Doploma in industrial safety chappter - 3 Notes

1. DIPLOMA IN INDUSTRIAL SAFETY

2. CHAPTER-3
WORK PROCEDURES
CONTENTS:
1. INTRODUCTION
2. INDUSTRIAL PSYCHOLOGY
3. EMPLOYEES TRAINING IN SAFETY
4. DIFFERENCE BETWEEN EDUCATION AND TRAINING
5. ASSESSMENT OF TRAINING NEEDS
6. METHODS OF TRAINING
7. RISK ANALYSIS
8. RISK ASSESSMENT CONCEPTS

3. 9. HAZARDS CONTROL
10. QUANTITATIVE RISK ANALYSIS PROCEDURES
11. RISK TOLERABLITY
12. EMERGENCY CONTROL PLAN
13. DISEASTER MANAGEMENT
14. ON SITE EMERGENCY PLAN
15. OFF SITE EMERGENCY PLAN
16. GAS CYLINDERS
INTRODUCTION
INDUSTRIAL PSYCHOLOGY:
INDUSTRIAL PSYCHOLOGY IS STUDY OF HUMAN BEHAVIOUR AND IS CONCERNED
WITH THYE DISCOVERY OF INFORMATION RELATING TO HUMANBEHAVIOURAND IS
CONCERNED WITH THE DISCOVERY OF INFORMATION RELATING TO HUMAN
BEHAVIOUR
IT IS CONCERNED WITH PHYSICAL ASPECTS OF WORK ENVIRONMENT LIKE
LIGHTING TEMPERATURE AND THEIR EFFECT ON OUTPUT AND SAFETY OF THE
WORKER

4. SCOPE OF INDUSTRIAL PSYCHOLOGY:
TO INVESTIGATE IN AN UNBIASED MANNER THE WAYS IN WHICH
PSYCHOLOGICAL PROBLEMS ARE HANDLED AT PRESENT
TO DEVELOP[ NEW METHODS AND TO MODIFY THE METHODS WHICH HAVE
BEEN TRIED OUT AND EVALUATE THEM.
TO FORMULATE CERTAIN PRINCIPLE THIS WILL HELP IN THE SOLUTIONS OF
HUMAN RELATIONS PROBLEMS
IT OMITS MANY OF THE ROUTING ADMINISTRATIVE DETAILS
INDUSTRIAL PSYCHOLOGY EMPHASIZES THE SCIENTIFIC AND RESEARCH ASPECTS
OF PEOPLE AT WORK
ADVANTAGES OF TAINTING IN SAFETY ARE:
1. TRAINING HELPS TO DEVELOP SAFETY CONSCIOUSNESS AMOUNT THE
EMPLOYEES AND BUILD UP FAVOURABLES ATTITUDES ON THEIR PART
TOWARDS SAFETY MEASURES AND SAFETY PRECAUTIONS

5. 1. TRAINING IMPARTS KNOWLEDGE AND SKILL WHICH IMPROVE PRECEPTIONS
ANDLEADS TO SAFE WORK PERFORMANCES ON THE PART OF THE EMPLOYEES
2. TRAINING ACTIVITIES INDIRECTLY DEMONSTRATE COMPANY INTEREST IN
EMPLOYEES WHICH LEADS TO GOOD HUMAN RELATIONS AT WORK.
LEVEL:
1. HELPERS(1 DAY)
 NEED FOR SAFETY AT WORK
 HAZARDS CONDUCTED WITH THEIR TASKS AND WAYS TO SAFEGUARD
 SAFETY IN HANDLING AND STORAGE
 STEPS IN HANDLINGS AND STORAGE
 STEPS TO BE TAKEN IN EMERGENCY
2. OPERATORS(3 DAYS)
 INTRODUCTION TO SAFETY AND COMPANYS POLICY
 COMMON CAUSES OF ACCIDENTS

6. ACCIDENTS PREVENTION
SAFETY REQUIREMENTS IN THE JOB
ROLE OF WORKMEN IN SAFETY
SAFETY IN HANDLING AND STORAGE
INDUSTRIAL HYGIENE AND OCCUPATIONAL HEALTH
PERSONAL PROTECTIVE EQUIPTMENTS
STEPS TO BE TAKEN IN EMERGENCY AND FIRST AID
SUPERVISORS(5 DAYS)
SAFETY AND COMPANYS POLICY
SAFETY AND THE LAW
PLANT HOSUEKEEPING
COMMON CAUSE OF ACCIDENTS IN THE PLANT
ACCIDENTS INVESTGATION AND ANALYSIS
PLANT SAFETY INSPECTION
FIRE PREVENTION AND CONTROL
PERSONAL PROTECTIVE EQUIPTMENTS

7. EMPLOYEES EDUCATION AND MOTIVATION
ROLE OF SUPERVISORS IN SAFETY
MANAGERS:
INTRODUCTION TO SAFETY AND HEALTH AND COMPANYS POLICY
LEGAL RESPONSIBILITY OF THE EMPLOYER
IDENTIFICATRION AND CONTROL OF HAZARDS
ELEMNTS OF INDUSTRIAL HYGIENE AND ENVIRONMENTAL
MONITORING
OCCUPATIONAL HEALTH
ACCIDENTS AND ASSOCIATED COSTS.
MANAGING SAFETY
ROLE OF MANAGERS IN SAFETY
PREVENTIVE AND CONTROL MEASURES

8. ASSESSMENT OF TRAINING NEEDS:
a. WHAT ARE THE CURRENT SAFETY PROBLEMS OF THE ORGANIZATION(I.E
ACCIDENTS/ OCCUPATIONAL DISEASE ETC)?
b. WHAT ARE AREAS OF SAFETY TRAINING?
c. WHEN TRAINING SHOLUD BE IMPARTED?
d. WHO SHOULD BE GIVEN TRAINING?
e. WHEN AND HOW TO EVALUATE EFFECTIVENESS OF TRAINING?
METHODS OF TRAINING:
a. ON THE JOB INSTRUCTIONS BY THE SUPERVISOR OR A SENIOR WORKER AT
THE TIME OF ALLOCATIONS OF THE JOB TO THE WORKER
b. LECTURE ON SAFETY BY EXTERNAL INTERNAL FACULTY UTILIZING SUITABLE
BLEND OF ORAL INSTRUCTIONS AND AUDIO VISUAL AIDS
c. DISCUSSIONS LED BY EXPERT FACULTY MEMBERS COVERING RELEVANT SAFETY
ISSUES.

9. RISK ANALYSIS
 HAZARDS IDENTIFICATION
CAUSE CONSEQUENCES ANALYSIS
HAZARDSAND OPERABILITY STUDIES
FAULT TREE/EVENT ANAKYSIS FOR FREQUENCE ASSESSEMENT
SAFETY AUDIT STUDIES
INDIVIDUAL AND SOCIETIES RISK ASSESSMENT
RISK CONTOUR MAPPING
THE REQUIREMENTS OF QRA ARE:
SYSTEMS ARE IN PLACE TO IDENTIFY HAZRADS ANALYZE RISKS FROM THE
HAZARDS AND EVALUTE WAYS EITHER TO ELIMINATE HAZARDS OR TO MANAGE
RISKS.
APPROPRAITELY REVIEW OF RISKS TOBE CONDUCTED AT LEAST ONCE IN THREE
FOR EXISTING UNITS PIPELINES AND MARKETING INSTALLATIONS FOR ONGOING
OPERATIONS BASED ON

10. 1. MULTI DISCIPLINARY INETRNAL SAFETY AUDITS
2. OISDS EXTERNAL SAFETY AUDITS
3. REGULATORY COMPLIANCES
4. WALK THROUGH ASSESSMENT
5. HAZOP
6. PREVIOUS RISK ASSESSMENT
7. PREVIOUS QUANTITIES RISK ANALYSIS
 APPROPRIATE RISK ANALYSIS ANSD ASSESSEMENTS ARE CONDUCTED FOR
NEW PROJECTS THAT INCLUDE
1. PHILOSOPHY REVIEW
2. PLANT REVIEW PLANT LAYOUT PROCESS TECHNOLOGY ETC.
3. INHERENT SAFETY
4. PROCESS DESIGN SAFETY
5. HAZOP
6. QUANTITATIVE RISK ANALYSIS
7. CONSTRUCTION RISK SAFETY

11. RISK ANALYSIS INVOLVES:
THE DEFICATION OF RISKS HOWVERE THEY MAY ARISE AND WHOEVER THEY MAY
AFFECT
THE ASSESSMENT OF THE RISKS AS TO THEIR PROBABILITY OF OCCURING AND
THE IMPACT THEY WOULD HAVE IF THEY DID OCCUR
TO ALLOCATE SUCH RISKS BETWEEN THE MAN PROJECT PARTIES.
 PROJECT MANAGEMENT STRUCTURE: WHATEVER THE CONTRACTING
PHILOSOPHY, A STRONG PROJECT MANAGEMENT STRUCTURE AND CULTURE IS
REQUIRED IN ORDER TO DEAL WITH THE COMPLEX ISSUES INVOLVED IN
DELIVERING A FUNCTIONING PLANT TO TIME AND BUDGET. IT IS PARTICULARLY
IMPORTANT IN MINIMIZING THE CONSEQUENCES OF THE PROBLEMS WHICH
OCCUR IN EVERY PROJECT.
SCOPE AND BASIS OF TURKEY CONTRACT: IDEALLY, THE TURNKEY CONTRACT
SHOULD COVER THE ENTIRE SCOPE OF THE PROJECT, BUT OFTEN THE
INFRASTURCTURE REQUIREMENTS BEYOND THE ISTE BOUNDARY WILL BE OUTSIDE
THE SCOPE.SINCE EVERY ADDITIONAL

12. GROUND CONDITION AND GEOLOGICAL RISK: IT IS USUALLY THE CASE THAT
TURNKEY CONTRACTORS WILL ACCEPT GROUND CONDITIONS AND GEOLIGICAL
RISK ONCE THEY HAD THE OPPURTUNITY TO CARRY OUT A SURVEY.IN THE ABSENCE
OF SUCH A SURVEY, OF IF THE SITE CHOSEN AS OBVIOUS GEOLOGICAL DRAW BACKS
THE TURKEY CONTRACTS PRICE IS UNLIKELY TO BE FIRM
RISK ARISING FROM DESIGN: WHERE THE TURNKRY CONTRACT HAS BEEN PLACED
ON THE BASIS OF A FUNCTIONAL SPECIFICATION, THEY WILL CLEARLY RESPONSIBLE
FOR THE DESIGN OF THE PLANT. BUT IF THE DESIGN HAS BEEN ESTABLISHED BY TH
PROJECT
 CONSTRUCTION RISKS: THE PRINCIPAL RISKS ASSOCIATED WITH THE
CONSTRUCTIONS OF THE PLANT ITSELF SHOULD BE TRANSFERRED TO THE TURNKEY
CONTRACTOR
CLIMATE AND WEATHER RISKS: CLEARLY THE MONSOON CREATES GREAT
DIFFICULTIES OR OUTDOOR CONSTRUCTIONS, WHICH HAS TO BE PROGRAMMED
WITH PERIOD OUTSIDE THEN MONSOON SEASON, WITH WEATHYER TIGHT
STRUCTURES COMPLETED BEFORE THE RAINS ARRIVE. ANY PROJECT DELAYS CAN

13. HAZARDS CONTROL
i. ADMINISTRATIVE CONTROL MEASURES(PERSONAL HOUSE KEEPING,
MAINTENANCE ETC.) AND
ii. ENGINEERING CONTROL MEASURES (ISOLATION, DESIGN FEATURES,
OPERATING PROCEDURES, WORKING, WORKING EQUIPTMENTS,ETC.)
HUMAN CAPABILITIES AND LIMITATIONS MUST BE GIVEN DUE
CONSTRUCTIONS IN ANY TYPE OF CONTROL MEASURES.
EMERGENCY CONTROL PLAN:
OBJECTIVES OF DISASTER MANAGEMENT
 RAPID CONTROL AND CONTAINMENT OF THE AFFECTED PERSONS
MINIMIZING THE ISK AND IMPACT OF EVENT/ACCIDENTS ON PEOPLE, PROPERTY
AND ENVIRONMENT
EFFECTIVE REHABILITION OF THE AFFECTED PERSONS
MANUFACTURING PROCESS
LOCATION OF THE INDUSTRY
PLANT LAYOUT AND MATERIALS HANDLING

14. 1. ON SITE EMERGENCY PLAN
 EMERGENCY ORGANIZATION
 PLANT RISK EVALUATION
 MEDICAL FACILITIES
 EMERGENCY EQUIPMENT AND FACILITIES
 CONVEYANCE SYSTEMS
 NOTIFICATION AND COMMUNIACTION SYSTEMS
 SAFETY TRAINING
 DRILLS AND EXERCISES
 TESTING AND EVALUTIONS OF THE EMERGENCY PLAN
OFF SITE EMERGENCY PLAN
EMERGENCY ORGANIZATIONS:
SELECTING PERSONS IN CHARGE/ALTERNATES
SPECIFYING THE FUNCTIONS OF EACH KEY INDIVIDUAL AND GROUP
MAINTAINING TELEPHONE NUMBERS(OFFICE AND HOE) OF KEY PEOPLE
ALTENATES

15. RISK EVALUATION:
DETAILS OF HAZRADOUS MATERIALS
QUANTITY OF HAZRADOUS MATERIALS
LOCATIONS OF HAZARDOUS MATERIALS
PRPERTIES OF EACH (MSDS SHEET) HAZARDOUS MATERIALS
HANDLING MATERIALS REQUIREMENTS
SPECIAL FIRE FIGHTING PROCEDURES(IF ANY)
EMERGENCY EQUIPTMENTS AND FACILITIES:
FIRE FIGHTING EQUIPTMENTS
EMERGENCY MEDICAL SUPPLIES
SELF CONSTRAINED BREATHING APPARATUS
GOOGLES, BOOTS, RUBBER GLOVES, HELMETS
OTHER PERSONAL PROTECTIVE EQUIPTMENTS

16. SAFETY TRAINING:
 INDUCTION TRAINING FOR NEW EMPLOYEES
SAFE HANDLING OF CHEMICALS/INFLAMMABLE EQUIPTMENTS
PROCEDURES FOR REPORTING EMERGENCIES
KNOWLEDGE OF ALARM SYSTEMS
USE OF FIRE FIGHTING EQUIPTMENTS
PERMIT PROCEDURES
 USE OF PERSONAL/PROTECTIVE EQUIPTMENTS
EVACUATION PROCEDURES
DRILLS AND EXERCISES: OBJECTIVES
PROVIDE HAND ON EXPERIENCE WITH THE PROCEDURES TO BE IMPLEMENTED
DURING AN EMERGENCY DURING AN EMERGENCY
TEST THE VALIDITY OF THE PLAN AND PROCEDURES
FAMILIARIZE THE RESPONSE PERSONNEL WITH EQUIPTMENTS

17. TESTING AND EVALUATING AN EMERGENCY PLAN
ASSESS OF EFFECTIVENESS OF THE PLAN AND ITS RESPONSE
ESTABLISH CRITERIA FOR CORRECTIVE AND PREVENTIVE ACTIONS
TEST KNOWLEDGE AND SKILL OF PARTICIPATING PERSONNEL
IDENTIFY TRAINING NEEDS OF RESPONSE PERSONNEL
TEST THE COMMUNICATIONS NETWOORK AND COOPERATIVE RESPONSE SKILLS.
OFF SITE EMERGENCY PLAN REQUIRE ATTENTION TO THE FOLLOWING ACTIVITIES:
EMERGENCY ACTIONS
COMMUNICATIONS WITH AUTHORITIES CONCERNED
EVACUATION SHELTERING PLAN
GAS CYLINDERS
1. CYLINDERS MANUFACTURED IN INDIA ARC FITTED WITH SAFETY RELIEF
DEVICES. SUCH DEVICES SHLL BE MANUFACTURED AND MAINTAINED IN
ACCORDANCE WITH INDIAN STANDARD 5903

18. HANDLING STORAGE
1. CYLINDERS SHALL BE ADEQUATELY SUPPORTED DURING HANDLING
2. TROLLEYS AND CRADLES OF ADEQUATE STRENGHT SHALL BE USED WHEN
MOVING THE CYLINDERS
3. SLIDINTHE CYLINDERS SHALL BE HANDLED CAREFULLY AND NOT BE ALLOWED
TO ALL UPON ONE ANOTHER OR OTHERWISE SUBJECTEDTO ANY UNDUE
SHOCK
4. LIQUEIFIED PETROLEUM GAS CYLINDERS AND CYLINDERS CONTAINING
LIQUEFIED GASES SHALL ALWAYS BE KEPT IN AN UPRIGHT POSITION AND
SHALL BE SO PLACE THAT THEY NOT BE KNOCKED OVER
5. OPEN FLAMES LIGHTS, LIGHING OF FIRES WELDING AND SMOKING SHALL BE
PROHIBITED IN CLOSE PROXIMITY TO ANY CYLINDERS CONTAINING
CLAMMABLE GASES EXCEPT THOSE WHOLE IN USE FOR WELDING CUTTING
AND HEATING
6. G,DROPPING, OR PLAYING WITH CYLINDERS PROHIBITED

19. JOB SAFETY ANALYSIS
JOB SAFETY BREAK DOWN SHEET CONSISTING OF THE FOLLOWING:
1. NAME OF OPERATION FOR JSA
2. DESCRIPTION OF THE OPERATION
3. HAZARDS(POTENTIAL/EXISTING)
4. PRECAUTION/REMEDIES
JSA: A PERSON WELL CONVERSANT WITH THE JOB OPERATION SHOULD DO JSA A
SUPERVISOR IN ASSOCIATION WITH SENIOR PERSONNEL OR OFFICER CAN DO IT OR
A SMALL COMMITTEE CAN DO IT.
ADVANTAGES :
i. HELPS TO IDENTIFY HAZARDS AND PREVENT ACCIDENT
ii. HELPS TO ESTABLISH SAFE WORK METHOD WORKING CONDITONS SUITABLE
PLANT SAFETY RULES,PPE REQUIREMENTS ETC.
iii. HELPS TO ESTABLISH IN PLANT SAFETY INSPECTION HELPS TO ACCESS THE
REQUIREMENTS INCLUDING SAFETY TRAINING OF NEW WORKERS/EXISITING
WORKERS.

20. A LIST GUIDED WORDS ARE GIVEN BELOW
1. NO OR NOT
2. MORE
3. LESS
4. AS WELL AS
5. PART OF
6. REVERSE
7. OTHER THAN
A SIMPLE EXAMPLE IS GIVEN BELOW
i. SUPPLY TANK IS EMPTY
ii. PUMP FAILS TO TURN
iii. MECHANICAL ELECTRICAL FAILURE
iv. PUMP IS SWITCHED OFF
v. PIPE LINE IS FRACTURED
vi. ISOLATION VALUE IS CLOSED.

21. DEVIATION IS LESS PASSED INOT THE REACTION VESSEL THE CAUSES MAY BE
1. ISOLATION VALVE IS SLIGHTLY CLOSED
2. THE PUYMP IS PARTLY BLOCKED
3. THE PUMP FAILS TO PRODUCE FULL FLOW-BECAUSE THE IMPELLERS ARE
ERODED BECAUSE VALVE IS WORN ETC.
PRINCIPLE OF TOTAL LOSS INCIDENT CONTROL:
 TRY TO INVESTIGATE ALL ACCIDENTS, FIND OUT THE CAUSES INCLUDING
CONTRIBUTING CAUSES AND WORK OUT REMNEDIAL MEASURES TO PREVENT
RECURRENCES OF SUCH ACCIDENTS.
 ANTICIPATE POTENTIAL ACCIDENTS UNDER CERTAIN CIRCUMSTANCES AND
WORK THEIR CONTROL PREVENTION E.G.UNUSUAL NON ROUTINE WORK AND
PRODUCTION ACTIVITIES MAINTENANCE WORK SOURCES OF HIGH ENERGY
WHICH MAY LEAD TO EXPLOSION FIRE TO TOXIC RELEASE ETC.,

22. 3.SAFETY SHOULD BE CONSIDERED AS ANOTHER NORMAL ACTIVITY OF THE
FACTORY MANAGEMENT SHOULD REALIST THAT SAFETY IS ANALOGOUSS TO COST
QUALITY AND QUANTITY OF PRODUCTION MANAGEMENT MAY SET GOALS FOR
SAFETY PLANNING COORDINATING AND CONTROLLING TO ACHIEVE THE
GOALS/OBJECTIVES FAULT TREE ANALYSIS IS A BIOGRAPHICAL REPRESENTATION OF
THE LOGICAL RELATION BETWEEN A PARTICULAR SYSTEM ACCIDENT(TO
PREVENT)AND THE PRIMARY CAUSE EVENTS.
4.THE KEY TO EFFECTIVE LINE SAFETY PERFORMANCE LIES IN THE ESTABLISHMENT
OF PROCEDURES BY MANAGEMENT FOR FIXING ACCOUNTABILITY FOR SAFETY.IF
WE ENSURE #4,#3 WILL BW EFFECTIVE SINCE #3,#4 ARE COMPLEMENTARY. LOSS
CONTROL MANAGEMENT INVOLVES CONTROL OVER AVAILABLE LOSSES LIKE MEN,
MATERIALS AND WORKING ENVIRONMENT.

23. COURSES:
 Diploma in occupational Health And Safety
 Diploma in industrial safety
 Diploma in electrical safety
 Diploma in fire fighting
 Diploma in construction safety
 Certificate in fire and safety engineering
 Diploma in fire and safety engineering
 PG diploma in fire and safety engineering
 Certificate in oil and Gas safety
 Diploma in oil and Gas safety
 Diploma in health ,safety and Environment
 PG diploma in Health ,safety Environment

24. JOB PLACEMENT :
NSA will give100% job placement assistance to all successful candidates. Some of
the Industries are listed below.
Oil Refineries,
Port trust,
Airport,
Chemical Industries,
Insurance,
Construction and
service industries are main job providers.
Students passed out from this institute can find job opportunities as Safety
Supervisor, Safety Inspector, Safety Officer, Safety Manager, Fireman and Fire
Officer.

25. Contact us:
No. 714, 1st Floor, M.T.H Road,
Mannurpet, Chennai – 600 050.
+91 7667442300
Ph: 26242038 ,26242318
Mobile No:8643055672
Website – http://safetyacademy.in/
Email : info@safetyacademy.in