute or quarrel. Therefore the workers or union must participate to show their abilities in this area and thus strengthening their relationship with the management and saving their own lives from accidents. Supervisor's Safety Contact: role of the supervisors is explained at length. By their key position between workers and management and by their constant contact with workers they can easily and effectively promote workers' participation in safety. The
- 481. supervisor should alwaystry to get such participation. A critical incident technique explained in Part 1.11 and -1.12 of Chapter-19 is based on such safety contacts of plant people. Safety contact by safety manager, safety engineer/officer is also useful. MAIN SAFETY COMMITTEE OR CENTRAL SAFETY COMMITTEE As per factories act 1948, section 41G it's mandatory to form safety committee and the details as follows: 41G. Workers' participation in safety management. (1) The occupier shall, in every factory where a hazardous process takes place, or where hazardous substances are used or handled, set up a Safety Committee consisting of equal number of preventatives of workers and management to promote cooperation between the workers and the management in maintaining proper safety and health at work and to review periodically the measures taken in that behalf: Provided that the State Government may, by order in writing and for reasons to be recorded, exempt the occupier of any factory or class of factories from setting up such Committee. (2) The composition of the Safety Committee, the tenure of office of its members and their rights and duties shall be such as may be prescribed. Rule prescribed under sections 41 and 41G ; As per Maharastra Factories Rules 1963 it's as follows: 73-J. Safety Committee - (1) In every factory- (a) wherein 250 or more workers are ordinarily employed; or
- 482. (b) which carrieson any process or operation declared to be dangerous under section . 87 of the Act; and employs more than 50 workers; or (c) which carries on 'hazardous process' as defined under section 2(cb) of the Act and employs more than 50 workers, there shall be a Safety Committee. (2) The representatives of the Management on Safety Committee shall include- (a) A senior official, who by his position in the organization can contribute effectively to the functioning of the Committee, shall be the Chairman; (b) A Safety Officer and Factory Medical Officer, wherever available and the Safety Officer in such a case shall be the Secretary of the Committee; (c) A representative each from the production, maintenance and purchase departments. (3) The workers' representatives on this Committee shall be elected by the workers. (4) The tenure of the Committee shall be two years. (5) Safety Committee shall meet as often as necessary but at least once in every quarter. The minutes of the meeting shall be recorded and produced to the Inspector on demand. (6) Safety Committee shall have the right to- (a) ask for necessary information concerning health and safety of the workers; (b) seek any relevant information concerning health and safety of the workers. (7) Functions and duties of the Safety Committee shall include- (a) assisting and co-operating with the management in achieving the aims and objectives outlined in the 'Health and Safety Policy' of the occupier; (b) dealing with all matters concerning health, safety and environment and to arrive at practicable solutions to problems encountered; (c) creating safety awareness amongst all workers; (d) undertaking educational, training and promotional activities;
- 483. (e) deliberating onreports of safety, environmental and occupational health surveys, emergency plans safety audits, risk assessment and implementation of the recommendations made in the reports; (f) carrying out health and safety surveys and identify causes of accidents; (g) looking into any complaint made on the likelihood of an imminent danger to the safety and health of the workers and suggest corrective measures; and (h) reviewing the implementation of the recommendations made by it. 8. Where owing to the size of the factory, or any other reason, the functions referred to in sub-rule (7) cannot be effectively carried out by the Safety Committee, it may establish sub-committee as may be required, to assist it. Plant safety committee:- Plant safety committee is constituted to discuss safety related activities and take immediate measure on the suggestion made by the members to keep the plant safe .It encourage and ensures the use of ppe’s and also get the safety suggestion from workers . Plant safety inspection is being carried out with the help of plant safety committee members. Plant managers chairs it and plant in-charge or safety officer acts as a secretary.Concerned officer employees from mechanical ,electrical,instrument,are nominated as member. Technical safety committee:- is useful for specialized knowledge on guards,process,safety, and revision to improve safety and risk analysis, accidents investigation etc. Safety committee: structure and function Statutory Provisions: A new provision was added since 23.09.87, u/s 41 G of the Factories Act to set up a safety committee consisting of equal number of representatives of workers and management to promote cooperation between the workers and the management in maintaining proper safety and health at work and to review periodically the measures taken in that behalf. Thereafter by addition of rules 73 J in the Maharastra Factories Rules, following Revisions are added regarding safety committee: Applicability: 1. Factories employing workers more than 250. 2. Factories carrying dangerous operations u/s 87.
- 484. 3. Factories listedin the First Schedule. Formation, Tenure & Rights: 1. A senior official shall be the Chairman. 2. A Safety Officer or Factory Medical Officer shall be the Secretary. 3. A representative each from the production, maintenance and purchase departments shall be members. 4. Workers representatives, of equal number, shall be elected by the workers. 5. The tenure of the committee shall be 2 years. 6. At least one meeting in 3 months. Minutes shall be recorded and produced before the Factory Inspector on demand. 7. The committee has right to be informed of potential hazards of work places and data on accidents and working environment. The committee shall keep the data confidential and use it solely to guide on safety measures. Functions & duties: 1. Co-operation to implement health and safety policy. 2. All matters of health, safety and environment and solutions to problems in that regard. 3. Creation of safety awareness amongst workers. 4. To conduct educational, training and promotional activities. 5. To discuss reports on safety, health and environmental surveys, safety audits, risk assessment, 1. emergency plans and implementation of the recommendations of the reports. 6. To carry out health and safety surveys and identify causes of accidents. 7. To look into complaints of imminent danger and suggest corrective measures. 8. To review the implementation of its own recommendations. 9. To form sub-committees, if necessary. The main object of the committee is to advise to Managing Director and the Safety Board or the top executive of the company on all matters of safety and health of the workers. It is not a substitute for the management. Like other committees it is an organ or part of the management function and helps the management in specific area of safety. It is a body of safety representatives for group suggestions and decisions, co- operative safety efforts and a two-way channel of communication through which suggestions can flow from employees to management and vice versa. It does not bypass the overall management control of general supervision and communication, but it aids to it. Its advantages are:
- 485. (1) brings togethervarying view points, yield sounder .decisions than the individual members. (2) widens interest by allowing participants of work-people in their own .work and. (3) allows checks and cross-checks by different opinions which are essential for safety. Toolbox Talks: Toolbox talks are a way to ensure all workers are participating in safety activities, and have an opportunity to discuss hazards/controls, incidents and accidents. As part of the Health and Safety at Work Act, employers must provide employees the opportunity to regularly engage in health and safety discussions. If you are a Site Safe Member, you can access Site Safe Toolbox Talks to help guide you through relevant and beneficial health and safety discussions. Sign in to the members area (/Portal/login)to gain access to your members only Toolbox Talks. There's a wide range of topics to choose from so you can tailor these discussions specifically to your project. How to run a toolbox talk Inform workers of changes to company procedures Identify new hazards and review existing hazards Develop/review hazard controls Discuss/review accident and incident data Discuss the work programmed for the day/week ahead Have company leaders talk about the business direction or a particular topic Discuss any new equipment on site Provide a short training session (Site Safe provides exclusive toolbox talk topics to its members for upskilling and informing workers). 1. Schedule the meeting Let the team know where and when the meeting is. At the start of the day works best with most workplaces. 2. Set the scene for the meeting — keep it real and be positive Encourage everyone to join in and provide their own feedback, knowledge and experiences. Use simple language for everyone to understand to convey the key health and safety messages. Toolbox meetings are an opportunity to provide positive feedback for safe actions, hard work and initiatives. It’s also important to avoid criticism and acknowledge
- 486. everyone for theircontributions. The meeting shouldn’t be a lecture, but a chance for engagement with the team. Ensure that running and attending toolbox safety meetings is recognized as an important part of a person’s role. If the worker regards health and safety as an add-on, it will often be neglected. 3. Follow an agenda Follow an agenda to make sure you cover everything off: 4. Close the meeting Thank the team for their time and let them get to work. 5. Record meeting notes Topics to discuss: What items would workers like to discuss? Introduction of new plant or processes Development of task analysis or methodologies Changes in season e.g. sun smart, dehydration Use of plant Handling of materials Identifying training requirements. Free toolbox meeting minute template SAFETY KAIZEN: Kaizen literally means improvement - improvement in your personal life and your working life. When a company adopts the kaizen model, it strives to improve its processes in small but meaningful ways. And not just a one-time improvement, but a commitment to excellence by constantly testing and improving the workflow, day in and day out. Kaizen was first introduced in the Toyota manufacturing plant in Japan in the early 1950s and it has since become one of the main reasons for the country’s success. In Japan, kaizen is a way of life in the workplace, from the office of the CEO all the way down to shop apprentice. The Japanese take it very seriously, and for good reason. Kaizen Concepts Management In kaizen, management has two functions: maintenance and improvement. Setting standards and keeping them is an important part of kaizen. One of management’s
- 487. primary roles isto maintain the technological and operating standards that have been put into place. They make sure that everyone performs their assigned tasks according to explicitly outlined standards and performs them on a daily basis. Man other role is improvement. They must be constantly looking for ways to raise the current operating standards. This is an ongoing effort and must be a daily part of the manager’s job. PDCA Cycle The PDCA cycle is a system used to ensure the contin kaizen principles. It is a vital part of the process. Plan refers to establishing a target and a strategy for improvement. This is a must. Without a target, how do you know if you have achieved success? Do refers to the implementation of your you determine if your plan actually improved the process. Act is the process of standardizing the improved procedure so that it can be continued and so that the problem will not return. By following the PDCA cycle, you will ensure that process improves and does not degrade. Quality First Quality is always the highest priority in a kaizen system. But quality does not only refer to the finished product, it also refers to the processes and standards that create the product. It runs primary roles is to maintain the technological and operating standards that have been put into place. They make sure that everyone performs their assigned tasks according to explicitly outlined standards and performs them on a daily basis. Man other role is improvement. They must be constantly looking for ways to raise the current operating standards. This is an ongoing effort and must be a daily part of the PDCA Cycle The PDCA cycle is a system used to ensure the contin kaizen principles. It is a vital part of the process. Plan refers to establishing a target and a strategy for improvement. This is a must. Without a target, how do you know if you have achieved success? Do refers to the implementation of your you determine if your plan actually improved the process. Act is the process of standardizing the improved procedure so that it can be continued and so that the problem will not return. By following the PDCA cycle, you will ensure that process improves and does not degrade. Quality First Quality is always the highest priority in a kaizen system. But quality does not only refer to the finished product, it also refers to the processes and standards that create the product. It runs through all phases of company activity: design, production, primary roles is to maintain the technological and operating standards that have been put into place. They make sure that everyone performs their assigned tasks according to explicitly outlined standards and performs them on a daily basis. Management’s other role is improvement. They must be constantly looking for ways to raise the current operating standards. This is an ongoing effort and must be a daily part of the PDCA Cycle The PDCA cycle is a system used to ensure the continuation of the kaizen principles. It is a vital part of the process. Plan refers to establishing a target and a strategy for improvement. This is a must. Without a target, how do you know if you have achieved success? Do refers to the implementation of your plan. Check is when you determine if your plan actually improved the process. Act is the process of standardizing the improved procedure so that it can be continued and so that the problem will not return. By following the PDCA cycle, you will ensure that your Quality First Quality is always the highest priority in a kaizen system. But quality does not only refer to the finished product, it also refers to the processes and standards that through all phases of company activity: design, production,
- 488. management, sales, andservice. It is both the goal and the method of the production cycle. 5S The heart and soul of visual management is 5S. It is systematic approach to workplace organization and cleaning that will transform a disorganized workplace into an efficiently running machine. 5S creates a strong foundation that allows businesses to employ additional lean manufacturing tools such as kaizen. When the work environment is orderly, people can more easily identify opportunities for improvement. 1. Sort (Seiri) - The first step in 5S is to eliminate all the things in the workspace that are not being used and store them away. If a tool or material is not used on a daily basis, eliminate it from the workstation. 2. Set in Order (Seiton) -The second step is to arrange the items used on a daily basis so that they can be easily accessed and quickly stored. Your goal is to eliminate any unnecessary movements and actions by the worker to make the process as efficient as possible. 3. Shine (Seiso) - Next is to get everything cleaned and functioning properly. The goal is to remove all the dirt and grime and to keep it that way on daily basis. You want to get it clean and keep it clean. 4. Standardize (Seiketsu) -The fourth step is to develop a routine for sorting, setting, and shining. Standardize creates a system of tasks and procedures that will ensure that the principles of 5S are performed on a daily basis. 5. Sustain (Shitsuke) - In the last step, you want to create a culture that will follow the steps on a daily basis. The chief objective of sustain is to give your staff the commitment and motivation to follow each step, day in and day out. ONE POINT LESSON: (OPL) A tool to convey information.
- 489. Designed toenhance knowledge and skills in a short time, at the right time, whenever needed. To upgrade levels of expertise by having individuals study, learn and then train others in the knowledge or skill. One point Lesson is a learning tool. It normally consists of 80% diagram and 20% words all produced by hand. How to fill the OPL: Key point to remember when fill up the OPL form: Only one point of illustrated on single sheet of paper As many senses as possible as should be addressed. It must be write as simple as possible
- 490. Safety Suggestion Scheme: This is an old practice to invite safety suggestion for improvement in process, method, equipment, safety meetings, contests, inspection procedure etc. Criticisms should be replied in the plant magazine or on the notice board to provoke further suggestions and ideas. For suggestion scheme to be successful it is advisable that the employees' effort must be acknowledged, even if the suggestion is not adopted. It must be given careful consideration. Good suggestions should be rewarded among others to encourage them to participate. Written suggestions are the best, but, the oral or telephonic should also be allowed. Sometimes a contest of submitting good suggestions provides useful information and stimulates such effort. This system is effectively accepted by Japanese management. Boxes and forms can also be used to collect suggestions. Safety campaigns:- The Healthy Workplaces Campaigns are our flagship awareness-raising activity. They are the main way of getting our message to workplaces .in this employees are involved in safety campaign arranged for a week, or year month on different activities such as PPE use, good housekeeping etc. such cam[aligns keep the employees attentive and also create awareness that helps to promote safety in the organization Safety Competitions: This is another method of workers' participation in safety. Competitions (contests) are of two types: (1) Individual comparison - where individual worker takes part in competition and award is given by comparing individual performance. Examples are safety speech or quiz, essay, poem or slogan writing, posters or cartoons etc. (2) Group comparison - where groups take part in competition and award is given by comparing group versus group. Examples are department wise housekeeping competition. Safety Incentive Schemes : (i) Financial Incentive: Financial reward to the most useful suggestion or activity in safety is the commonest method. Other financial incentives should also be given for suggestion to solve
- 491. particular safety problemof plant or process, machine or equipment etc. Suggestion of good design for a guard or safety device should always be rewarded by handsome amount. (ii) Non-Financial Incentives: Award for safety performance, trophy, memento, certificate of merit, public honour, praise or pride, awarding special safety hat or kit or symbol of recognition, awarding special status and duties of safety work, giving special position such as honorary member of safety committee, raising the cadre or post, giving extra designation for any remarkable safety contribution are all examples of non-financial incentives. These non-financial incentives are self preservation, personal and material gain, loyalty, responsibility, pride, conformity, rivalry, leadership, logic and humanity. If these incentives are properly utilised they help much in accident prevention work. Safety performance (frequency and severity rates) of different groups can be compared for the same period. Here groups are motivated for competition. Similarly factories can be invited for contest if district, state or nation-wide competition is arranged. State and National Safety Councils do this. Every year safety competitions are held among similar class of factories to boost up safety activities and group motivation. In any type of safety contest the rules of contest and comparison must be well defined, declared beforehand and fair and reasonable to all participants. Scoring system should be simple or easy to understand. Winners may get shield, certificate or good prize but non-winning participants should also be compensated for encouragement. The competition movement as a whole should be encouraged as this effort itself is most important. Care should be taken to avoid any discredit. Cheating or malpractice like compelling an injured worker to continue work to show less man-days lost, shall be disregarded. Similarly false reporting of safety figures should also be avoided. Competition should be fair and fine and fitting to its noble cause. Safety Quiz:-is one type of safety competition or contest. It can be conducted by asking questions to participants or by giving them an objective question paper containing quiz questions to be answered in a stipulated time. It touches wide area of safety in short time and participation looks live. Audio-Visual Publicity : As we saw in foregoing Part 10.7 of this Chapter, a trainee tends to remember 50% of what he sees and hears and 70% of what he sees and talks. This is possible by audio visual aid only. Television and video effectively reproduce actual happening. Therefore safety education and training by safety films on TV is the most powerful
- 492. method. Only difficultyis in getting safely films or safety video cassette easily and frequently. This should be made possible if we wish to utilise its full role in increasing safety. used to die extent possible to hold the picture to discuss and understand it in details which is not possible with a moving film. Modern media is a closed circuit television. Travelling units are complete television studios in themselves and have up-to-date equipment with the control room housed in a single vehicle. There are fixed and moving cameras, telecine equipment, a video tap recorder and monitor screens which can be installed up to 500 meter away from the studio. Using both inside and outside cameras, extensive safety programmes can be broadcast through the closed network. Such unit can be hired also. Other Promotional Methods : Other promotional teaching methods for employees' participation are safety posters, cartoons, signs and education and training, demonstration, safety meetings, safety campaigns and stunts, first-aid training, fire brigades, safety- inventory or questionnaire, accident investigation, inspection, job safety analysis etc. slogans, publications, booklets, bulletin boards, safety contests and rewards, counselling of education and training, demonstration, safety meetings, safety campaigns and stunts, first-aid training,fire brigades, safety- inventory or questionnaire, accident investigation, inspection, job safety analysis etc. CHAPTER: 4BEHAVIOUR BASED SAFETY What is behavior based safety? Behavior Based Safety (BBS): “focuses on what people do, analyses why they do it, and then applies a research- supported intervention strategy to improve what people do. Observation of unsafe act and conditions, their reporting and taking action is key while maintaining safety standards within the working environment. Safe Behaviour Observation Program-BBS Understanding what influences the culture of your organisation can make a significant contribution to changing employee attitudes and behaviours in relation to workplace health and safety. For a safety culture to be successful it
- 493. needs to beled from the t practiced by the CEO and senior managers. As a safety leader you should ask yourself or people? Individuals hold safety as a ‘value’ and not just a priority. Individuals take responsibility for the safet themselves and all level of employee are willing and able to act on their sense of responsibility –they can go ‘beyond the call of duty'. BBS capability development program for Leadership Middle Managers/Supervisors Workers After BBS program, teams start Knowing the risks; Knowing the precautions to minimize or control the risks; Regularly taking those precautions by change in thinking that truly can help them improve their own safety performance and the performance of their fellow workers. Cycle of BBS: needs to be led from the top—that is, safety culture needs to be embraced and practiced by the CEO and senior managers. As a safety leader you should ask yourself or people? Individuals hold safety as a ‘value’ and not just a priority. Individuals take responsibility for the safety of their co-workers in addition to themselves and all level of employee are willing and able to act on their sense they can go ‘beyond the call of duty'. BBS capability development program for Middle Managers/Supervisors After BBS program, teams start Knowing the precautions to minimize or control the risks; Regularly taking those precautions by change in behaviours and they develop safety thinking that truly can help them improve their own safety performance and the performance of their fellow workers. that is, safety culture needs to be embraced and workers in addition to themselves and all level of employee are willing and able to act on their sense and they develop safety thinking that truly can help them improve their own safety performance and the
- 494. Benefits of BBSfor the company: Enhanced reporting Increased hazard recognition Share recognized hazards Data gathered is used to develop trends Trended data can be used to improve overall safety for employees Employees have greater sense of ownership of the HSE program Incentives may be tied to best quality observations Increased employee retention Common stated causes of dissatisfaction • Narrow scope, focused on behavior change rather than concurrently addressing causes for at-risk behavior • One-size-fits-all approach rather than a BBS system tailored to organizational characteristics and culture • Poorly integrated with existing safety management systems • No management commitment • Lack of belief in its efficacy by the workforce emanating from a lack of awareness/understanding • Debate between ‘quality’ and ‘quantity’ of observations and how to effectively analyze these Common causes in India • Inadequate understanding of BBS and its effect on the safety culture of an organization • Failure to translate BBS principles into effective action plans • Lack of perceived ownership for safety programs that are ‘off the shelf’ and ‘not bespoke enough to make employees own them’ as their own • Insufficient worker Involvement • Invisible top down support • Too few champions • Poor measures of success • Not recognizing the small milestones of success and celebrating them – not adequate positive reinforcement
- 495. Biggest causes ofBBS problems worldwide Common causes in India Inadequate understanding of BBS and its effect on the safety culture of an organization Failure to translate BBS principles into effective action plans Biggest causes of BBS problems worldwide Common causes in India: Inadequate understanding of BBS and its effect on the safety culture of an organization Failure to translate BBS principles into effective action plans Inadequate understanding of BBS and its effect on the safety culture Failure to translate BBS principles into effective action plans
- 496. Lack ofperceived ownership for safety programs that are ‘off the shelf’ and ‘not bespoke enough to make employees own them’ as their own Insufficient worker Involvement Invisible top down support Too few champions Poor measures of success Not recognizing the small milestones of success and celebrating them – not adequate positive reinforcement The six pillars of behavior based safety: 1. Leadership 2. Engagement 3. Coaching 4. Communication 5. Recognition 6. Measurement PERCEPTION OF DANGER AND ACCEPTANCE OF RISK: What is risk perception? ▷ Risk is not a physical thing: is it really possibly to perceive it? ▷ Objective risk as used in engineering approaches: • estimated from historical observation of frequencies and consequences • assuming that history + risk modelling allows us to predict the future ▷ Subjective risk as analyzed by social scientists: • risk concerns thoughts, beliefs and constructs
- 497. • level ofperceived risk is a subjective risk judgment Impact of risk perception Why is it important to understand the mechanisms underlying risk perception? ▷ Strong impact on societal acceptance/tolerance of various hazardous activities ▷ Big influence on individuals’ “safety behavior’s” when exposed to a hazard ▷ Phenomenon called risk homeostasis: people tend to act so that the level of risk to which they feel exposed is roughly constant • Example: car drivers tend to keep the perceived level of risk at a constant level • Impact of technological safety measures (abs, better lighting, smoother roads) is limited because drivers compensate by increasing their speed Poor perception of probabilities ▷ If you tell investors that, on average, they will lose all their money only every 30 years, they are more likely to invest than if you tell them they have a 3.3% chance of losing a certain amount each year ▷ Most people rate themselves as being a better driver than the average driver ▷ The vast majority rate the probability for themselves to experience negative events to be lower than that for the average citizen [McKenna 1993] ▷ Phenomena of unrealistic optimism and illusion of control: • rare, striking events tend to be overestimated • frequency of common events tend to be underestimated Main factors affecting risk perception These factors combine several characteristics of a risk that tend to be perceived in the same manner by lay people into one “label”: ▷ “Dread risk”: perceived lack of control, catastrophic potential, inequitable distribution of risks and benefits, involuntary ▷ “Unknown risk”: not observable, effects are delayed, little scientific knowledge on the risk, unknown by those people exposed, new risk ▷ “People affected risk”: personally affected, general public affected and future generations affected. Impact of control
- 498. ▷ People toleratesubstantially more risk when they engage in voluntary behavior ▷ Related to a sense of controllability: less risk is perceived in situations that are under personal control ▷ Phenomenon of illusion of control • the risk of winning the lottery is perceived to be higher if we pick the numbers ourselves [Langer 1975] • a person who sees themselves as being in control (driving the car vs being a passenger) perceives the risk to be smaller [McKenna 1993] Why different people have different perception on danger/risk Unaware the fact about risk - Ignorance about hazard. Overconfidence Previous experience. Shortcut Priority v/s Value Showoff Training Education Theory X – Theory Y Management Theory Dr. Douglas McGregor (1906-64): • Social psychologist Douglas McGregor of MIT expounded two contrasting theories in the 1960s • Theories are about human motivation and management • McGregor personally promoted Theory Y more than Theory X
- 499. Theory X • Assumesemployees are naturally unmotivated and dislike working • Encourages an authoritarian style of management. • Usually the minority • In mass organizations, such as large scale production environment, theory X is unavoidable. TheoryY • A participative style of management that is de-centralized • Assumes employees are happy to work, self-motivated, etc. • More widely applicable • People at lower levels of the organization are involved in decision making and have more responsibility. Roles of Supervisor & Safety Department in motivation: Supervisors
- 500. You are directlyresponsible for the safety and health of employees and other workers that you direct or supervise. Here are your roles and responsibilities: Ensure the health and safety of all workers under your direct supervision Know the WorkSafe safety requirements that apply to the work being supervised and ensure they are followed Ensure workers under your supervision are aware of all known or reasonably foreseeable health and safety hazards where they work Provide orientation and training to new and existing workers at your workplace Consult and cooperate with the Joint Occupational Health and Safety Committee members or worker representatives, and cooperate with others carrying out occupational health and safety duties, including WorkSafeofficers Ensure that the appropriate personal protective equipment and clothing are available, worn when required, and inspected and maintained Investigate unsafe conditions reported to you, and ensure that corrective action is taken without delay Learn more about accident prevention and investigation. General Safety Roles & Responsibilities All workers have safety roles and responsibilities. Follow safe work procedures, report unsafe conditions or incidents and be prepared to respond in the event of a workplace injury or emergency. Whether you are a supervisor or front-line staff, be sure to Understand your workplace health and safety requirements Inspect equipment and the workplace regularly Be alert for hazards Immediately report unsafe work practices and conditions to your supervisor Report accidents, near misses, injuries and illnesses immediately to your supervisor Follow safe work practices and procedures Cooperate with others on matters relating to occupational safety and health CONFLICT AND FRUSTRATION Conflict is… • a normal, inescapable part of life
- 501. • a periodicoccurrence in any relationship • an opportunity to understand opposing preferences and values • Disagreement about ideas and approaches • Issue focused, not personal • Characteristic of high performing groups • Personal blame fueled by differences of opinion • Destructive to group performance and goal How can we keep conflict Thinkable? 1. Make the approach 2. Share perspectives 3. Build understanding 4. Agree on solutions 5. Plan next steps Step 1. Make the approach Discuss before you begin Invite the other party to a conversation Be clear about your intentions State your goal - a positive resolution Step 2. Share perspectives Ask for the other person’s perspective Interpretation, summary what you hear Acknowledge your contribution Describe your perspective Step 3. Build understanding Discuss one issue at a time Clarify assumptions Explore interests and feelings Step 4. Agree on solutions Reality test – Is this doable? Durability test – Is this durable? Interest test – Does this meet all parties’ interests? Step 5. Plan next steps Jointly create action plan
- 502. What needsto happen? Who needs to do what? By when? How will interaction take place if problems occur? CHAPTER 5.MANAGEMENT INFORMATION SYSTEM (MIS) is a computerized database of financial information organized and programmed in such a way that it produces regular reports on operations for every level of management in a company. It is usually also possible to obtain special reports from the system easily. Management Information System (MIS) has become a powerful tool for industry, trade and business in the modern world. It should be user friendly and easy to understand. With the Age of Computers, the speed, capacity, accuracy and a variety of uses of Information has been tremendously increasing in almost all walks of life. Computers are useful not only for storing information but also for generating data, designing, programming, processing, controlling, running robots and microprocessors, communication, developing science, technology and management systems, analysing and using information, forecasting and personal use. We have entered the age of internet, web-site and information highways. The information (data-processing) must be accurate, pertaining to the point, concise, updated, meaningful, trust worthy and as per the need of the user. There should be effective MIS between Safety Department and the top management of the company to appraise the work being done by the Department. Similarly it should also be developed/extended for bottom line management and the outside authorities to provide quick and tabulated information in wide areas of safety, health & environment. Application of MIS from book:- Computer Application and Use:
- 503. Use of computersfor safety and health information systems became critical from 1.970s with the inception of Occupational Safety and Health Act in USA as much documentation, reporting and analysis were required by that Act. In our country, still it is in process. Manifold use of computers for safety, health and environment is as under : 1. As its general use in science and engineering, computers are used for mathematical and statistical calculations, graphics, documentation, typing, printing, indexing, searching for literature, data reduction, recording and maintenance of data, control of automated production lines (CAD, Computer Aided Design, CAM, Computer Aided Manufacturing and DCS process control) etc. 2. Automation of information paths and use of Safety Internet System. 3. Process control in plants and laboratories. 4. Accident and medical records. 5. Costing of accidents and losses. 6. Causation analysis of accidents or hazardous events. 7. Signal analysis and medical decision making, e.g. ECG analysis and diagnosis of heart problems, sonography, scanning, surgery etc. 8. Preventive Medicine and Epidemiology, screening, examinations of ill population and comparison of their data with the healthy population for early diagnosis of diseases. 9. Maintaining a long-time qualitative and quantitative record of chemical exposures to workers. 10. Maintaining environmental sampling and measurement data. Using for gas dispersion models and mathematical models for reliability engineering. 11. Preparing and maintaining periodical statements of accidents, injuries, causation wise breakups, compensation and other costing, first aid cases, near miss cases, safety training, status of compliance etc. 12. Safety reports, manuals, procedures, audit points, mutual aid systems and emergency plan items can be quickly stored, updated and reproduced. 13. Maintaining information of workplace conditions, engineering controls, fire and gas leak controls, administrative controls, medical controls, personal protective equipment and their selection, training programmes etc. 14. Maintaining employee demographics and job histories. 15. Scheduling of inspections, surveys, meetings, workplace monitoring, biological monitoring, condition monitoring, corrosion monitoring, maintenance programmes etc. 16. Reporting at any time to internal management or external statutory authorities or private agencies. 17. Keeping records of Material Safety Data. Sheets, Indian Standards, Statutory Provisions and Forms, Reports for Pollution Control Boards etc. 18. Statistical analysis by using ready-made or self-designed software.
- 504. 19. Using robots,auto-controls and safety-devices to avoid accidents to persons and property. 20. Simulations to determine where hazards reductions would be more effective and the change in failure probability that would result useful to carry out hazards analysis, fault tree analysis etc. The special use of computers in addition to general benefits of software (Expertise, Up-to-date information and Improved management) is for Accident recording and analysis. Information on chemical hazards. Audit recording and analysis etc. Data on such points are as under: 1. Automatic printing of statutory and other safety forms. 2. Automatic generation of periodical reports. 3. Analysis of near misses in the same details as injury accidents. 4. Multiple records of injury, property and vehicle damage from the same incident Linked incident costing so that reports can automatically include details of the costs involved. 6. Automatic summaries and their graphical displays. 7. On-line computing using own computer to contact the library or publisher's computer to obtain and read off the information required. 8. CD-ROM (Compact Disc - Read Only Memory) and player for the computer and special software on chemical hazards and control technology. The information from the disc is displayed on the computer screen. Conversely, information in the computer can be copied on CD by using CD writer. 9. Use of floppy-discs, CDs and Pendrive to read off the information. 10. Database from CAMEO, COSHH, APELL etc. and onsite and offsite emergency plans (see 11. Safety audit and environmental audit details by using a set of audit questions (also known as audit protocol). Such audit software packages include: a) The ability to edit the audit questions and add audit questions as new risks are identified. b) The ability to add guidance for the auditors to specific questions, including details of any relevant standards. c) Displaying two or more sets of audit results on the screen at a time and to compare them. d) Graphical display of audit summaries. e) Automatic generation of audit reports, including action plans. f) Diary facilities to assist in managing an audit schedule and keeping track of Recommendations for remedial action.
- 505. Advantages of computerizedinformation systems are - 1. Ready availability of data and ready reproduction (printed copy) of the stored data. 2. Elimination of monotonous or exhaustive manual labour. 3. No need to keep duplicate records (copies). Reducing files and their storing space. A shared information can be seen at many places (i.e. in different department, conference hall etc.). 4. Improved communication with neat, clean and correct copies. Electronic mail systems can facilitate communication within and between facilities and within short time. 5. Data standardisation and accuracy. 6. Improved analytical capabilities. Analyses not manually practical, can be easily done by a computer. Graphs and Chartes also available. 7. Cost savings by increasing employee productivity, decreasing manpower etc. Disadvantages (limitations) of computerized nation systems are 1. According to circumstances, need of computers is not always justified. Sometimes it may be premature or totally unjustified on economic grounds. 2. Computers' limitations should be understood. They are not designed for automatic information generation or processing. An operator is required to make data-entry or supply basic information (programme) to computers and his error can give wrong or incomplete information or sometimes rase it and manual search becomes necessary. Mistakes can become repetitive if not corrected in time. 3. Computers can suggest references to documents. They cannot eliminate the need to go through these documents to locate the required information. A typical virus can wash out all information stored in the computer. Then retrieval or restoration of data becomes necessary. 5. Manpower reduction for unemployment. Status and Future Goals of Computer Utilization in SHE Services: Status of computer utilization is being increased and spreading very fast. Today we are rapidly entering in the age of information technology, information highways, internet systems, super-computers to design, scan, develop, store, exchange and transmit data for many complex systems and for many purposes. Paper files and record rooms are all shortened and it seems that in every walk of life computer has to" play some role. Safety, health and environment being the vital subject, cannot remain w