Industrialsafety

INDUSTRIAL HAZARDS AND SAFETY
Prof. Dr. Basavaraj K. Nanjwade M. Pharm., Ph. D
Department of Pharmaceutics
KLE University College of Pharmacy
BELGAUM-590010, Karnataka, India
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com
24 August 2012 KLE College of Pharmacy, Nipani 1

CONTENTS
• Introduction
• Types of hazards
• Recommendations and Suggestions
• Industrial effluent testing and treatment
• Discussion on industrial accident case
studies
• Questions
• References

INTRODUCTION
Industrial hazards:
It can be defined as any condition produced by
industries that may cause injury or death to
personal or loss of product or property.

Heat and Cold
Burns
Heat stroke
Heat cramps
Foot sore
Immersion foot
Frost bite
Preventive Measures
A reasonable temp. of 20-250C must be maintained

Noise have two type of effects
 Auditory
 Non auditory effects
 Preventive measures
a. At source:
• Source of noise can be enclosed with an insulation
material or concrete wall.
• Proper maintenance of machinery
b. By distance
c. Personal protection against noise.

Equipment noise sources ,level & potential control solutions
Equipment Sound level in
dBA at 3 feet
Possible noise control
treatments
Air coolers 87-94 Aerodynamic fun blades,↓
revolutions/min ↑ pitch,↓
pressure drop
Compressors 90-120 Install mufflers on intake,&
exhaust, enclosure the
machine with casing,
vibration isolation & lagging
of piping system
Electric motors 90-110 Acoustically lined fun
covers, enclosure 7 motor
mutes

Equipment noise sources ,level & potential control solutions
Heater &
furnaces
95-110 Acoustic plenums, intake
mufflers, lined & damped ducts
Valves <80-108 Avoid sonic velocities, limit
pressure drop & mass flow,
replace with special low noise
valves
Piping 9-105 Inline silencers, vibration isolation

Radiation
Radiation are divided into two groups
Natural Man made
Cosmic rays Medical /dental x-rays isotopes
Environmental (radioactive
elements e.g. uranium)
Occupational exposure
Internal (potassium,) Nuclear radioactive fallout
Approx 0.1 rad/yr Miscellaneous
Use of radio active substances
by different industries

Effect of hazards
 Somatic
 Genetic
i. Preventive measures
ii. Radiation source should be housed in a building
that shields any surrounding area.
iii. Radiation badges should be worn.
iv. Periodical medical examination.
v. Proper use of lead shields & lead rubber aprons.

Fire & explosion hazards
Causes
Smoking in the factory
Defective heating equipment, electrical equipment &
wiring.
Explosive gas leakage.
Inadequate protection of electric motors
Sparking of electric wires & equipment
Protection & prevention
Types of fire

Preventive measures
• Prohibition of smoking in manufacturing areas.
• Oxygen present in the inflammable atmosphere may
be ↓by dilution with gases such as nitrogen, co2,steam
or combination of these.
• Hazardous operation should be isolated
• Eliminating the ignition sources
• Using fire resistant material in construction
• Suitable emergency exits
• Adequate venting

• Automatic sprinklers
• Equipment should design to meet the specifications &
code of recognized authorities, such as ISA, API
&ASME
• The design & construction of pressure vessels &
storage tanks should follow API & ASME codes.
• Inspection

Chemical Hazards
Local
– Dermatitis
– Eczema
– Ulcers
– Cancer
Inhalation
– Gas Poisoning
Ingestion
Living tissue may be destroyed by chemical reactions such as
Dehydration
Digestion
Oxidation

Source, effect & precautions of chemical hazards
Type/ source of
chemical contaminant
Effect/ organ
affected
Precautions to be taken
Acridines,
phenothiazines
Dermatitis Cleanliness, removal of people
from the areas as soon as first
sign of skin reaction is observed.
Solvents like
chloroform, benzene
Handle with care
Vegetable drugs like
capsicum &
podophyllum
Dust evolves,
affects eye
Goggles are to be worn
Long term use of filter
without cleaning
Dust explosion Regular cleaning

Source, effect & precautions of chemical hazards
Improper use of
cleaning agents
contamination Follow established
cleaning procedures
Working with radio
pharmaceuticals
Hazards due to
emitted radiation
Wearing lead coat,
maintaining pressure
of working area
slightly less than
atmospheric pressure
Underground tanks Difficulty in
monitoring
interior & exterior
Minimal use of
underground tanks

PREVENTIVE MEASURES
• Tolerance levels for toxic chemicals set by federal
regulations have to be followed.
• Strict observation of operations of all safety
regulations

Biological hazards
• Disease due to biological hazards
Brucellosis (dairy industry)
Byssinosis (textile industry)
Bagassosis (sugar-cane)
Loco motor disorder
• Preventive measures
Periodic health check up
Personal protection
The manufacturer should also provide
First aid facilities
Initial examination
Facility for vaccination
Routine sanitation programme

Mechanical hazards
• Accidents usually take place by the combination of unsafe
condition & carelessness.
• Most of industrial accidents are due to
 Faulty inspection
 Inability of employee
 Poor discipline
 Lack of concentration
 Unsafe practice
 Mental & physical unfitness for job
 Faulty equipment or improper working condition
 Improper training regarding the safety aspects

Mechanical hazards
•In order to prevent mechanical accidents factories act
lay down certain requirements
For cranes
End buffers
Indicating lamps
Signals
Proof loading
upto20 tons 25% in excess
20 to 50 tons 5 tons in excess
above 50 tons 10% in excess

Mechanical hazards

Building planning
• Floors must be of unskid/non-slippery type.
• Enough space for employees to work.
• Passages between working places.
• Proper arrangements of temperature control; like fans,
A.C., heaters.

Building planning

Safe material handling
• Careless handling of heavy materials and components
should be avoided.
• Full use of mechanical material handling equipment.
• All material handling equipments should be repaired
and maintained properly.
• Containers employed to transport liquids should not
be defective or leaking.

Personal protective devices
• Protection of head by using hard hats/helmets.
• Protection of ears by using earmufffs and plugs.
• Protection of face by using face marks, face
shields.

Electrical hazards
• Shocks
• Sparking
• Fire
• Wiring faults
Preventive measures
Proper maintenance of wiring & equipment
High voltage equipment should be properly enclosed
Good house keeping
Water should not be used for dousing electric fire
Worker should avoid working in electric circuits or
equipment in wet clothing or shoes.

Pollution hazards
• Types
a. Air pollution
b. Water pollution
c. Thermal pollution
d. Sound pollution
Air pollution
• Sources
 Automobiles
 Industries
 Domestic

Preventive measures
i. Those suitable for removing particulate matter
a. Ventilation
 Exhaust ventilation
 Plenum ventilation
a. Air purifying equipment
ii. Those associated with removing gaseous pollutants
Water pollution
1. Types of water pollutants
 Physical
 Chemical
 Physiological
 Biological 24 August 2012 KLE College of Pharmacy, Nipani 32

Preventive measures
2. Problems of water pollution
3. Preventive measure
a. Control of water pollution
i. Physical treatment
 Storage
 Filtration
ii. Chemical treatment
iii. Biological treatment
b. Treatment of industrial waste
Primary treatment
Secondary treatment
Tertiary treatment

Preventive measures
c. Thermal pollution
• Effects
 Damage to aquatic environment
 Reduction in assimilative capacity of organic waste
• Various off stream cooling systems
i. Wet cooling towers
ii. Dry cooling towers
iii. Cooling ponds
iv. Spray ponds

Recommendations & suggestions
Proper treatment & disposal methods for effluents
should be adopted
An awareness program
Measures for increase efficiency of the water use

Classification of signs according to use –
(1) Danger signs.
The DANGER header is used when there is a hazardous
situation which has a high probability of death or severe
injury. It should not be considered for property damage
unless personal injury risk is present.

2) Caution signs. (i)
The CAUT I O N h e a d e r i s u sed to indicate a hazardous
situation which may result in minor or moderate
injury. However, Caution should not be used when
there is a possibility of death or serious injury.

(3) Safety instruction signs
General Safety Signs (SAFETY FIRST, BE
CAREFUL, THINK) should indicate general
instructions relative to safe work practices,
reminders of proper safety procedures, and the
location of safety equipment.

(4) Biological hazard signs.
The biological hazard warning shall be used to
signify the actual or potential presence of a
biohazard and to identify equipment, containers,
rooms, materials, experimental animals, or
combinations thereof, which contain, or are
contaminated with, viable hazardous agents.

Pictograph
Pictograph means a pictorial representation used to
identify a hazardous condition or to convey a safety
instruction

Signal Word
Signal word means that portion of a tag's inscription
that contains the word or words that are intended to
capture the employee's immediate attention.

Tag
Tag means a device usually made of card, paper, pasteboard,
plastic or other material used to identify a hazardous
condition.

Danger Tags
Danger tags shall be used in major hazard situations
where an immediate hazard presents a threat of death
or serious injury to employees. Danger tags shall be
used only in these situations.

Caution Tags
Caution tags shall be used in minor hazard situations
where a non-immediate or potential hazard or unsafe
practice presents a lesser threat of employee injury.
Caution tags shall be used only in these situations.

Warning Tags
Warning tags may be used to represent a hazard level
between "Caution" and "Danger," instead of the
required "Caution" tag, provided that they have a
signal word of "Warning," an appropriate major
message

Biological Hazard Tags
The symbol design for biological hazard tags shall
conform to the design shown below:

Color Coding-Danger Tag
"DANGER" -- Red, or predominantly red, with
lettering or symbols in a contrasting color.

Color Coding-Caution Tag
"CAUTION" -- Yellow, or predominantly yellow, with

Color Coding-Warning Tag
"WARNING" -- Orange, or predominantly orange, with

Biological Hazard Tag
BIOLOGICAL HAZARD -- Fluorescent orange or
orange-red, or predominantly so, with lettering or
symbols in a contrasting color.

Industrial effluent testing and treatment
• Effluent is an outflowing of water from a natural body
of water, or from a man-made structure.
• Water pollution or waste water discharge from the
industrial facilities.
REASON OF TESTING
• To find out
-Pollution load
-Presence of toxic ingredients
-Color, turbidity, odour and quality of water
-pH and acidity / alkalinity
-Suspended solids and dissolved solids
-Phenolic compounds and oily materials

GUIDELINES FOR TESTING EFFLUENTS
• Samples may be collected at specific intervals and
finally can be mixed before analysis.
• Containers made up of glass, polythene or any suitable
plastic material may be used.
• Samples may also be refrigerated to avoid loss of
volatile matter
• Samples could be preserved after adjusting the pH
• O2, CO2, CO may be estimated

THE RESULTS OF TESTING ARE REPORTED
AS FOLLOWS:
• Effluents may be expressed as mg/ltr, ppm, %/ltr, and
mcg/ltr
• Acidity / Alkalinity / Oil / Grease / CN / Phenol / Dyes
content should be reported
TESTING OF WASTE WATER (EFFLUENT)
TEST TREATMENT METHOD
pH
Acidic
Basic
Lime or NAOH
H2SO4

AS FOLLOWS:
Suspended Solids Sedimentation
Oil and grease -grease taps
-skimming
Cyanide
Chlorinated & complex with pyridine
pyroxolene
-Colourimetrically
-alkaline chlorination
-oxidation with ozone
-oxidation with H2O2
Phosphates
-Convert to ammonium molybdatephosphates
-extracted with benzene/ isobutyl alcohol
mixture
-organic phase treated with tin chloride (blue)
Colourimetrically
-ppt with chalk or lime
-coagulation with alum

AS FOLLOWS:
Mercury
-treated with nitric acid and potassium
dichromate soln- treared with tin chloride
Vapour determined by spectrophotometry
-Coagulation
-chelation with
trimercaptotriazine
Phenolic compounds
Steam distillation-acidify (pH<4)- add CuSO4
soln-
Add aminoantipyrine soln- extracted with
chloroform
calorimetrically
Removal by polymeric
adsorbents

BIOLOGICAL OXYGEN DEMAND
• It is the amounts of oxygen required by micro organisms to
bio chemically oxidize carbonaceous organic matter at 20 0C
in 5 days.
• 10 mg/litre or less
• Excess makes water toxic
MEASUREMENT
• Special designed bottle with flared cap
• Incubated at 20 0C for 5 day measuring DO
• Microorganism added if required

Dissol oxy in ppm (mg/ltr) = N(V) (8) (1000)
V1
V = Volume of sodium thio sulphate required.
N = Normality
V 1= Volume of sample taken.
CHEMICAL OXYGEN DEMAND
• Oxygen equivalent of organic matter present in waste water
that is susceptible to oxidation
• Waste water sample is refluxed with a known excess of pot.
dichromate in a 50% sulphuric acid solution in presence of
silver sulphate and mercuric sulphate

CHEMICAL OXYGEN DEMAND
• The organic matter of the sample is oxidised to water, carbon
dioxide and ammonia
• The excess of dichromate remaining untreated in the solution
is titrated against standard ferrous ammonium sulphate
• COD(mg/l) = (V1-V2) x N x 8 x100
Where, X
V1 = Volume of ferrous ammonium sulphate solution
consumed in blank
V2 = Volume of ferrous ammonium sulphate solution
consumed for test solution
X= Volume of sample
Nta=k eNnormality of ferrous ammonium sulphate solution 24 August 2012 KLE College of Pharmacy, Nipani 58

Limit for Discharge into Systems
Sr. No. Parameters Tolerance limits
1 pH 5.5 – 9.0
2 Oil and grease 10
3 Total suspended solid, mg/l 100
4 BOD, mg/l 30
5 COD, mg/l 50
6 Mercury 0.01
7 Arsenic, mg/l 0.20
8 Cyanide, mg/l 0.10
9 Sulphides, mg/l 2.00
10 Phosphates, mg/l 5.00

Waste Water Treatment
Waste Water Pretreatment
• Attempted to render the effluent suitable for further
treatment
• Equalization
Concentrated waste is diluted if necessary
-by mechanical mixing
-by aeration mixing
• Neutralization
• Removal of Grease and Oils

Primary Treatment of Waste Water
• Removal of large floating or suspended particle by
physical and chemical treatment
 Screening
• Large particles are removed
• Coarse screen of metal bars or heavy wires spaced 25-50
mm apart
• Finer materials are separated by screening through 0.8-6
mm meshes
 Grit Chambers
• Removal of particles by centrifugal action and friction
against tank walls
• Diffused air used for mixing pattern

• It is used
To prevent any damage to equipment
To avoid settling in pipe bends

 Chemical Reaction
• Involves agglomeration of tiny particles into large
particles
 Flocculation
-by mechanical stirring and by chemical flocculants
 Precipitation
-Large amount of suspended solid formed
 Coagulation
-Formation of large and quick settling flocs by
a) Reduction of charges and repulsive force
b) Adsorption on long chain molecular structure

Secondary Treatment of Waste Water
• It is a biological process
• C, H, and O sources are available
• Nitrogen should be 5% of the BOD
• Phosphorus should be 20% of mass of nitrogen
• Environmental conditions are provided
Advantages
• Continuous waste treatment is favored
• Low cost system
Disadvantages
• Prior prediction of biological degradability is not possible
• Solubility limits biodegradability

Activated Sludge Process
• Microbial Floc is suspended in tank
• Air is continuously supplied
• Biological degradation of waste into CO2 and H2O
• Bacterial flora grows and remains suspended in the form
of floc called as “activated sludge”
• 20% of sludge is recycled
• 6 to 24 hours aeration is required

• Advantages
-Removal of soluble organic substance, colloidal
matter, particulate matter, inorganic substance
-Produce high quality effluent
• Disadvantage
-Maintenance cost is high
-Growth of anaerobic bacteria fungi etc

Activated Sludge Process

Trickling filtration process
• Microorganisms are attached to fixed bed
• It acts as a filter
• Bed is maintained at height of 2.5 meter
• Gelatinous film is formed
• Effluent is sprayed over the surface
• Slots at the bottom for air inlet
• Aerobic metabolism occur on the surface
• Anaerobic metabolism occur at the bottom

Trickling Filtration Process

Trickling Filtration Process
Advantages
• Produce effluent of consistent quality
• Aerobic and anaerobic digestion are achieved
• More economical
• Sludge can be removed quickly
Disadvantage
• Cost for ventilation duct for air supply is high
• Efficiency decreases in the winter

Oxidation Ponds
• Depth should be 1 to 2 meters.
• Bottom and sides are lined with polyethylene, cement.
• Oxygen released by algae, carbon dioxide generate from
biodegradative
• Aerobic oxidation producing carbon dioxide and water.
Advantage:
• Operation is simple and economical.
Disadvantages:
• Required disinfections
• Use for wastes having low BOD.

Tertiary Treatment Of Waste Water
• Meant for polishing the effluents.
• Bacteria are removed by keeping in maturation
ponds.
• Chlorinated, if still contain bacteria.
• Methods are more expensive than biological
treatment.
 Coagulation :
• Reaction take place upon addition of the
coagulants.
-Metal salts
-Organic Polymers
• In water, form insoluble product with impurities.

 Coprecipitation :
• Ions in solution phase precipitate with the carrier
molecule by
-Adsorption Process
-Inclusion Process
 Filtration
• Most common type in addition to disinfection.
• Practiced prior to the chlorination.
• Should be done after coagulation.
• May be made up of sand, activated charcoal.

Adsorption
• Involves treatment with activated carbon.
• Useful for removal of pesticides

REFRENCES
• Pharmaceutical Production and Management By C. V. S. Subrahmanyam
• www.geocities.com
• www.britannica.com
• http://nptel:iipm.ac.in
• www.waste_management_world.com
• Sewage and Industrial Effluent Treatment, 2 nd edition By John Arundel
• The Theory & Practical of Industrial Pharmacy By Leon Lachman, Herbert
A. Lieberman, Joseph Kiang, 3RD Edition Varghese Publishing House.
• www.osha.gov

THANK YOU
Cell No: 00919742431000
E-mail : nanjwadebk@gmail.com

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