Industrial hazards and plant safety

1. INDUSTRIAL
HAZARDS and
plant safety
PRESENTED BY
GAURAV R. BHALKAR
1st year M. Pharm(Pharmaceutics)

2. INDUSTRIAL HAZARD
 Industrial hazards may be defined as
any conditions produced by industries
that may cause injury or death to
personnel or loss of product or property.
 Industrial hazards are of various types

3. • Fire and explosion hazards
• Electrical hazards
• Chemical hazards
• Gas hazards
• Mechanical hazards
• Dust hazards

4. FIRE AND EXPLOSION HAZARDS

5. CAUSES
 Electrical systems that are overloaded, resulting
in hot wiring or connections
 Combustibles near equipment that generates
heat, flame, or sparks.
 Flammable liquids and aerosols
 Electrical wiring in poor condition
 Batteries
 Smoking in the factory premises by workers.

6. PREVENTIVE MEASURES
 Not exceeding the
maximum occupancy within any part of the
building.
 Maintaining proper fire exits and proper exit
signage (e.g., exit signs pointing to them that
can function in a power failure).
 Prohibiting flammable materials in certain
areas of the facility.
 Smoking is prohibited in industrial premises.

7.  Don’t wear nylon cloths at work place .
 Each and every section of the industry
should have fire extinguisher .
 Make sure that all employees are familiar
with fire extinguisher.

8. HOW FIRE OCCURS ?
• Fire naturally occurs when the elements
are present and combined in the right
mixture.
• The elements are heat, fuel, and
an oxidizing agent (usually oxygen).
• These elements comes together and
form a model called FIRE TRIANGLE. And
hence fire is formed.

10. FIRE CLASSES
 Class A fires involve organic solids such as paper and wood.
 Class B fires involve flammable or combustible liquids,
including petrol, grease, and oil.
 Class C fires involve flammable gases.
 Class D fires involve combustible metals.
 Class E Fires involving ELECTRICAL APPARATUS
 Class F fires involve cooking fat and oil.

11. SAFETY MEASURES
1. Fire extinguisher
Types of fire extinguisher
 Water fire extinguisher
 Foam fire extinguisher

12.  Dry chemical powder
 co2 fire extinguisher

13.  wet chemical fire extinguisher
 metal fire extinguisher

14. Use of fire extinguisher
Types of fire
extinguisher
CLASS
A
CLASS
B
CLASS
C
CLASS
D
CLASS
E
CLASS
F
WATER √
FOAM √ √
DCP √ √ √ √
co2 √ √ √
WET CHEMICAL √ √
METAL √

15. 2. Fire tenders
Types of fire tenders
 Water fire tender

16.  Carbon dioxide fire tender
 Dry chemical fire tender

17. ELECTRICAL HAZARDS

18. CAUSES
 The improper use of machinery or
apparatus
 The improper use of electrical outlets
 The improper use of electrical equipment,
such as cables and power cords
 The improper maintenance of apparatus,
outlets, and electrical equipment
 An overloaded circuit
 The improper joints of two wires.

19. PREVENTIONS
 Use extension cords only for
temporary purposes.
 Do not use any equipment or cords
that have splices.
 Do not use three-to-two prong
adapters.
 Don't overload outlets.

20.  Because of the chemicals, check the
connection and power cords are not
degrading.
 Indication of DANGER SIGN at every
high voltage terminal.
 Proper maintenance of wiring and
equipment.
 Never use the power cord to move or
carry apparatus.

21. Effect of the shock
Current Reaction
1 Milliampere Perception level
5 Milliamperes Slight shock felt; not painful but
disturbing
6-30 Milliamperes Painful shock; "let-go" range
50-150 Milliamperes Extreme pain, respiratory arrest,
severe muscular contraction
1000-4,300 Milliamperes Ventricular fibrillation
10,000+ Milliamperes Cardiac arrest, severe burns and
probable death

22. Safety measure
• Electric gadgets should be repaired only by a
qualified person.
• Disconnect electrical gadgets when not in use.
• Never touch electrical equipment with wet
hands.
• Electric wires or cords, if faulty, should never be
used until repaired.
• Avoid contact with energized electrical circuits.

23. • Place rubber mats in front of electrical switch
boards.
• Make sure that all employees are familiar with
the location and use of fire fighting apparatus
• Use sand or blanket to control fire caused due
to electrical accidents

24. CHEMICAL HAZARDS

25. CAUSES
 Irritants are materials that can cause
inflammation of the body surface with which they
come in contact. Common irritants substances
such as: NITROGEN DIOXIDE, OZONE ETC.
 Chemical asphyxiants render the body
incapable of maintaining an adequate oxygen
supply. Examples include: CARBON MONOOXIDE
ETC.

26.  Depressant effect upon the central nervous
system, particularly the brain. Examples
include: CHLOROFORMS, ALCOHOLS ETC.
Hepatotoxic agents can cause damage to the
liver. Examples include: CARBON TETRACHLORIDE,
METYLENE CHLORIDE ETC.
 Nephrotoxic agents can damage the
kidneys. Examples include: URANIUM COMPOUND.

27. PREVENTIONS
 Train employees to follow safe handling and
application procedures for maintenance or pesticides
chemicals.
 Do not use excessive grease or lubricants on
equipment.
 Regularly re-evaluate all procedures to ensure they
effectively remove chemicals.
 Store chemicals in designated areas away from
food, ingredients and packaging.

28.  Ensure chemical container are clearly labeled
or colour coded, and that they are used only for
chemicals.
 Receive raw ingredients from reputable
suppliers that effectively control chemical hazards.
 Ensure restricted ingredients and additives are
correctly measured.
e.g Hexachlorophene. Because of its toxic
effect it penetrate human skin. So it used only
when an alternative preservative has not been
shown to be as effective.

29. Safety measures
 Respirator must be used in all the gas storage
places.(specifically chemical gas)
 Body should be fully covered whenever people
are interacting with hazardous chemicals.
 When skin burn happens due to chemicals use
alkaline solution always instead of water.

30. GAS HAZARDS

31. THREE MAJOR TYPES OF GAS
HAZARDS
1. Flammable
Risk of fire and / or explosion e.g. Methane,
Butane, Propane

32. 2. Toxic
Risk of Poisoning e.g. Carbon Monoxide,
Hydrogen, Carbon Dioxide,
Chlorine

33. 3. Asphyxiant
Risk of suffocation e.g. Oxygen deficiency.
Oxygen can be consumed or displaced
by another gas.

34. Gas Safety at Work
The Gas Safety (Installation and Use) Regulations 1998
require the following:
 All gas appliances, pipe work and safety devices
must be maintained in a safe condition and be
inspected by a competent person.
 When a gas appliance is installed, it must be
located in a position that is easily accessible for use,
inspection and maintenance.
 Employers, the self-employed, or anyone
responsible for business premises, must not allow a
gas appliance to be used it may be dangerous.

35. BHOPAL GAS TRAGEDY
• It occurred on the night of 2–3
December 1984 at the Union Carbide
India Limited (UCIL) pesticide plant
in Bhopal, Madhya Pradesh.
• The official immediate death toll was
2,259. The government of Madhya
Pradesh confirmed a total of 3,787 deaths
related to the gas release.

36. THE RELEASE OF GAS
• In November 1984, most of the safety systems were not
functioning and many valves and lines were in poor
condition.
• Several vent gas scrubbers had been out of service.
• The reaction was sped up by the presence of iron from
corroding non-stainless steel pipelines. The
resulting exothermic reaction increased the temperature
inside the tank to over 200 °C (392 °F) and raised the
pressure. This forced the emergency venting of pressure
from the MIC holding tank, releasing a large volume of toxic
gases. About 30 metric tons of methyl isocyanate (MIC)
escaped from the tank into the atmosphere in 45 to 60
minutes.

37. MECHANICAL HAZARDS

38. Work Equipment Examples
Hand tools Hammers, Knives, Screwdrivers etc.
Power tools powered screw drivers, drill machine etc.
Machinery Photocopiers, food production line etc.
Apparatus Bunsen burners
Other Ladders etc.
EXAMPLE OF WORK EQUIPMENT

39. CAUSES AND PREVENTIONS
 Rotating Machinery
causes
Machinery with rotating parts can catch loose
clothing, hands or hair, potentially
causing serious injuries.
Prevention
Ensure rotating shafts, belts and pulleys are
covered by guards, lids or covers.
 Tools
Causes
Careless use of tools or use of tools in poor
condition can cause injuries to the hands, eyes,
head and limbs.
Prevention
regularly check tools for defects or damage

40.  Magnets
Causes
Large, powerful magnets or electromagnets can attract
other magnets or iron/nickel objects which can cause
painful pinching of fingers or hands if caught between the
two.
Prevention
inform peoples of this hazard before such magnets are
used.
 Glassware
Causes
Any kind of glassware has the potential to break, thus
creating the risk for cuts.
Preventions
• wear goggles for eye protection.
• use heat-resistant glassware.
• clean up any broken glass immediately and dispose of in
a special waste bin.

41. DUST HAZARDS

42. How does dust hurt you?

43.  Chronic Obstructive Pulmonary Disease
(COPD) :-
‘Obstructive’ lung conditions which reduces
airflow out of the lungs.
 Asthma :-
Another obstructive lung disease, which can
be caused by exposure to irritants at work
place and causes shortness of breath.
 Cancers :-
Tumours, particularly of the lung and nose, are
related to substances commonly encountered
at work including asbestos, silica, nickel,
cadmium and wood dust.

44.  Heart disease :-
Dust-affected lungs put extra strain on the
heart, which can lead to right-sided heart
failure.
 Extrinsic allergic alveolitis (EAA) :-
An allergic condition, which affects workers
exposed to biological dusts, causing
conditions including farmers’ lung.

45. PREVENTIONS
 Safe machinery and equipment :-
• Dusty work processes should be isolated if
possible.
• An exhaust ventilation system is often
needed to suck dust away.
 Safe procedures :-
• Standardised working procedures are
needed in areas where dust can be a problem.
• Information and training is important.
• Warning signs may be needed.

46.  Respirators
If steps 1 and 2 are not completely effective
then an approved respirator is needed. Make
sure that
(A) It fits properly and is the right kind of
respirator
(B) Training in how to use it is provided and
(C) Maintenance checks are carried out.

47. INDUSTRIAL POLLUTION

48. AIR POLLUTION
CAUSES :-
1. Emissions from industries and manufacturing
activities.
2. Burning Fossil Fuels.
3. Household and Farming Chemicals.
COMMON AIR POLLUTANT :-
 Carbon monoxide
 Lead
Nitrogen dioxide
Sulfur dioxide

49. Effect on health :-
 Acidification
Asthma
Cancer (like lung cancer)
 COPD
Effect on children(risk of asthma, pneumonia etc)

50. How to avoid air pollution ?
Practice
• Recycling
• Reusing
• Waste minimisation
• Mitigating
• Preventing
• Compost

51. Pollution control devices
1. Dust collection systems
• Baghouses
• Cyclones
• Electrostatic precipitators
2. Scrubbers
• Baffle spray scrubber
• Cyclonic spray scrubber
• Ejector venturi scrubber
• Mechanically aided scrubber
• Spray tower
• Wet scrubber

52. WATER POLLUTION
CAUSES
 Industrial waste
 Sewage and waste water
 Ocean and marine dumping
 Oil Pollution

53. Effect on health
 Diseases like Cholera
 Malaria
 Typhoid (spread during the rainy season )
 Aquatic life gets destroyed

54. Control of water pollution
Pollution control devices
Sewage treatment
•Sedimentation (Primary treatment)
•Activated sludge biotreaters (Secondary treatment; also used
for industrial wastewater)
•Aerated lagoons
•Constructed wetlands (also used for urban runoff)
Industrial wastewater treatment
•API oil-water separators
•Biofilter
•Dissolved air flotation (DAF)
•Powdered activated carbon treatment
•Ultrafiltration

55.  Throw waste material only in dust bin.
 Use water wisely. Do not keep the tap running
when not in use.
 Do not throw chemicals, oils, paints and medicines
down the sink.
 don’t overuse pesticides and fertilizers in farm.
 Rivers should not be used for washing clothes or
bathing animals in.

56. SOIL POLLUTION
CAUSES
• Application of pesticides and fertilizers
• Mining
• Oil and fuel dumping
• Disposal of coal ash
• Leaching from landfills
• Drainage of contaminated surface water into the soil
• Discharging urine and faeces in the open

57. Effects by soil pollution
• Causes problems in the human respiratory system.
• Causes problems on the skin.
• Causes various kinds of cancers.
• Very bad smell and odour in the town.
• Landfills breed rodents like rats, mice and insects,
who in-turn transmit diseases.

58. Prevention on soil pollution
• More and more land should be brought under farming.
• Trees should be planted everywhere.
• Waste matter should be disposed immediately.
• Avoid using more fertilizers and Pesticides.
• Don’t dump oil and fuel on the ground.

59. REFERENCES
 Pharmaceutical And Production
Management
C.V.S Subrahmanyam
 www.wikipedia.com