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General Safety In Industry
QUEST MANAGEMENT SOLUTIONS
2
5/7/2024
What is Safety ?
• Freedom from incident
which can be achieved by
identification of hazards and
prevention of damage to men,
Materials, machines, product
and Environment
3
5/7/2024
Why Safety?
Legal
Why
Safety
Humanity
Business
Legislation
WHY SAFETY
• Save Human Life & avoid accidents
• Improve quality of work
• Create smooth & healthy atmosphere
• Reduce time involvement
• Built confidence internally & externally.
• Save production cost & Improve productivity.
• Prevent national loss.
• Improve economical growth.
• Healthy atmosphere to society.
8
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• People do not want to meet with the accidents
• Accidents are caused, they do not just happen
• Primary responsibility of accident prevention lies with the Management.
• There are multiple contributory factors for accident
• Accidents occur after repeated violations
• Root cause of almost all accidents is inadequacies in Management Control
systems
• All accidents are preventable
• Proactive approach is better than reactive approach
Philosophy
9
5/7/2024
What is an Incident ?
Event that gave rise to an accident or have the potential to lead to an accident.
The term incidents includes “nearmiss”
Types of Incidents
• Accidents
•Fire/ Property Damage
•Damage to Environment reputation/
•Damage to local communities
•Near miss
•Close calls
10
5/7/2024
What is an Accident ?
Any event which results in harm to personnel, damage to property, production loss or
causes damage to the environment
Type of Accidents :
 First aid Case :
 Medical Treatment Case
 Lost Time injury
 Fatal
11
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Near-miss is a Warning for
ACCIDENTS !!!!
What is Near miss?
12
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Near-miss is an event which could result in
Accident..
But, Averted by
Circumstances!!
What is Near miss?
13
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Thumb Rule
14
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15
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16
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17
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Stop!!!!
Ouch..!!
18
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Classification of Incidents
19
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Source, situation, or act with a potential for harm in terms of human injury or ill
health), or a combination of these
What is Hazard
Examples :
• Falling from height
• Spillage of chemicals
• Heat radiation
• Falling of material, etc..
20
5/7/2024
Combination of the likelihood of an occurrence of a hazardous event or exposure and
the severity of injury or ill health that can be caused by the event or exposure
What is Risk
Examples
• Cut, blunt, crush injury
• Fatal accident
• Property damage
• Environment affected, etc..
21
5/7/2024
Theories of Accident Causation
HW Henriech- Analysis of 75000 accidents in 1931
24000
600
Near Miss / Unsafe conditions
300
No Injuries
Minor Injuries
1
24000
600
Near Miss / Unsafe conditions
300
No injury
29
Minor Injuries
1
LTI
•The above figures are averages. Injury can occur the first time also
•No proactive methods
•Activities are generally carried out for injury prevention than accident
prevention
•Should analyze root cause of problem than attacking the symptoms
22
5/7/2024
CAUSES OF ACCIDENTS
ACCIDENT CAUSES
INDIRECT CAUSE
DIRECT CAUSE
PHYSIOLOGICAL
UNSUITABILITIES
PHSYCOLOGICAL
UNSUITABILITIES
LACK OF
KNOWLEDGE
& SKILL
UNSAFE
ACT
UNSAFE
CONDITION
23
5/7/2024
Causes of Accident
Direct Indirect
Unsafe Act
Unguarded or inadequately guarded
machines / equipments
Defective conditions of m/c’s,
equipments, tools etc.
Unsafe methods of storing, piling etc.
Inadequate or incorrect illumination
Inadequate Ventilation
Improper House Keeping-- things not
at their proper places
Unsafe design or construction of
machines and equipment etc.
Operating without authority
Bypassing safety devices
Operating at unsafe speed
Using wrong tool / equipment
Unsafe Placing
Unsafe Loading
Taking unsafe position or posture
Working on dangerous or moving
equipment
Not using PPE
Horse playing at work place etc.
Causes
Unsafe Condition
24
5/7/2024
Causes of Accident
Physiological
Unsuitability’s
Indirect Causes
Poor eye sight
Hard to hearing
Intoxicated
Physiological disabled
Psychological
Unsuitability's
Negative attitude
towards safety
Ignorance of safety
rules and procedures
Frustration & Conflict
Morale
Individual differences
Acclimatization
Motivation & aspiration
Boredom & monotony
Lack of Knowledge &
Skill`
DSG 25
UNSAFE ACTS 88 %
UNSAFE CONDITIONS 10 %
ACTS OF GOD 2 %
Hazard in Process Industry
• Physical hazards such as trip, slip and fall.
• Fire hazard.
• Chemical hazards
• Electrical hazards
• Mechanical hazard
• Equipment and job related.
• Tool related.
• Area related.
Maintenance Hazards and
Controls
53
ELECTRICAL SAFETY
Electrical Injuries
There are four main types of electrical injuries:
• Direct:
Electrocution or death due to electrical
shock
Electrical shock
Burns
• Indirect - Falls
OSHAX.org - The Unofficial Guide To the
OSHA
54
Shock Severity
• Severity of the shock
depends on:
–Path of current through
the body
–Amount of current
flowing through the body
(amps)
–Duration of the shocking
current through the body,
• LOW VOLTAGE DOES NOT
MEAN LOW HAZARD
OSHAX.org - The Unofficial Guide To the
OSHA
55
BODY RESISTANCE
• BODY AREA RESISTANCE IN OHMS
• DRY SKIN 1,00,000 TO 6,00,000
OHMS
• WET SKIN 1000 OHMS
•
• INTERNAL BODY
• HAND TO FOOT 400 TO 600 OHMS
• EAR TO EAR (ABOUT) 100
OHMS
BODY CURRENT
WET CONDITIONS
I= V / R
230 / 1000
0.230 A
230 mA (enough to kill a person)
DRY CONDITIONS
I= V / R
230/100000
0.0023 A
2.3 mA
Dangers of Electrical Shock
Currents above 10 mA* can
paralyze or “freeze” muscles.
Currents more than 75 mA can
cause a rapid, ineffective
heartbeat -- death will occur in
a few minutes unless a
defibrillator is used
75 mA is not much current – a
small power drill uses 30 times
as much
OSHAX.org - The Unofficial Guide To the
OSHA
58
* mA = milliampere = 1/1,000 of an ampere
Defibrillator in use
Burns
Most common shock-related
injury
Occurs when you touch
electrical wiring or
equipment that is improperly
used or maintained
Typically occurs on hands
Very serious injury that needs
immediate attention
OSHAX.org - The Unofficial Guide To the
OSHA
59
Falls
• Electric shock can also
cause indirect injuries
• Workers in elevated
locations who
experience a shock may
fall, resulting in serious
injury or death
OSHAX.org - The Unofficial Guide To the
OSHA
60
Electrical Hazards and How to
Control Them
Electrical accidents are
caused by a combination
of three factors:
– Unsafe equipment and/or
installation,
– Workplaces made unsafe
by the environment, and
– Unsafe work practices.
OSHAX.org - The Unofficial Guide To the
OSHA
61
Hazard – Exposed Electrical Parts
Cover removed from wiring or breaker box
OSHAX.org - The Unofficial Guide To the
OSHA
62
Control – Isolate Electrical Parts - Cabinets,
Boxes & Fittings
Conductors going into them must be protected,
and unused openings must be closed
OSHAX.org - The Unofficial Guide To the
OSHA
63
Control - Overhead Power Lines
• Stay at least 10 feet away
• Post warning signs
• Assume that lines are
energized
• Use wood or fiberglass
ladders, not metal
• Power line workers need
special training & PPE
OSHAX.org - The Unofficial Guide To the
OSHA
64
Hazard – Defective Cords & Wires
• Plastic or rubber
covering is
missing
• Damaged
extension cords
& tools
OSHAX.org - The Unofficial Guide To the
OSHA
65
Hazard – Damaged Cords
 Cords can be damaged by:
 Aging
 Door or window edges
 Staples or fastenings
 Abrasion from adjacent
materials
 Activity in the area
 Improper use can cause shocks,
burns or fire
OSHAX.org - The Unofficial Guide To the
OSHA
66
Temporary Lights
Protect from contact and damage, and don’t
suspend by cords unless designed to do so.
OSHAX.org - The Unofficial Guide To the
OSHA
67
Clues that Electrical Hazards Exist
• Tripped circuit breakers or blown
fuses
• Warm tools, wires, cords,
connections, or junction boxes
• GFCI that shuts off a circuit
• Worn or frayed insulation around
wire or connection
OSHAX.org - The Unofficial Guide To the
OSHA
68
Lockout and Tagging of Circuits
• Apply locks to power source after de-
energizing
• Tag deactivated controls
• Tag de-energized equipment and
circuits at all points where they can
be energized
• Tags must identify equipment or
circuits being worked on
OSHAX.org - The Unofficial Guide To the
OSHA
69
Safety-Related Work Practices
To protect workers from electrical shock:
– Use barriers and guards to prevent
passage through areas of exposed
energized equipment
– Pre-plan work, post hazard warnings
and use protective measures
– Keep working spaces and walkways
clear of cords
OSHAX.org - The Unofficial Guide To the
OSHA
70
EFCOG Electrical Improvement Project
 One of the most common occurrences with
electrical systems around the DOE complex is
excavating, cutting or drilling into electrical
systems.
 There are many methods of trying to identify
buried or concealed electrical conduits and
cables. None of them are fool proof.
Electrical System
Intrusions
 Facilities have developed methods and procedures to
help prevent these occurrences.
 If you are involved in this type of activity, it is your
responsibility to comply with facility requirements.
ELECTRICAL EQUIPMENT INSTALLATION
Clear Space for Switchboards :-
1. Width in front of panel - > 1 mtr
2. Back of the panel - < 0.3 mtr
( so that nobody can attempt to get there)
or > 1 mtr clear to a height of 3 mtrs
ELECTRICAL EQUIPMENT
INSTALLATION
Earth pit value
1. Power stations - 0.5 ohms
2. Major Substations - 1.0 ohms
3. Other Substations - 2.0 ohms
4. Distribution
Transformer stations - 5.0 ohms
5. Overhead line supports - 25.0 ohms
Preventing Electrical Hazards -
Planning
Plan your work with
others
Plan to avoid falls
Plan to lock-out and tag-
out equipment
Remove jewelry
Avoid wet conditions and
overhead power lines
OSHAX.org - The Unofficial Guide To the
OSHA
74
EFCOG Electrical Improvement Project
Moisture provides a conductive path
that could result in death.
Never work with wet tools or clothing.
Remove
Your
Jewelry.
•Legislations on chemical safety
•Types of chemicals
• Classification of chemicals
• Health hazards of chemicals
•Route of entry of chemical
• Personal Control strategy
• protective equipment
• Chemicals fire and explosion hazards
•Fire and explosion hazard control and prevention
• Hazard communication
•Material safety data sheet
• Material Handling
Chemical Safety
Agenda
CHEMICAL SAFETY NEEDS MORE ATTENTION.
BECAUSE, EACH CHEMICAL HAS,
• MANY PROPERTIES.
• MANY PROCESSES.
• MANY HAZARDS.
• MANY CONTROLS.
• THE STATE OF C HEMICAL, PRESSURE, TEMPERATURE,
PROCESS PARAMETERS ARE VARIABLE.
• MANY HAZARD DATA AND COMPLETE REACTION DOCUMENTS
ARE NOT AVAILABLE.
• ENG-CONTROL,CONTROL DEVICES, PPEs ARE INADEQUATE
• GAS LEAKAGES AFFECTS GENERAL POPULATION AS WELL.
TYPES OF CHEMICALS.
1 POISONS. SOLID POISON-ARSENIC.
LIQIUID POISON-ACRYLONITRITE.
GAS-POISON-CARBON MONOXIDE.
2 OXIDISING AGENTS. BROMIC ACID.
3 REDUCING AGENTS. HYDRAZINE.
4 REACTIVE CHEMICALS. EPICHLOROHYDRINE.
5 CORROSIVES. ACIDS,PHENOL.
6 SOLVENTS. BENZENE.CHLOROFORM.
7 INFLAMMABLES. LIQUIDS-TOLUENE, SOLVENTS
GASES-ETHYLENE OXIDE. ACETYLENE
8 EXPLOSIVES. NITROGLYCERIN, TNT.
9 PESTCIDES, INSECTICIDES, FUNGICIDES, HERBICIDES,
VERMICIDES.
10 ALCOHOLS.
11 REFRIGERANT GASES.
12 ESTERS.
13 ETHERS.
14 ENZYMES.
15 RESINS.
16 ACIDS. INORGANIC-ACIDS, ORGANIC-ACIDS
FIRE SAFETY
FIRE SAFETY
Fire Chemistry
• The Fire Tetrahedron.
– The removal of any one element extinguishes the
fire.
145
OXYGEN
FUEL
HEAT
CHEMICAL CHAIN REACTION
Sources of Ignition
• Smoking
• Electrical equipment
• Heaters
• Contractors tools and equipment
• Arson
147
5/7/2024
FUEL
Solid Liquid Gas Metals
( Combustible)
• Wood
• Paper
• Cotton
• Textiles
• Petrol
• Diesel
• Kerosene
• Paint
• Oils
• LPG
• Acetylene
• Hydrogen
• Methane
• Sodium
• Potassium
• Magnesium
• Lithium
• Transformer
• Welding M/C
• Generators
• Panel Boards
Electrical
(No class)
Classes of fire
• Fires are classified by the material
that is burning.
• Fires are designated as:
–Class A
–Class B
–Class C
–Class D 148
Classes of fire
• "Class A fire" means a fire involving
ordinary combustible materials such
as paper, wood, cloth, and some
rubber and plastic materials, leaving
an ash residue and burn with a
white to gray smoke.
149
Classes of fire
• "Class B fire" means a fire involving
flammable or combustible liquids,
flammable gases, greases and
similar materials, and some rubber
and plastic materials.
150
Classes of fire
• "Class C fire" means a fire involving
energized electrical equipment
where safety to the employee
requires the use of electrically
nonconductive extinguishing media.
151
Classes of fire
• "Class D fire" means a fire involving
combustible metals such as
magnesium, titanium, zirconium,
sodium, lithium and potassium.
152
Water (Class “A” Agent)
• Removes heat, best on Class “A” fires, best overall
agent.
• Very bad for Class “B” fires as it spreads the fuel.
• Very bad for Class “C” fires as it conducts
electricity.
• Disastrous on a Class “D” fire, may cause an
explosion.
153
Carbon dioxide (Class “BC” Agent)
• "Carbon dioxide" means a colorless, odorless,
electrically nonconductive inert gas that is a
medium for extinguishing fires by reducing the
concentration of oxygen or fuel vapor in the air to
the point where combustion is impossible.
154
Carbon dioxide (Class “BC” Agent)
• Displaces oxygen reducing its concentration to
below the level capable of supporting combustion.
• Good for Class “B” and “C” fires.
• Not good for Class “A” fires.
• Hazardous to humans.
155
Dry chemicals
• Ordinary dry chemical powder (Class “BC” Agent)-
– Siliconized Sodium Bicarbonate.
– Airborne powder interrupts the chemical chain
reaction.
– Does not smother, cool or remove fuel.
– Good for Class “B” and Class “C” fires.
156
Dry Chemicals
• Multipurpose dry chemical powder (Class “ABC”
Agent)
– Siliconized Ammonium Phosphate.
– Performs as above, plus the powder melts when it
contacts a hot surface, sealing the oxygen away from
the fuel.
– Good for Class “B” and Class “C” fires.
– Fair for Class “A” fires.
157
Foam (Class “AB” Agent)
–Water based detergent floats on surface of
burning liquids, excluding oxygen from the
fuel.
–Excellent cooling qualities, same as water.
–Not suitable for a Class “C” fire.
158
Dry powder (Class “D” Agent)
–Only for Class “D,” metal fires.
–Low velocity, sodium bicarbonate or
sand.
–Attempts to smother fire; however,
some metal fires will continue to burn
with no apparent source of oxygen.
159
PERSONAL
PROTECTIVE
EQUIPMENTS
5/7/2024
173
PERSONAL PROTECTIVE EQUIPMENT
5/7/2024
174
175 5/7/2024
No specific personal protective equipments is named in Factories Act, but
working conditioned mentioned in sections 14, 33, 35, 36, 37, 38, 87, 111 and 114
are such that free of charge Personal Protective Equipments should be provided
by the Occupier for the protection from hazards due to dust fume, gas, vapour,
flying particles, glare, revolving machinery, entry in to confine space, explosive
or flammable atmosphere and dangerous operation and hazardous process.
STATUTORY PROVISIONS
176 5/7/2024
If any workers employed in a factory
contravenes any of the provisions of this
section or any rule or order made there
under, he shall be punishable with
imprisonment for a term which may extend
to 3 months, or fine which may extends to
one hundred rupees or both.
177 5/7/2024
PERSONAL PROTECTIVE
EQUIPMENT (PPE)
It can be defined as any
item of clothing or
equipment which is used
by employees to reduce
their exposure to hazards in
the work place.
Job Hazards
• Examples of Job Hazards are:
• Noise
• Chemicals
• Accidental Impact
• Sharp objects
• Flying Particles
• Dust & Mists
• Bright Light
• Vibration
Respiratory
(Breathing)
Air
Purifying
Chemical
filters
Mechanical
Filters
Combination of
Chemical and
Mech. filters
Dust or
Nuisance
filters.
Micro
filters
Chemical
gas mask.
Chemical
cartridge.
Self-rescue
filters
Non
Respiratory
For the
Protection of
Head
Eyes
Ears
Face
Hands
Arms
Feet
Lags
Supplied Air
Air-lined Self contained
Air line
respirator.
Suction
hose mask.
Pressure
hose mask.
Demand
Type
Recalculating
Type
Compressed
air
Compressed
oxygen
Compressed
oxygen.
Regenerated
oxygen
CLASSIFICATION OF PPEs.
180
5/7/2024
Environmental Employees
Maintenance Employees Production Employees
Fire & Safety Employees
Contractor Employees
HEAD PROTECTION
Foot Protection
• Heavy objects such as barrels or tools that
might roll or fall onto your feet.
• Sharp objects such as nails or spikes that
might pierce the soles or uppers of
ordinary shoes.
• Molten metal that might splash
• Hot, slippery or wet surfaces
• Corrosive Chemicals
Hazardous conditions…
• IMPACT - Carrying or handling materials such as
packages, objects, parts or heavy tools which could be
dropped
• COMPRESSION - Work activities involving skid trucks
(manual material handling carts, around bulk rolls,
around heavy pipes
• PUNCTURE - Sharp object hazards such as nails, wire,
tacks, screws, large staples, scrap metal, etc
• CHEMICAL - Check MSDS for protection
183 5/7/2024
FOOT PROTECTION
•Toe protection Sole protection
183
184 5/7/2024
HAND PROTECTION
184
Your hands may well be the most valuable tools you have. To protect them from
the many chemical compounds we use, you should always wear gloves. But
choosing the right glove for the job takes some careful consideration. A variety
of glove materials exist on the market today; such as rubber, neoprene, nitrile,
latex, polyethylene, PVC, butyl, PVA...; which are specially designed to resist
certain chemicals better than others.
THERE IS NO UNIVERSAL GLOVE THAT WILL PROTECT YOU FROM
ALL CHEMICALS!
185 5/7/2024
TYPE OF HAND
GLOVES
185
1. Cotton or Canvas Hand Gloves
2. Leather Hand Gloves
a. Full Leather Hand Gloves
b. Only Leather Palm Hand Gloves
3. Rubber Hand Gloves
a. Ordinary Rubber Hand Gloves
b. Latex Rubber Hand Gloves
c. Electrical Resistance Hand Gloves
4. Cut Resistance Nitrile Dipped Hand Gloves
5. Kevler Material (Substitute of Asbestoses) Hand Gloves
6. Aluminised Fabric Hand Gloves
Hand Hazards
• Cuts & punctures
• Chemical exposure
• Vibration
• Electric shock
• Burns
• Heat & Cold
• Biohazards
Hand Gloves
FACE & EYES PROTECTION
• Your eyes are very sensitive organs and may
be easily injured. Eye Hazards include:
– Chemical Splashes
– Flying dist, chips, sparks
– High Heat
– Intense or UV light
Specific hazards include…
• IMPACT - Chipping, grinding machining, masonry work,
woodworking, sawing, drilling, chiseling, powered
fastening, riveting, and sanding.
• HEAT - Furnace operations, pouring, casting, hot dipping,
welding
• LIGHT or RADIATION - Electric arc welding, gas welding,
gas cutting
• IRRITANTS / CORROSIVES - mists, dusts, sprays, splashes
Face Protection
• Use a faceshield when any of the following
hazards exist:
• Chemical splashes
• Liquid spray
• Flying chips or sparks
• High Heat
– Special face shield
191 5/7/2024
FACE
PROTECTION
Full face shield
Adaptable on a helmet.
The only overall protection for the face.
Electric Arc Welding Face Shield
Types of Eye Protection
• Zero Power Spectacle – for flying chips &
low hazards
Types of Eye Protection
• Polycarbonate – for dust and non-
hazardous mist
HEARING PROTECTION
• Use hearing protection when:
• in high noise areas
• using power saws, impact tools, etc.
• off the job when shooting, using power tools, etc.
• Replace damage hearing protectors
immediately
EAR MUFFS Easier to use.
Allow to communicate (radio, conversation, etc).
HEARING PROTECTION
• High noise can seriously damage the auditory system.
Hearing protection are mandatory in
areas where equipment is being
operated and noise is above 90 dBA.
195
EAR PLUGS
Be careful of the hygiene conditions
when using it (clean hands, etc).
196
5/7/2024
Fitting of earplugs
197
5/7/2024
RESPIRATORY PROTECTION
• Dust Mask
• Protect from large dust particles
• Single use
• Air purifying mask
• Half mask - Full Face Mask
• Do NOT use in oxygen deficient atmosphere.
• Use in presence of gas and vapor contaminants
Good maintenance of cartridge is essential.
Adequate cartridge depends on the polluent.
198
Working on height Protection
5/7/2024
199
Protect yourself…
•Use the right PPE for the Hazard
•Inspect your PPE before using
•Replace damaged or worn PPE
•Store your PPE properly so it will be ready for the
next use
•Keep your PPE clean
•Notify your supervisor if you need new PPE
THANKING YOU
Wishing you all the Best!
BE SAFE & BE HAPPY
GENERAL SAFETY IN AN INDUSTRY-n.pptx Chemical as well as specialist chemicals

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GENERAL SAFETY IN AN INDUSTRY-n.pptx Chemical as well as specialist chemicals

  • 1. General Safety In Industry QUEST MANAGEMENT SOLUTIONS
  • 2. 2 5/7/2024 What is Safety ? • Freedom from incident which can be achieved by identification of hazards and prevention of damage to men, Materials, machines, product and Environment
  • 4. WHY SAFETY • Save Human Life & avoid accidents • Improve quality of work • Create smooth & healthy atmosphere • Reduce time involvement • Built confidence internally & externally. • Save production cost & Improve productivity. • Prevent national loss. • Improve economical growth. • Healthy atmosphere to society.
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  • 8. 8 5/7/2024 • People do not want to meet with the accidents • Accidents are caused, they do not just happen • Primary responsibility of accident prevention lies with the Management. • There are multiple contributory factors for accident • Accidents occur after repeated violations • Root cause of almost all accidents is inadequacies in Management Control systems • All accidents are preventable • Proactive approach is better than reactive approach Philosophy
  • 9. 9 5/7/2024 What is an Incident ? Event that gave rise to an accident or have the potential to lead to an accident. The term incidents includes “nearmiss” Types of Incidents • Accidents •Fire/ Property Damage •Damage to Environment reputation/ •Damage to local communities •Near miss •Close calls
  • 10. 10 5/7/2024 What is an Accident ? Any event which results in harm to personnel, damage to property, production loss or causes damage to the environment Type of Accidents :  First aid Case :  Medical Treatment Case  Lost Time injury  Fatal
  • 11. 11 5/7/2024 Near-miss is a Warning for ACCIDENTS !!!! What is Near miss?
  • 12. 12 5/7/2024 Near-miss is an event which could result in Accident.. But, Averted by Circumstances!! What is Near miss?
  • 19. 19 5/7/2024 Source, situation, or act with a potential for harm in terms of human injury or ill health), or a combination of these What is Hazard Examples : • Falling from height • Spillage of chemicals • Heat radiation • Falling of material, etc..
  • 20. 20 5/7/2024 Combination of the likelihood of an occurrence of a hazardous event or exposure and the severity of injury or ill health that can be caused by the event or exposure What is Risk Examples • Cut, blunt, crush injury • Fatal accident • Property damage • Environment affected, etc..
  • 21. 21 5/7/2024 Theories of Accident Causation HW Henriech- Analysis of 75000 accidents in 1931 24000 600 Near Miss / Unsafe conditions 300 No Injuries Minor Injuries 1 24000 600 Near Miss / Unsafe conditions 300 No injury 29 Minor Injuries 1 LTI •The above figures are averages. Injury can occur the first time also •No proactive methods •Activities are generally carried out for injury prevention than accident prevention •Should analyze root cause of problem than attacking the symptoms
  • 22. 22 5/7/2024 CAUSES OF ACCIDENTS ACCIDENT CAUSES INDIRECT CAUSE DIRECT CAUSE PHYSIOLOGICAL UNSUITABILITIES PHSYCOLOGICAL UNSUITABILITIES LACK OF KNOWLEDGE & SKILL UNSAFE ACT UNSAFE CONDITION
  • 23. 23 5/7/2024 Causes of Accident Direct Indirect Unsafe Act Unguarded or inadequately guarded machines / equipments Defective conditions of m/c’s, equipments, tools etc. Unsafe methods of storing, piling etc. Inadequate or incorrect illumination Inadequate Ventilation Improper House Keeping-- things not at their proper places Unsafe design or construction of machines and equipment etc. Operating without authority Bypassing safety devices Operating at unsafe speed Using wrong tool / equipment Unsafe Placing Unsafe Loading Taking unsafe position or posture Working on dangerous or moving equipment Not using PPE Horse playing at work place etc. Causes Unsafe Condition
  • 24. 24 5/7/2024 Causes of Accident Physiological Unsuitability’s Indirect Causes Poor eye sight Hard to hearing Intoxicated Physiological disabled Psychological Unsuitability's Negative attitude towards safety Ignorance of safety rules and procedures Frustration & Conflict Morale Individual differences Acclimatization Motivation & aspiration Boredom & monotony Lack of Knowledge & Skill`
  • 25. DSG 25 UNSAFE ACTS 88 % UNSAFE CONDITIONS 10 % ACTS OF GOD 2 %
  • 26. Hazard in Process Industry • Physical hazards such as trip, slip and fall. • Fire hazard. • Chemical hazards • Electrical hazards • Mechanical hazard • Equipment and job related. • Tool related. • Area related.
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  • 54. Electrical Injuries There are four main types of electrical injuries: • Direct: Electrocution or death due to electrical shock Electrical shock Burns • Indirect - Falls OSHAX.org - The Unofficial Guide To the OSHA 54
  • 55. Shock Severity • Severity of the shock depends on: –Path of current through the body –Amount of current flowing through the body (amps) –Duration of the shocking current through the body, • LOW VOLTAGE DOES NOT MEAN LOW HAZARD OSHAX.org - The Unofficial Guide To the OSHA 55
  • 56. BODY RESISTANCE • BODY AREA RESISTANCE IN OHMS • DRY SKIN 1,00,000 TO 6,00,000 OHMS • WET SKIN 1000 OHMS • • INTERNAL BODY • HAND TO FOOT 400 TO 600 OHMS • EAR TO EAR (ABOUT) 100 OHMS
  • 57. BODY CURRENT WET CONDITIONS I= V / R 230 / 1000 0.230 A 230 mA (enough to kill a person) DRY CONDITIONS I= V / R 230/100000 0.0023 A 2.3 mA
  • 58. Dangers of Electrical Shock Currents above 10 mA* can paralyze or “freeze” muscles. Currents more than 75 mA can cause a rapid, ineffective heartbeat -- death will occur in a few minutes unless a defibrillator is used 75 mA is not much current – a small power drill uses 30 times as much OSHAX.org - The Unofficial Guide To the OSHA 58 * mA = milliampere = 1/1,000 of an ampere Defibrillator in use
  • 59. Burns Most common shock-related injury Occurs when you touch electrical wiring or equipment that is improperly used or maintained Typically occurs on hands Very serious injury that needs immediate attention OSHAX.org - The Unofficial Guide To the OSHA 59
  • 60. Falls • Electric shock can also cause indirect injuries • Workers in elevated locations who experience a shock may fall, resulting in serious injury or death OSHAX.org - The Unofficial Guide To the OSHA 60
  • 61. Electrical Hazards and How to Control Them Electrical accidents are caused by a combination of three factors: – Unsafe equipment and/or installation, – Workplaces made unsafe by the environment, and – Unsafe work practices. OSHAX.org - The Unofficial Guide To the OSHA 61
  • 62. Hazard – Exposed Electrical Parts Cover removed from wiring or breaker box OSHAX.org - The Unofficial Guide To the OSHA 62
  • 63. Control – Isolate Electrical Parts - Cabinets, Boxes & Fittings Conductors going into them must be protected, and unused openings must be closed OSHAX.org - The Unofficial Guide To the OSHA 63
  • 64. Control - Overhead Power Lines • Stay at least 10 feet away • Post warning signs • Assume that lines are energized • Use wood or fiberglass ladders, not metal • Power line workers need special training & PPE OSHAX.org - The Unofficial Guide To the OSHA 64
  • 65. Hazard – Defective Cords & Wires • Plastic or rubber covering is missing • Damaged extension cords & tools OSHAX.org - The Unofficial Guide To the OSHA 65
  • 66. Hazard – Damaged Cords  Cords can be damaged by:  Aging  Door or window edges  Staples or fastenings  Abrasion from adjacent materials  Activity in the area  Improper use can cause shocks, burns or fire OSHAX.org - The Unofficial Guide To the OSHA 66
  • 67. Temporary Lights Protect from contact and damage, and don’t suspend by cords unless designed to do so. OSHAX.org - The Unofficial Guide To the OSHA 67
  • 68. Clues that Electrical Hazards Exist • Tripped circuit breakers or blown fuses • Warm tools, wires, cords, connections, or junction boxes • GFCI that shuts off a circuit • Worn or frayed insulation around wire or connection OSHAX.org - The Unofficial Guide To the OSHA 68
  • 69. Lockout and Tagging of Circuits • Apply locks to power source after de- energizing • Tag deactivated controls • Tag de-energized equipment and circuits at all points where they can be energized • Tags must identify equipment or circuits being worked on OSHAX.org - The Unofficial Guide To the OSHA 69
  • 70. Safety-Related Work Practices To protect workers from electrical shock: – Use barriers and guards to prevent passage through areas of exposed energized equipment – Pre-plan work, post hazard warnings and use protective measures – Keep working spaces and walkways clear of cords OSHAX.org - The Unofficial Guide To the OSHA 70
  • 71. EFCOG Electrical Improvement Project  One of the most common occurrences with electrical systems around the DOE complex is excavating, cutting or drilling into electrical systems.  There are many methods of trying to identify buried or concealed electrical conduits and cables. None of them are fool proof. Electrical System Intrusions  Facilities have developed methods and procedures to help prevent these occurrences.  If you are involved in this type of activity, it is your responsibility to comply with facility requirements.
  • 72. ELECTRICAL EQUIPMENT INSTALLATION Clear Space for Switchboards :- 1. Width in front of panel - > 1 mtr 2. Back of the panel - < 0.3 mtr ( so that nobody can attempt to get there) or > 1 mtr clear to a height of 3 mtrs
  • 73. ELECTRICAL EQUIPMENT INSTALLATION Earth pit value 1. Power stations - 0.5 ohms 2. Major Substations - 1.0 ohms 3. Other Substations - 2.0 ohms 4. Distribution Transformer stations - 5.0 ohms 5. Overhead line supports - 25.0 ohms
  • 74. Preventing Electrical Hazards - Planning Plan your work with others Plan to avoid falls Plan to lock-out and tag- out equipment Remove jewelry Avoid wet conditions and overhead power lines OSHAX.org - The Unofficial Guide To the OSHA 74
  • 75. EFCOG Electrical Improvement Project Moisture provides a conductive path that could result in death. Never work with wet tools or clothing. Remove Your Jewelry.
  • 76. •Legislations on chemical safety •Types of chemicals • Classification of chemicals • Health hazards of chemicals •Route of entry of chemical • Personal Control strategy • protective equipment • Chemicals fire and explosion hazards •Fire and explosion hazard control and prevention • Hazard communication •Material safety data sheet • Material Handling Chemical Safety Agenda
  • 77. CHEMICAL SAFETY NEEDS MORE ATTENTION. BECAUSE, EACH CHEMICAL HAS, • MANY PROPERTIES. • MANY PROCESSES. • MANY HAZARDS. • MANY CONTROLS. • THE STATE OF C HEMICAL, PRESSURE, TEMPERATURE, PROCESS PARAMETERS ARE VARIABLE. • MANY HAZARD DATA AND COMPLETE REACTION DOCUMENTS ARE NOT AVAILABLE. • ENG-CONTROL,CONTROL DEVICES, PPEs ARE INADEQUATE • GAS LEAKAGES AFFECTS GENERAL POPULATION AS WELL.
  • 78. TYPES OF CHEMICALS. 1 POISONS. SOLID POISON-ARSENIC. LIQIUID POISON-ACRYLONITRITE. GAS-POISON-CARBON MONOXIDE. 2 OXIDISING AGENTS. BROMIC ACID. 3 REDUCING AGENTS. HYDRAZINE. 4 REACTIVE CHEMICALS. EPICHLOROHYDRINE. 5 CORROSIVES. ACIDS,PHENOL. 6 SOLVENTS. BENZENE.CHLOROFORM. 7 INFLAMMABLES. LIQUIDS-TOLUENE, SOLVENTS GASES-ETHYLENE OXIDE. ACETYLENE
  • 79. 8 EXPLOSIVES. NITROGLYCERIN, TNT. 9 PESTCIDES, INSECTICIDES, FUNGICIDES, HERBICIDES, VERMICIDES. 10 ALCOHOLS. 11 REFRIGERANT GASES. 12 ESTERS. 13 ETHERS. 14 ENZYMES. 15 RESINS. 16 ACIDS. INORGANIC-ACIDS, ORGANIC-ACIDS
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  • 145. Fire Chemistry • The Fire Tetrahedron. – The removal of any one element extinguishes the fire. 145 OXYGEN FUEL HEAT CHEMICAL CHAIN REACTION
  • 146. Sources of Ignition • Smoking • Electrical equipment • Heaters • Contractors tools and equipment • Arson
  • 147. 147 5/7/2024 FUEL Solid Liquid Gas Metals ( Combustible) • Wood • Paper • Cotton • Textiles • Petrol • Diesel • Kerosene • Paint • Oils • LPG • Acetylene • Hydrogen • Methane • Sodium • Potassium • Magnesium • Lithium • Transformer • Welding M/C • Generators • Panel Boards Electrical (No class)
  • 148. Classes of fire • Fires are classified by the material that is burning. • Fires are designated as: –Class A –Class B –Class C –Class D 148
  • 149. Classes of fire • "Class A fire" means a fire involving ordinary combustible materials such as paper, wood, cloth, and some rubber and plastic materials, leaving an ash residue and burn with a white to gray smoke. 149
  • 150. Classes of fire • "Class B fire" means a fire involving flammable or combustible liquids, flammable gases, greases and similar materials, and some rubber and plastic materials. 150
  • 151. Classes of fire • "Class C fire" means a fire involving energized electrical equipment where safety to the employee requires the use of electrically nonconductive extinguishing media. 151
  • 152. Classes of fire • "Class D fire" means a fire involving combustible metals such as magnesium, titanium, zirconium, sodium, lithium and potassium. 152
  • 153. Water (Class “A” Agent) • Removes heat, best on Class “A” fires, best overall agent. • Very bad for Class “B” fires as it spreads the fuel. • Very bad for Class “C” fires as it conducts electricity. • Disastrous on a Class “D” fire, may cause an explosion. 153
  • 154. Carbon dioxide (Class “BC” Agent) • "Carbon dioxide" means a colorless, odorless, electrically nonconductive inert gas that is a medium for extinguishing fires by reducing the concentration of oxygen or fuel vapor in the air to the point where combustion is impossible. 154
  • 155. Carbon dioxide (Class “BC” Agent) • Displaces oxygen reducing its concentration to below the level capable of supporting combustion. • Good for Class “B” and “C” fires. • Not good for Class “A” fires. • Hazardous to humans. 155
  • 156. Dry chemicals • Ordinary dry chemical powder (Class “BC” Agent)- – Siliconized Sodium Bicarbonate. – Airborne powder interrupts the chemical chain reaction. – Does not smother, cool or remove fuel. – Good for Class “B” and Class “C” fires. 156
  • 157. Dry Chemicals • Multipurpose dry chemical powder (Class “ABC” Agent) – Siliconized Ammonium Phosphate. – Performs as above, plus the powder melts when it contacts a hot surface, sealing the oxygen away from the fuel. – Good for Class “B” and Class “C” fires. – Fair for Class “A” fires. 157
  • 158. Foam (Class “AB” Agent) –Water based detergent floats on surface of burning liquids, excluding oxygen from the fuel. –Excellent cooling qualities, same as water. –Not suitable for a Class “C” fire. 158
  • 159. Dry powder (Class “D” Agent) –Only for Class “D,” metal fires. –Low velocity, sodium bicarbonate or sand. –Attempts to smother fire; however, some metal fires will continue to burn with no apparent source of oxygen. 159
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  • 175. 175 5/7/2024 No specific personal protective equipments is named in Factories Act, but working conditioned mentioned in sections 14, 33, 35, 36, 37, 38, 87, 111 and 114 are such that free of charge Personal Protective Equipments should be provided by the Occupier for the protection from hazards due to dust fume, gas, vapour, flying particles, glare, revolving machinery, entry in to confine space, explosive or flammable atmosphere and dangerous operation and hazardous process. STATUTORY PROVISIONS
  • 176. 176 5/7/2024 If any workers employed in a factory contravenes any of the provisions of this section or any rule or order made there under, he shall be punishable with imprisonment for a term which may extend to 3 months, or fine which may extends to one hundred rupees or both.
  • 177. 177 5/7/2024 PERSONAL PROTECTIVE EQUIPMENT (PPE) It can be defined as any item of clothing or equipment which is used by employees to reduce their exposure to hazards in the work place.
  • 178. Job Hazards • Examples of Job Hazards are: • Noise • Chemicals • Accidental Impact • Sharp objects • Flying Particles • Dust & Mists • Bright Light • Vibration
  • 179. Respiratory (Breathing) Air Purifying Chemical filters Mechanical Filters Combination of Chemical and Mech. filters Dust or Nuisance filters. Micro filters Chemical gas mask. Chemical cartridge. Self-rescue filters Non Respiratory For the Protection of Head Eyes Ears Face Hands Arms Feet Lags Supplied Air Air-lined Self contained Air line respirator. Suction hose mask. Pressure hose mask. Demand Type Recalculating Type Compressed air Compressed oxygen Compressed oxygen. Regenerated oxygen CLASSIFICATION OF PPEs.
  • 180. 180 5/7/2024 Environmental Employees Maintenance Employees Production Employees Fire & Safety Employees Contractor Employees HEAD PROTECTION
  • 181. Foot Protection • Heavy objects such as barrels or tools that might roll or fall onto your feet. • Sharp objects such as nails or spikes that might pierce the soles or uppers of ordinary shoes. • Molten metal that might splash • Hot, slippery or wet surfaces • Corrosive Chemicals
  • 182. Hazardous conditions… • IMPACT - Carrying or handling materials such as packages, objects, parts or heavy tools which could be dropped • COMPRESSION - Work activities involving skid trucks (manual material handling carts, around bulk rolls, around heavy pipes • PUNCTURE - Sharp object hazards such as nails, wire, tacks, screws, large staples, scrap metal, etc • CHEMICAL - Check MSDS for protection
  • 183. 183 5/7/2024 FOOT PROTECTION •Toe protection Sole protection 183
  • 184. 184 5/7/2024 HAND PROTECTION 184 Your hands may well be the most valuable tools you have. To protect them from the many chemical compounds we use, you should always wear gloves. But choosing the right glove for the job takes some careful consideration. A variety of glove materials exist on the market today; such as rubber, neoprene, nitrile, latex, polyethylene, PVC, butyl, PVA...; which are specially designed to resist certain chemicals better than others. THERE IS NO UNIVERSAL GLOVE THAT WILL PROTECT YOU FROM ALL CHEMICALS!
  • 185. 185 5/7/2024 TYPE OF HAND GLOVES 185 1. Cotton or Canvas Hand Gloves 2. Leather Hand Gloves a. Full Leather Hand Gloves b. Only Leather Palm Hand Gloves 3. Rubber Hand Gloves a. Ordinary Rubber Hand Gloves b. Latex Rubber Hand Gloves c. Electrical Resistance Hand Gloves 4. Cut Resistance Nitrile Dipped Hand Gloves 5. Kevler Material (Substitute of Asbestoses) Hand Gloves 6. Aluminised Fabric Hand Gloves
  • 186. Hand Hazards • Cuts & punctures • Chemical exposure • Vibration • Electric shock • Burns • Heat & Cold • Biohazards
  • 188. FACE & EYES PROTECTION • Your eyes are very sensitive organs and may be easily injured. Eye Hazards include: – Chemical Splashes – Flying dist, chips, sparks – High Heat – Intense or UV light
  • 189. Specific hazards include… • IMPACT - Chipping, grinding machining, masonry work, woodworking, sawing, drilling, chiseling, powered fastening, riveting, and sanding. • HEAT - Furnace operations, pouring, casting, hot dipping, welding • LIGHT or RADIATION - Electric arc welding, gas welding, gas cutting • IRRITANTS / CORROSIVES - mists, dusts, sprays, splashes
  • 190. Face Protection • Use a faceshield when any of the following hazards exist: • Chemical splashes • Liquid spray • Flying chips or sparks • High Heat – Special face shield
  • 191. 191 5/7/2024 FACE PROTECTION Full face shield Adaptable on a helmet. The only overall protection for the face. Electric Arc Welding Face Shield
  • 192. Types of Eye Protection • Zero Power Spectacle – for flying chips & low hazards
  • 193. Types of Eye Protection • Polycarbonate – for dust and non- hazardous mist
  • 194. HEARING PROTECTION • Use hearing protection when: • in high noise areas • using power saws, impact tools, etc. • off the job when shooting, using power tools, etc. • Replace damage hearing protectors immediately
  • 195. EAR MUFFS Easier to use. Allow to communicate (radio, conversation, etc). HEARING PROTECTION • High noise can seriously damage the auditory system. Hearing protection are mandatory in areas where equipment is being operated and noise is above 90 dBA. 195 EAR PLUGS Be careful of the hygiene conditions when using it (clean hands, etc).
  • 198. RESPIRATORY PROTECTION • Dust Mask • Protect from large dust particles • Single use • Air purifying mask • Half mask - Full Face Mask • Do NOT use in oxygen deficient atmosphere. • Use in presence of gas and vapor contaminants Good maintenance of cartridge is essential. Adequate cartridge depends on the polluent. 198
  • 199. Working on height Protection 5/7/2024 199
  • 200. Protect yourself… •Use the right PPE for the Hazard •Inspect your PPE before using •Replace damaged or worn PPE •Store your PPE properly so it will be ready for the next use •Keep your PPE clean •Notify your supervisor if you need new PPE
  • 201. THANKING YOU Wishing you all the Best! BE SAFE & BE HAPPY