The document discusses work permits and safety procedures for hazardous work. It defines what a work permit is and its usefulness in spelling out job tasks, hazards, and safety precautions. It discusses the general principles of work permit systems, including management and training. It outlines factors that can contribute to accidents, such as failing to recognize hazards or comply with permit procedures. The document also describes different types of work permits for hot work, vessel entry, excavation, cold work and situations where permits are not required. It provides examples of precautions for different permit types.

1. PRINCIPLES OF SAFETY
MANAGEMENT
Module 4

2. What is a work permit?
• Work permit is essentially a document that, categorically spells out
the tasks. Equipment involved, its location, personnel involved, time
limitations, precautionary measure to be taken together with likely
hazards to be encountered if any.

3. Usefulness of Permit:
• Work permits provide written information on the prevent hazards
connected with the job performance. It spells out the suitable
remedial measure to adopted to encounter the hazardous conditions
that are prevailing or that can be encountered while performing the
job. It also stipulates various conditions and limitations on the part of
persons actually required to perform the job. It indicates the various
types of personal protective equipment to used at different stages of
work.

4. • It serves as a predetermined check-list for various safety precautions
to be taken. It also serves as media of information to all concerned in
advance. It provides a written record of the operation including the
personnel who were involved in authorizing and carrying out the
operations. The permit system (which necessitates carrying out of
various testes and safe guards) Teach a sense of security from
accidents in the minds of the crew performing the job.

5. General principles
• The following aspects should be considered with respect to Permit to
Work Systems:
• Human factors;
• Management of the work permit systems;
• Poorly skilled work force;
• Unconscious and conscious incompetence;
• Objectives of the work permit system;
• Types of work permits required; and
• Contents of the work permits.

6. • The following issues may contribute towards a major accident or
hazard:
• Failing of the site safety management system;
• Failure to recognise a hazard before and during maintenance;
• Failure to comply with the work permit system in hazardous environments;
and
• Communication failure during the use of a work permit system.

7. Contributory factors for an assessor to
consider concerning the Work Permit System
The Safety Report should address the following points:
• Whether staff have been sufficiently informed, instructed, trained and
supervised to minimise a potential human failing during operation of the
work permit system;
• Whether the work permit system includes sufficient safety information,
maintenance instructions, correct PPE and equipment for use;
• Whether the work permit contains sufficient information about the type of
work required (Equipment removal, excavation, hot/cold work, repairing
seals, vessel entry, waste disposal, isolation);
• Whether there is sufficient provision available to fulfil the requirements of
the work permit system;

8. • Whether the employees responsible for control of the maintenance work are identified within
the work permit system and that the work is properly authorised by a responsible person;
• Whether the work permit system is managed, regularly inspected and reviewed;
• Whether all work permits are kept on file;
• Human factors (stress, fatigue, shift work, attitude);
• Whether sufficient precautions are taken prior to initiating a work permit (isolation, draining,
flushing, environmental monitoring, risk assessments, communication, time allotted for the
work);
• Whether staff are aware of the type of environment they are working in during the operation of a
work permit (flammable, corrosive, explosive, zones 0, 1 & 2, electricity supplies);
• Whether the person responsible for operating the plant is aware of the type of maintenance
involved and how long it is likely to take; and
• Whether the work permit system involves a formal procedure whereby the maintained plant or
equipment is handed back to operation.

9. Major hazards
Major hazards could arise from the following:
• Wrong type of work permit used;
• Wrong information about work required on the work permit;
• Failure to recognise the hazards where work is carried out (e.g. flammable substances);
• Introduction of ignition source in controlled flameproof area (e.g. welding, non spark-
proof tools, non-intrinsically safe equipment used in intrinsically safe zones);
• Terms of work permit not adhered to (e.g. failure to isolate plant and/or drain lines of
hazardous substances);
• Failure to hand-over plant in safe condition on completion of work/cancelling of work
permit;
• Unauthorised staff performing work permit functions;
• Poor management of the work permit system; and
• Insufficient monitoring of the work permit system.

10. Types of permit:
• Hot work permit
• Safety Entry work permit
• Acid area work permit
• Working at height work permit
• Cold working permit
• Excavation permit

11. HOT WORK PERMIT
• During process of work where ignition comes out or heat generates its own
is considered as hot work.
• The permit is required for following jobs:
• Welding
• Flame cutting
• While using pneumatic/ hydraulic power tools
• The Hot work permits, typically colored red or the red-edged, are more
generally applied to any type of the work which includes the actual or the
potential sources of the ignition and which is done in an area where there
may be the risk of the fire or explosion, or which includes the emission of
the toxic fumes from the application of the heat.

12. Precautions
• 1. Equipment of the area should be tested to determine the explosive
range (through explosive meter/ by taking air samples). Cleaning or
ventilating can clear explosive content
• 2. Cover all pits, sumps, opening etc. with fireproof material to
prevent spark entering and causing explosion or fire. Area and
surrounding are sufficiently wetted to facilitate extinguishments of
sparks, hot slag etc.
• 3. Adequate fire fighting equipment should be kept ready along with
the person who know the operation of the equipment.

13. SAFE ENTRY OR VESSEL ENTRY PERMIT
• A vessel entry permit will only authorize entry into vessel.
• Separate hot work permit should be issued, if such work is done on
the vessels
• Examples of vessels are tanks, drums, boilers, furnaces, barrels,
pipelines, sewer, pits etc.
• The hazard may be presence of toxic inflammables vapours of gases,
suffocation due to lack of oxygen, slipping and falling etc.

14. SAFE ENTRY OR VESSEL ENTRY PERMIT
Precautions
• Isolate the equipment/ vessel from all source through which any energy,
stock or harmful substance can get introduced by disconnecting, blinding,
blanket etc.
• Drain clear, wash the equipment vessel to make it free from toxic/
flammable gases and other harmful substances
• Test the vessel inside and determine the presence of explosive mixture
and deficiency of oxygen and further ventilate the workroom till the
oxygen content increased to 17%
• In case of deficiency of oxygen cannot be improved , entry of explosive
should be restricted

15. EXCAVATION PERMIT
• Hazards in excavation are breaking of pipe likely carrying hazardous
substances, breaking of electrical / telephone cables etc. It results
into:
• 1. Accidents
• 2. Disruption/ delay in production
• 3. Loss of life
• 4. Loss of property
• 5. Disruption in communication

16. EXCAVATION PERMIT
Precaution
• Permits can be prepared with the help of factory plan and sent to the
engineer / plant in charge for counter signing
• Plant incharge/ Engineer would suggest special precaution to avoid
accident, damage etc. before counter signing
• After counter signing permit can be used to executer/ receiver.
• Suitable PPE are to be used

17. Cold Work Permit
• The Cold work permits, typically blue-edged or the colored blue, are
usually used to cover the variety of the potentially hazardous
activities which are not of the type covered by the hot work permit.
• The activities for which the cold work permit may be relevant will
vary from the site to site but should be clearly defined.

18. A cold work permit is required for the potentially hazardous work not
covered by the other types of the work permits. Some examples include:
• Chemical cleaning or the use of solvents,
• Handling of the hazardous substances (e.g., toxic/corrosive chemicals,
asbestos, etc.)
• The Use of resins typically used during the blade repairs,
• Any painting activity,
• Heavy lifts (refer to Crane/Lifting procedure for definition),
• Erecting or the dismantling scaffolds,
• Any non-routine and the potentially hazardous activity,
• Any activity requiring the specific control measures to the confirm safety.

19. NO PERMIT REQUIRED
• No permit is required where work is carried out with standard
operating procedure (SOP) which will be issued by manufacturer
through servicing manuals
• Competent personnel or site supervisor perform the task

20. NO OBJECTION CERTIFICATE
• No objection certificate are the documents are required to satisfy a
permit issuer regarding the safety precautions taken before the start
of work:
• Confined space entry certificate
• Clearance for excavation certificate
• Clearance to move heavy equipment
• Movement of heavy vehicles
• Isolation confirmation certificate

21. LOG BOOKS
• Log books are for maintaining the records of movement of personnel
in restrained and hazardous zones

22. • Clause 2(0), Sch-19, rule 102, GFR, defines 'confined space' as any space by reason of its
construction as well as in relation to the nature of the work carried therein and where
hazards to the persons entering into working inside exist or are likely to develop during
working.
• Confined Space is also described as a place which,
1. Is mostly enclosed and partially open.
2. Is at atmospheric pressure and temperature.
3. Has limited or restricted openings for entry and exit.
4. Is not designed or intended for normal place of work (i.e. not for long time worker
occupancy).
5. Has unfavourable natural ventilation due to stagnant air, no free air movement,
oxygen deficiency or enrichment or nitrogen atmosphere.
6. Has contaminated air with toxic or / and flammable gas, dust etc and
7. May cause engulfment (swallowing) in unstable or loose material.
Examples (Types) of confined spaces are - Storage tank , Process vessels / Reaction Vessel,
Pressure Vessels, Boilers, Tank cars (trucks), Wells / bores, Under floor/ Floor opening,
Sumps, Pits, Silos, Pipes, Ducts, Gutters, Tunnels, Sewers, Vats, Bilges, Shafts, Go-down of
grain, sulphur, cement, clay and similarly loose material, Roof voids / Gap between roof
and false ceiling.

24. • Hazards of Confined Space can be classified as
1. Poor lighting and ventilation.
2. Oxygen deficiency.
3. Contamination of toxic and/or flammable gases.
4. Unexpected activation of machinery or flow.
5. No way or no time available for exit.
6. Engulfment (burying) in loose material.
7. Non specific work practices.
• Other hazards are suffocation, burning, poisoning, explosion, drowning, freezing,
crushing, entrapment, scalding, stroke, heat stress, radiation, physical trauma, injury
by moving machinery, slipping or falling etc.

25. Safety precaution for entering in confined
space
• Necessary work and safety permit must be obtained before anybody enters
tanks, drums or other vessels. Should there be any doubt about the presence of
gas while work is in progress, the work shall be stopped and arrangements made
for conducting necessary gas test and investigations.
• Process operators shall take all possible steps to remove maximum amount of oil
and gas from the vessel requiring the entry of personnel.
• Loose catalyst is a relatively poor conductor of heat so that while the surface of a
pile of catalyst may be cool, the interior may be very hot. Hence care should be
taken not to walk over catalyst lying on floor.
• Employees are not allowed to enter a vessel before gas tests are taken at various
points throughout the vessel to determine whether or not any combustible or
toxic gases are present. The general rule is that the vessel must be completely
free of combustible and toxic gases before entry permit can be issued.

26. • Maximum ventilation shall be provided in all cases. This provision shall include removing
cover plates from vessel and will also include installing mechanical ventilating
equipment.
• Whenever work is done within a vessel it may become necessary to have someone
standing by the vessel to render any help in the event of any emergency such as light
hydrocarbons escaping in the area or other recognised conditions, which might
jeopardize the safety of the employees working in the vessel.
• Where the vessel has contained tetra ethyl lead, either in the pure state or blended with
gasoline, employee shall follow the added safety precautions specified in the operating
manual.
• Tanks or vessels that contain or may contain self-igniting scales or other deposits that
may ignite spontaneously must be kept wet until such materials have been removed or
changed in such a manner that they will no longer ignite and cease to be a hazard.

27. The specific requirement for entry into a confined space based on the type of work
(normally applicable if not mentioned otherwise)
Unrestricted entry
• A joint inspection of all concerned in the work area is essential
• Complete lockout- mechanical as well as electrical
• There is no exception to this rule
• Blinds must be inserted immediately next to equipment or else no unrestricted
entry.
• Equipment must be absolutely free from flammable and toxic gases or vapors.
• Adequate ventilation is essential.
• Can a combustible or toxic mixture develop during job execution? If the answer is
yes, the entry can only be ‘Restricted Entry’ as below.
• What is the temperature inside the equipment? Would industrial air
conditioning/ ventilating units provide extra comfort for maximum output?

28. Safety equipment for working in a confined space

29. What is Restricted entry in confined space
• All condition of unrestricted entry is met except for the fact that combustible
and/ or toxic gas may become airborne in the execution of the job, ie; tank
cleaning when there is sludge on the bottom or if there is a possibility of release
of hydrocarbon from the scale on the walls of the tank. Such an entry may be
permitted on condition that:-
• Presence of knowledgeable supervisor equipped with breathing apparatus.
• The gas test is done at regular, specified intervals
• Use of respiratory protection equipment
• Continuous forced ventilation
• Workers to be made aware of the hazards of the job
• Work to be suspended if the gas test indicates 50%LEL.
• Depending on ambient temperature and work environment intermittent work
followed by a period of rest should be specified.

30. • PPE
• For any accident prevention work, engineering control is the best
control, and aid of personal protective equipment (PPE) should be
the last resort or a supplementary control.
• Nevertheless, the importance of personal protective equipment (PPE
in short) is not less, its scope and utility have been tremendously
increased during the last few years and wide varieties of such
equipment are available in the market.
• This requires a proper selection of quality and utility for a specific
purpose. The problem is not of the availability but is of its use by
workers on the shop floors.

31. • The conclusion is that @30 to 40% of total accidents can be prevented or
controlled by the proper use of personal protective equipment. This figure
is not small and highlights the need for PPE.
• The PPE provides good defense against hazards of toxic exposure, oxygen
deficiency, dusting, chemical splashes, steam, water and liquids, flying
particles, hot substances, radiation, sharp edges, welding, cutting, grinding,
striking against and stepping over objects, glare, personal falls and injury
due to falling bodies, noise, scrap cleaning, material handling, opening of
pipelines or any hazardous work, electric shocks, burn and firefighting.
• Many fatal accidents are caused due to these reasons and the use of
appropriate PPE can prevent or lessen many of them.

32. • Limitation of the protection by PPE should be well understood.
Respirators have limited use for the concentration and time
mentioned by the manufacturer. they cannot be used in higher
concentration for the longest time.
• In heavy concentration, only self-breathing apparatus (SBA) is
recommended and that too for a limited time. Instead of providing
hood and suction on flying particles, there is no meaning of giving
respirators to the worker.

33. The need for PPE can be well judged from:
• Visual and foreseeable hazards.
• Accident experiences.
• Report on the safety committee/representatives.
• Safety audits, surveys, sampling, job safety analysis and risk
assessment.
• Legal requirements and remarks of the authorities.

34. • The need for PPE exists because:
• Chances of failure of engineering controls, materials, process, equipment
and safety devices cannot be denied and in those circumstances, the PPE
can act as a barrier between the man and hazard and save from the injury.
• There are certain operations or accidental situations where engineering
controls are less possible and PPE becomes necessary. For repair or
maintenance or to enter into a toxic or oxygen-deficient atmosphere, or
while working at height or doing jobs like welding, cutting grinding,
chipping, PPE gives good protection.
• It effectively avoids the contact of dangerous substances, noise, vibration
and radiation.
• It protects from atmospheric contaminants.
• It is a legal as well as moral duty to provide suitable PPE.

35. • STATUTORY PROVISIONS FOR SAFETY
• No specific personal protective equipment is named by the Factories
Act, but working conditions mentioned in sections 14, 30, 33, 35, 36,
37, 38, 87, 111, and 114 are such that free of charge PPE should be
provided by the occupier for the protection from hazards due to dust,
fume, gas, vapor, flying particles, glare, revolving machinery, hot or
dangerous contents, entry in confined space, explosive or flammable
atmosphere, fire, dangerous operations, and hazardous process.

36. • Rules prescribed under the above sections provide further details. 27 schedules
of Rule 102 of the Gujarat Factories Rules indicate the need for PPE at many
places.
• Duty is cast upon the workers not to wilfully neglect to make use of such
equipment and not to interfere with or misuse them. Model Rule 58 u/s 35 and
Model Rule 95 u/s 87 also prescribe PPE for the specific process.
• Rule 68B, GFR states that the PPE shall conform to the Indian Standards. OSHA
standards prescribe tremendous details for PPE. Noise-induced hearing loss is an
occupational disease under the 3rd Schedule of the Factories Act. Schedule 23
u/r 102, GFR requires noise reduction below 90 dBA or to provide ear protectors
to workers and their auditory examination by the doctor. Sch. 27 required
protection against cotton dust.

37. SELECTION AND CLASSIFICATION
• Once it is decided that PPE is needed,
1. Select proper type of equipment and then
2. Make it sure that the supervisor sees to it that the worker uses and maintains-it
correctly. Proper selection, training and use of PPE are essential.
• Factors of selection or requisite characteristics of PPE are :
1. It should give adequate protection against the nature, severity and type of hazard.
2. It should be of minimum weight, should give minimum discomfort with protective
efficiency.
3. Attachment to the body should be flexible yet effective.
4. The wearer should not be restricted in movement" or perceptions required for the job.
5. It should be durable and attractive.
6. It should not cause any hazard through its material, design, defect, use or failure.
7. It should conform Indian Standards and tests required
8. It should be easy to clean, repair and maintain. The parts, piece and service should be
easily available

39. Selection and classification of PPE based on body part and hazards
Respiratory types
1 Self contained Breathing
Apparatus
2 Hose Mask and Blower with
escape provision

42. Fall Protection
Fall protection for the body includes safety belts, lifelines (ropes) and lanyards, harnesses (belts &
straps with buckles) and fall-arrester devices or safety net.
It is important to note that such safety belts and associated equipment are used when fall hazards
cannot be eliminated by strong support like railings, floors, platforms etc. OSHA Standard has
prohibited the use of a body belt-only for fall arrest and a fall arrest system is suggested, since 1-1-
1998.
Body belts are used where less than I m free fall is anticipated and a body harness (belts or straps on
chest, shoulders and thighs) is used for a limited fall upto 2 m. A harness can spread the shock load
over the shoulders, thighs and seat (hips). The body belt or lifeline D-ring should be arranged at the
back of the worker. The wearer of the safety belt should not tie off below waist level (to prevent
turning down head). A window cleaner's belt length is limited to 8 ft (2.5 m). The chest belt is worn
loosely to allow smooth breathing.

43. The lifeline may be vertical from a fixed anchorage or horizontal between two fixed anchorage
Body belts (work belts) are used to reduce the probability of falls. Chest harnesses are used where
there is limited fall hazard (not vertical free fall) such as for removal of a person from a tank or bin.
Body harnesses, covering chest, shoulders and thighs, are used to arrest the most severe free falls.
Retrieval method is necessary to shorten the hanging distance after a fall upto 6 ft (maximum limit of
free falls, for more fall height, other supporting fixed structure must be provided by fencing, railing,
platform, fixed-ladder with platform and handrails etc.).
Retractable lifeline, which will be shorten automatically (e.g. spring action) after its full length, can limit
falls to inches and avoid prolonged suspension causing high discomfort to a hanging person. Fall
arrester net, if used, should be tied firmly as near as possible under the working place to minimize the
fall distance. Belts, harnesses, lifelines, lanyards, buckles, joints, D-ring etc. should be checked for weak
points, washed regularly and kept dried at room temperature

44. CLASSIFICATION OF RESPIRATORS
Air Supplying Respirators :
1. Airline respirators
• Airline respirator consists of a face-piece (half or full mask or a loose fitting helmet or hood) to
which air is supplied through a small diameter hose. It may be a continuous flow type or a
demand type.
• In a constant or continuous flow type, air is supplied continuously to the face piece helmet or
hood. air or the excess air entering the face-piece escapes to the atmosphere
• In a pressure demand type respirator, air is supplied to a face-piece when the wearer inhales and
the rate is governed by his volume rate of breathing. Air from an air compressor cylinder is
supplied to the face-piece through a demand valve which is actuated by the slight negative
pressure created when the wearer inhales. On exhalation the demand valve closes and exhaled
air escapes to the surrounding atmosphere through exhalation valve. Helmets or hoods are not
used with demand type respirator.
• Airline respirators provide protection so long as the air supply is maintained but the wearer's
travel is restricted by the length of the air supply hose. They are not used in IDLH atmosphere. Air
temperature and pressure should be comfortable and the air should be supplied through an air-
cleaner. Care should be taken to ensure that the air supply is respirable and is not contaminated
and is free from objectionable odours, oil or water mist and rust particles from the supply line.
The air line connection should be tight (nondetachable) and should be checked before use.

45. 2. Suction Hose Mask
It consists of a full face piece connected to a large diameter flexible hose. The worker draws in air
by his own breathing effort, the hose is attached to the wearer's body by a suitable safety harness
with safety line and the air inlet end of the hose is provided with a filter to arrest particulate
matter. Air can be drawn in by respiratory effort of the wearer upto 30 ft length of the hose.
3. Pressure Hose Mask (Air supplied hoods):
This hose mask or hood is similar to suction hose mask except that the air is forced through a large
diameter hose by a hand or motor-operated blower or compressor. The blower is to be operated
continuously while the mask is in use. Respirable air of comfortable pressure and temperature
should be supplied at least 6 ft3 /min.
4. Air-Supplied Suits:
Air line respirators are used where normally nose and face are exposed to hazards and not the
other body parts. But where all body parts including nose, need protection, for example, to do any
repair or emergency work in extremely corrosive atmosphere affecting skin and mucous
membranes or acutely toxic and immediately dangerous to life, a full body suit of impervious
clothing with respirable air supply, is a must.
The air line is connected to the suit 'itself and also to helmet and distributing air evenly throughout
on the body, because without such ventilation and cooling effect, it is very difficult and fatiguing to
wear such suit for a longer time. Particularly, in our country where majority of the days are hot,
workers are reluctant to wear such full suit. They should be properly explained its need and utility.
They should be rotated in case of more inconvenience

46. Self-Contained Breathing Apparatus :
They are of two types.
(1) Self-Contained Compressed Air or Oxygen Breathing Apparatus:
This is a device by means of which the wearer obtains respirable air or oxygen from compressed
air or oxygen cylinder which is an integral part of the apparatus.
In a demand type Self-Contained breathing apparatus, air or oxygen is admitted to the face piece
through a two stage pressure reducing mechanism, only when the wearer inhales and the quantity
of air or oxygen admitted is governed by his breathing. The wearer's exhaled breath escapes to the
surrounding atmosphere.
In compressed oxygen cylinder recirculating type breathing apparatus, high pressure oxygen from
the cylinder passes through a pressure reducing and regulating valve into a breathing bag. The
wearer inhales this oxygen through a one-way breathing valve and his exhaled breath passes into a
canister containing chemicals to absorb exhaled carbon dioxide and moisture and then through a
cooler into the same breathing bag. Oxygen enters the breathing bag from the supply cylinder only
when the volume of gas in the bag has decreased sufficiently to allow the supply valve to open.
From respiratory point of view, self-contained breathing apparatus has no limitation as to the
concentration of the gas or deficiency of oxygen in the surrounding atmosphere but other factors
may limit the time that the wearer can remain in a contaminated atmosphere. Many gases are
very irritating to the skin and many can be absorbed in dangerous amounts through the unbroken
skin.

47. (2) Oxygen-Regenerating Recirculating type Self-Contained Breathing Apparatus:
In this type of apparatus moisture content from the wearer's exhaled breath reacts with granular
chemical in a canister to liberate oxygen. Also the exhaled carbon-dioxide is absorbed by the
chemicals in the canister. The oxygen enters the breathing bag from which the wearer inhales
through a corrugated breathing tube connecting the bag to the face-piece.
Air Purifying Respirators :
Air purifying respirators purify the air of gases, vapour and particulate, but do not supply clean or
fresh air. Therefore they must never be used in oxygen deficient atmosphere. Purification of
breathing air is done by mechanical filtration, adsorption, chemical reaction or catalysis. The life of
such respirators depends on concentration of the contaminant, scrubbing capacity of the medium
(cartridge) and breathing demand of the wearer. The respirator has a face piece and a connected
canister (box) or cartridge to purify the air passing through it. The canister or cartridge should not
be used –
1. After its date of expiry or after 100 hours after its first use.
2. When air coming to nose, gives irritation, smell or indication of saturation or non-effect of the
scrubbing medium.
3. When oxygen is less than 18% in air.
4. When the gas or vapour has no smell or odour.
5. When the gas or vapour is highly toxic.
6. When the gas or vapour is highly irritating to eyes without necessary eye protection, and
7. Above the limit of concentration marked on it.

48. • https://rlsdhamal.com/fact-about-ppe-personal-protective-
equipment/
• INDIAN STANDARD CODE OF PERSONAL PROTECTIVE EQUIPMENT
• https://rlsdhamal.com/indian-stranded-code-of-personal-protective-
equipment-ppe/

49. Safety Performance Rates :
1) Frequency Rate:
A question 'How often do injuries occur?' is replied by the frequency rate which is defined as
the disabling (lost time) injuries per 106 man-hours worked.
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.
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.
Since frequency rate F, is based on the lost time injuries reportable to the statutory authorities, it
ma) be used for official purposes only. In all other cases frequency rate F, should be used for
comparison purposes.
2) Percentage Reduction in Frequency rate :

50. 3) Weighted Frequency Rate:
While giving National Safety Award, this rate : considered and given by-
4) Safe T-Score :
Positive (+) STS indicates a worsening record while negative (-) STS indicates an improving record over the past
If, STS is It indicates

51. 5) 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 number of accidents or injuries, per 1000 persons employed.
6) Severity Rate:
A question 'How serious are the injuries? is replied by the severity rate which is defined as the
number of days of lost time per 106 man-hours worked.
Since severity rate SR is based on the lost time injuries reportable to the statutory authorities, it should
be used for official purposes only. In all other cases severity rate SL should be used for comparison
purposes

52. 7) Safety activity rate:
Here 'Safety activity' is the sum (during the unit period) of safety recommendations made, unsafe
practices reported, unsafe conditions reported and the number of safety meetings held. Thus a
safety activity rate curve can be plotted for any period - a week, month, year etc. and the safety
performance can be compared.

53. COST OF ACCIDENTS
ACCIDENT COST TO THE INJURED PERSON AND HIS FAMILY
• Accidents are costly to the injured person, to his family, to the management and to the society.
Let us see how much an injured worker would lose due to an accident to him. In addition to
pain, suffering, worries, incapacity, wage .loss, medical and other expenses, he also suffers as
under. If a worker is not covered by any insurance scheme, he has to bear the loss of wages
and the cost of medical expenses, transport, fruits, food etc.
• If he suffers permanent disablement, he loses his earning capacity for life. If a worker is insured
under any scheme, he gets some compensation, medical expenses and some daily allowance
which are hardly adequate.
• No costing is possible for his suffering, pain, worry and incapacitation. Even after return to
duty, he is unable to perform his normal work for many days and therefore may lose incentive
and overtime wages during that period. Another loss is his mental setback and inability to
social functions and recreation

54. ACCIDENT COST TO THE MANAGEMENT
Management suffers two types of costs
1. Direct or Insured or Tangible Costs and
2. Indirect or Uninsured or Intangible (hidden Costs)
Direct Costs
• This includes the compensation paid to the injured person, or insurance premium, medical and
hospital charges, transport charges directly paid by the employer.
• Direct costs are easy to calculate as their money value is directly available. Workers' legal
compensation or accident insurance premiums (net premiums after deducting refund if any),
medical expenses of doctors' bills, medicine bills, hospital/ dispensary charges etc., extra
compensation paid to the injured worker or his family and all other direct
expenses/expenditures paid, by the employer due to the accident, constitute direct costs
Indirect Costs
• Indirect costs are of many types and need careful consideration to determine their 'equivalent
money value'. Use of cost data sheets and other methods have been developed to calculate
indirect costs. They include following

55. 1. Cost of wages paid for working time lost by insured workers, other than workers'
compensation payments.
2. Cost of wages paid for working time lost by workers, other than the injured worker(s).
3. The net cost to repair, or replace material or equipment that was damaged in accident.
4. Extra cost due to overtime work necessitated by accident.
5. Cost of wages paid to supervisors for their time required for activities necessitated by
accident.
6. Wage cost due to decreased output of injured worker after return to work.
7. Cost of learning period and preparation of new worker(s).
8. Uninsured medical cost borne by the company.
9. Cost of time spent by higher officers, outsiders and clerical workers on investigations or in
restarting the production or in processing compensation application, procedure and other
administration.
10. Cost of work interruption due to idle machine, work stoppage or spoilage.
11. Cost of property (including material and equipment) damage due to accident.
12. Uninsured other costs and the miscellaneous unusual costs.

56. Utility (Usefulness) of Cost Data
• Direct cost of accident is directly available and is very much useful to calculate expenditure and
budgetary estimate on -predictable accidents or fire / explosion and other risks. Indirect costs
are also real costs and they should be calculated to quantify or demonstrate in meaningful way.
Such unproven costs may seem unreal to the management and it may not be convinced.
• Safety Officer should try to quantify these hidden costs, to explain to the management and to
draw a conclusion that 'preventive costs may be less than the total costs of accidents' - a
powerful stimulus for the management to invest for accident prevention' work.
• Each industry should try to calculate accident costs of all the accidents happened in last
(completed) year and to compare the ratio year to year. This will indicate where and how we
can reduce the accident costs. There is a great significance of this ratio of costs to statisticians,
employers, employees, safety officers and insurance salesmen.
• It supplies powerful stimulus to convince management for preventive action. It emphasizes
that -,
1. Cost estimates may remain underestimated and the million - rupees may be increased 4 to 5
times.
2. The employers must worry about accident cost and accept accident prevention as their
economic activity and duty.
3. The work of safety officer has a real monetary value and
4. It enhances the value of the service of an insurance salesman

57. PLANT SAFETY INSPECTION
• Safety inspection is defined as 'that monitoring function conducted in an organization to locate
and report existing and potential hazards which have the capacity to cause accidents in the
workplace.
• Safety and health inspection ensures that working conditions/environment and actions
(methods) conform to legal or safety requirement and combine efforts of employers,
employees, safety experts and inspectors to create a safe working environment.
• Objectives of Inspection are :
1. To find out hazards, accident causes (unsafe conditions and actions) losses and appropriate
remedial measures for their prevention and control.
2. To maintain safe work environment, operational profitability and control unsafe actions of
people.
3. To check statutory provisions of the Factories Act and similar other safety statutes.
4. To check the effectiveness of the existing systems and to find improvement if required for the
purpose of Total Loss Control.
5. To check quality control, product safety. Good Manufacturing Practice (GMP), wear and tear,
corrosion, tests and also personnel selection.
6. To gain workers' confidence in organized human activity and factory life

58. Types and Procedures
Inspections can be classified in many ways as explained below:
1. Planned Inspection :
These are of 4 types :
(i) Periodic Inspection : Plant, machinery, equipment, lifting machines, pressure vessels, apparatus, procedures,
methods and health of the workers should be examined at regular pre-planned period. Statutory forms,
checklists, tables and period of inspections, if any, must be strictly followed. Nonstatutory periodicity may be
decided according to the need. The whole area should be covered and plant people should be informed in
advance for necessary arrangement. It should be deliberate, thorough, detailed and systematic. Safety
committee, safety officer, competent person, safety consultant, industrial hygienist, doctors and other safety
and health personnel should carry out such inspections.
(ii) Intermittent Inspection : It is carried out at irregular intervals to check new equipment installations,
procedures and workers; modifications, accident analysis etc. Some partial inspections are also carried out at
uncertain intervals.
(iii) General Inspection : It is general or routine' inspection to check places which are not covered by .other
inspections. Isolated areas, parking places, side - walks, fencing, light - illumination, reporting after long
shutdown etc. are checked by such general or overhead inspections.
(iv) Special Inspection : Safety or hazard analysis, accident investigation, checking of dangerous operation or
vessel, building safety, subjects of complaint only, inspection during special campaigns and new installations,
and only for storages, processes, methods, hand-tools, scaffolds, guards, facilities, protective equipment etc.,
fall within this category.
2. Continuous (ongoing) Inspection:
Some personnel like safety officer, maintenance men, electricians etc. spend their all time in observing certain
equipment, vessels, processes, operations, safety devices, personal protective equipment etc., to maintain them in
safe and efficient working condition. Thus continuous watch and familiarity with employees, equipment, machines
and environment are maintained as part of informal and co-operative responsibility.

59. 3. Statutory Inspection :
This is carried out by to check the implementation of statutory provisions. Strict and timely compliance
is necessary. Breach of law may attract prosecutions. For most of the factories where there is no system
of internal inspection, statutory (government) inspection is the only effective inspection and therefore
it should be carried out in detail and the governments must employ sufficient staff to achieve better
safety inspections. Non-technical workload on Inspectors should be minimized. Inspectors' powers and
duties are statutorily prescribed.
Planning and Procedures
• The persons making inspections should be familiar with
(1) the know-how and sound knowledge of plant, relevant standards, codes, rules etc.
(2) the systematic inspection steps or checklists
(3) the method of using data, evaluating and report writing.
• They should behave like friends, philosophers & guides. They should explain what, why and how.
They should know the reasons of past accidents, working unsafely, the safe alternative or remedial
measures and they should convince the people for better practice.
• Basic Steps of inspection are :
(1) To contact the department head for his help
(2) To observe all conditions for compliance with established standards (checklists preferable)
(3) To observe all operations for unsafe acts or violations of safety rules and
(4) To prepare a systematic report with all hazards detected and corresponding remedial measures.
The report should include good suggestions of plant people and the recommendations may be
discussed with the persons concerned. The report should be sent to the concerned people for
compliance and follow-up actions should be continued till full compliance is achieved and reported
to the management.

60. Safety Sampling
• It is a systematic sampling of particular dangerous activities, processes or areas. Its a method of
measuring hazard or accident potential by random sampling and by counting safety defects while
touring specified location by a prescribed tour of @ 15 minutes at the weekly intervals.
• The quantum of defects noticed is used to portray trends in safety situation. The point on a safety
sampling sheet includes items such as nonuse of personal protection, obstructed fire exits,
environmental factors, lighting, ventilation, temperature, faulty hand tools, guarding position etc.
The results are collected by the Safety Officer and presented in graph form to monitor the
effectiveness of the safety programme.
Steps of the technique are :
1. List safety defects and hazards applicable to the area.
2. Define routes-at least two per section or department-which the observer can traverse within 15
minutes.
3. Train the observers for correct use of their respective routes and printed checklists.
4. Tell the workers the purpose of safety sampling.
5. Observers must meet at a convenient place once a. week or fortnight. One observer should cover
one route alone and mark his sheet.
6. Defects found should be corrected by supervisor or Department Head.
7. Results of Sampling Check List are added to summary sheets and plotted on a graph.
8. Comparing with the graphs of past period, deviation in the safety performance is noted and safety
measures are decided to improve the performance.

61. Advantages or Benefits of this technique are :
1. Management is provided with a week by week picture of accident potential.
2. Defects are cleared at least once a week. Many defects are cleared on the spot.
3. Supervisors' eyes are sharpened by practice and begin to be more vigilant.
4. Supervisors and Managers are put on the spot when they fail to take action after the defects have
been pointed out to them.
Subjects of Safety Sampling Checklist are:
1. Protective Equipment-Non use or misuse of guards, fire extinguisher, first aid box, safety notice,
machine under repair etc.
2. Protective Clothing - Non use, misuse or defects of goggles, mask, gloves, helmets, safety boots etc.
3. Housekeeping-Blocked passage way, stairways, slippery patches, chemical spillage, blocked drains,
tripping hazards etc.
4. Tools-Wrong or defective tools, using or towing tools unsafely, power tools, plugs, wiring etc.
5. Unsafe Conditions-Leaking joints, valves etc., fans not working, -poor supports, unsafe scaffolding,
erection, lifting machines, pressure vessels, dress, design and construction, improper illumination,
ventilation, material position etc.
6. Unsafe Actions - Adjusting, cleaning or oiling machinery in motion, operating at unsafe speed,
making safety device inoperative, distracting/ teasing, taking unsafe position, wrong ladder
position, unsafe method, carrying heavy load, hand trucks unsafely loaded, persons riding on fork
lift, trolleys, machine part etc.

62. Safety Survey:
A safety survey is a detailed examination of a narrower or specific major key area identified by
safety inspection or audit, individual plant, procedure or particular problem common to a works as
a whole. It is followed by a formal report, action plan and subsequent monitoring. .It is a general
inspection of the particular dangerous activities, processes or area. Its difference with safety audit
is evident. Safety audit covers all parts of a plant one by one, while safety survey picks up only one
or two most hazardous or important part of the plant and carries out its inspection in depth. It is
carried out by an expert team
Safety Tour :
It is an unscheduled examination of a work area carried out by works managers 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. It is general inspection of the workplace.
Safety Review :
Its purpose is to identify unsafe conditions or operating procedures that could lead to an accident.
It ensures that the plant and procedures (operating and maintenance) match the design intent and
standards. The procedure - initiates application of new technology to existing hazards. - Reviews
operating procedures for necessary revisions. - Reviews adequacy of maintenance of safety
inspections. - Keeps plant personnel alert to the process hazards.