Introduction and Purpose of Safety Guide

UPL Limited (Formerly United Phosphorus Ltd.) has evolved over a period of time, from a
small business specializing in Red Phosphorus to a wide range of products that has made its
presence felt in all corners of the country as well as the globe. The company is a leading
global producer of crop protection products, intermediates, specialty chemicals and other
industrial chemicals. Being the largest manufacturer of agrochemicals in India, company
offer a wide range of products that include Insecticides, Fungicides, Herbicides, Fumigants,
Plant Growth Regulator and Rodenticides. They operate in every continent and have a
customer base in 123 countries with their own subsidiary offices in Argentina, Australia,
Bangladesh, Brazil, China, Canada, Denmark, France, Germany, Hong Kong, Indonesia,
Japan, Korea, Mauritius, Mexico, New Zealand, Russia, Italy, Turkey, Spain, South Africa,
Taiwan, USA, UK, Vietnam, Zambia, Shanghai, Columbia and Netherland.
Its always said that a well informed employee takes a well informed decision. The purpose of
this Basic Safety guide is to act as resource to continually improve the Safety knowledge
level of UPL employees at all levels. This guide has been designed to compile in one place
all aspects of basic Safety.
UPL Limited has Manufacturing facilities in following Locations:
1. Unit 0, Vapi
2. Unit 1, Ankleshwar
3. Unit 2, Ankleshwar
4. Unit 3, Ankleshwar
5. Unit 4, Halol
6. Unit 5, Jaghadia
7. Unit 8, Jammu
8. Unit 9, Haldia
9. Unit 10, Tarapore
10. Unit 11, Ankleshwar
11. Unit 20, Jammu
12. Unit 25, Ankleshwar
13. Vietnam
14. Sandbach, UK
15. Brazil
16. Barranquilla, Columbia
17. Bassen, France
18. Le Canet, France
19. San Louis, Argentina
20. Abbott, Argentina
21. Rotterdam, Netherlands
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 HSE POLICY

8
SAFETY VISION

9
 Safety Benchmarking Performance Matrices

l Total Recordable Frequency rate (TRFR) < 0.40

l Zero Major Process Safety Incident (MPSI)
l Severity Index (SI) < 10

Definitions:
TRFR =
Number of Recordable Injuries X 2,00,000 / Total Manhours Worked

Severity Index (SI) =

Mandays Lost X 1,000,000 / Total Manhours Worked

Major Process Safety Incident (MPSI) =

Major Fire or Explosion or Major Toxic Release

10
 INVIOLABLE STANDARDS

l Changes to Technology / Facility / Personnel without

change Management.

l Hot Work / Confined Space / Working at Height /

Electrical Permit Violation.

l Safety Interlock bypassing without Authorization of

Unit Head.

l Violation of Process SOP

l New Joinee & Transferred Employee assigned into

the plant operation without level 2 Training

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 SITE SAFETY RULES

l Safety is everybody's responsibility.

l No work is to be conducted without pre-job risk assessment & a safety briefing.

l No camera is allowed without authorization & photography is strictly prohibited inside

the factory premises.

l Smoking is strictly prohibited in the factory premises.

l Max. speed for driving any vehicle inside factory premises is 10 Kms / hr.

l Do not operate any equipment unless you have been trained / instructed to do so.

l Consumption of Gutka or Pan Masala or Drugs or Cigarette / Bidi or any intoxicating

Material inside the site is strictly prohibited.

l Tampering with any Safety Equipments provided in the Factory Premises such as Fire
Extinguishers, Safety Shower and Eye Wash, Gas masks, Fire Hoses, Earthing
Equipments, Breathing Apparatus etc. is strictly prohibited.

l No Contract worker is allowed to carry mobile phone inside the Factory.

l Whereever & to whomever Mobile phones are allowed, Use of Mobiles phones on the
roads is strictly prohibited. The mobile phone can be used at the following places:
l Gate Building, OHC, Dispatch Office
l Admin Block
l Engineering & QC Office Block.
l Plant HODs Office
l Porta cabins of Projects..
l Clients, Foreign Visitors, Important Visiting Dignitaries & Govt. Officials will be allowed
mobile phones inside the site. However they can use only in the areas specified as
above.

l Wearing of Helmet and Safety Shoes is compulsory to enter any Plant of UPL.

l Running inside the site is strictly prohibited except in case of an emergency.

l Entering the Factory premises with Chappals or Slipper or Open Toe footwear or Sandals
is strictly prohibited.

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l Eating or Drinking inside the process plant is strictly prohibited. Consumption of Food
can be done only in the Canteen or designated area.

l Female workers cannot work inside the site from 1900 hrs. to 0600 hrs. Also Female
workers are not allowed to work inside a Process Plant.

l All workmen / Operators working in a Pesticide Plant have to take bath after the shift
and before leaving the Factory Premises.

l No Visitors & Contractor Employees can enter any unauthorized / restricted Area.

l Hydra cannot be used to shift Material/Equipment from one part of the site to the other.
They can only be used to shift material within a Project Site.

l No Contractor Employee will ride on a Fork Truck or JCB Cabin or Hydra Cabin or back
of Loaded Trucks and Tractor Trolley.

l Use of Bisleri Bottle or water container to store chemicals is not allowed.

l Extended load being taken in any truck or trolley to have a red flag during day time and
red light during night time

l No Fire Hydrant or Safety Shower Eye wash water to be used for washing or any other
purpose.

l Sleeping below a Truck or Container or any Vehicle or Sleeping above a vehicle is

strictly prohibited.

l Playing Cards or Gambling inside Factory premises is strictly prohibited.

l All Vehicles entering any of the UPL sites need to get fitted with a Spark Arrestor at the
Gate.

l No Employee will go inside the Plant without completing Level 0 & 1 Safety Orientation.

l No Employee / Contract employee is allowed to work in Plant without BCA test or if BCA
test result is less 75%. (Applicable for all sites handling Organophosphorus or Carbamate)

l No UPL Employee can be given independent charge / Responsibility without going

through Level 2 training and validation with score of at least 80%.

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 Manufacturing Do's and Don'ts
Production
Sr. No. Dos Sr. No. Don't
1 Check your BCA as per decided 1 Don't Eat anything in the
frequency for Members working Manufacturing area.
in Manufacturing area.
(Organophorus Compounds/
Carbonate Compounds)
2 Follow Process SOP religiously. 2 Don't block pathways &
Emergency Exits.
3 Use Scrubber system wherever 3 Don't bypass any Safety interlock.
installed.
4 Use Earthing during loading & 4 Don't keep solvent or flammable
unloading of flammable material. material below Electrical fixtures.
5 Take bath after working and before 5 Don't deploy any person without
going home if you work in proper training.
Manufacturing
6 Wash your Hands with Soap 6 Don't horse play inside plant
before Eating premises
7 Hand Over Shift Charge only in 7 Don't keep any material without
the Plant proper identification & labelling
8 Use Cage Hoist for Material 8 Don't block any Safety Equipment
movement only.
9 Always use Proper PPE for the 9 Don't use loose hose.
work you are doing
10 Use Prescribed PPE's for all 10 Don't use any Chemical which
activities in the Process Plant does not have proper identification
thru a proper and legible Label

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 Manufacturing Do's and Don'ts
Engineering
Sr. No. Dos Sr. No. Don't
1 Use proper PPE's during . 1 Don't Start height work without
maintenance work proper access.
2 Keep all Tools & Tackles at 2 Don't deploy any person for any
designated place only after work activity without training.
3 Take proper Work Permits for 3 Don't use any Equipment & Tools
any non- routine work. including Lifting Tools without
inspection and tagging / Labelling.
4 Barricade work area where 4 Don't use Faulty Equipment without
maintenance work is to be done. “Approved” Tag
5 Do Five minutes Tool Box Talk 5 Don't stand or keep your legs on
about the work to be performed any Chemical/Steam line during
before starting the work. height work.
6 Check all Machines like Cutting set, 6 Don’t Perform any Height work
Welding Machine, Portable Electrical after Sunset
Tools before using.
7 Remove all Debris / Scrap from the 7 Don't allow any Contract Worker
areas after the work is completed inside the Plant without Proper
SHE Orientation
8 Use only Non-Sparking tools for 8 Don't put the scrap in undesignated
Activities in Flammable Areas place.
9 Check PPEs before use for its 9 Don't Eat or Drink inside the
condition and Quality Plant premises
10 Wash your Hand properly 10 Don't use jointed cables
before eating

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 Manufacturing Do's and Don'ts

Store

Sr. No. Dos Sr. No. Don't

1 Use Proper PPE's while 1 Don't Drive forklift without
performing any work. authorization.
2 Inspect Forklift as per checklist 2 Don't Store incompatible material
before taking it for use. in same area.
3 Check all Documents of each 3 Don't over stack the material.
Vehicle & ensure compliance
4 Maintain Minimum stock 4 Don't allow tankers inside unit
of all PPE's without proper identification of the
content of the Chemicals in it.
5 Maintain Minimum Stock of 5 Don't allow Vehicle inside the unit
First Aid Items without the spark arrestor.
6 Store all Material as per its 6 Don't Store incompatible material
compatibility with other Chemicals in the same area.
7 Store all Gas Cylinders Safely in 7 Don't Store RM / FG on road
shed with identification & secure without shed and in Open
with Chain
8 Store Gas Cylinder away from 8 Don't Unload any Tanker,
Combustibles / oil / grease If you are not sure of identity
of the material
9 Store all Cylinders in upright 9 Don't Unload Chemicals after
Position only 1800 hrs without prior
approval of UH
10 Ensure that all Containers / Tankers
have legible Label for
proper identification

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 Manufacturing Do's and Don'ts

Electrical & Instrument

Sr. No. Dos Sr. No. Don't

1 Take Electrical Work Permit 1 Don't use Cables which have been
before start of the work. jointed by Insulating Tape
2 Use Electrical Arc Flash Resistant 2 Don't Clean Electric Switches,
suit for working on Electrical Panel Boards etc. with WET cloth.
& HT yard.
3 Use only Standard Electrical 3 Don't wear ornaments like bracelet,
Appliances. ring, chain during electrical work
4 Check Supply Cable / Wire for 4 Don't block Emergency Exits of the
good condition, free from cuts & area.
damaged insulation.
5 Close the Panel properly after work 5 Don't keep the doors of flameproof
and fasten the bolts. panel open after work.
6 Update regularly Earth pit test, 6 Don't use bare wire for connecting
reports and Tagging to the Source of Supply
7 Do regular Inspection, Audit of 7 Do not allow any Non Electrically
Electrical Equipment /Appliances Qualified per to work on Electrical
System
8 Keep the HT Switch yard 8 Don't Store cloths, Uniform in any
Closed always MCC / PCC Room
9 Always Use Rubber Mats in 9 Don't Work on any Electrical
front of all Electrical Panels System if you are not Electrically
Qualified

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 Manufacturing Do's and Don'ts

QA / Max Pro / R&D

Sr. No. Dos Sr. No. Don't

1 Use proper PPE's as per 1 Don't keep incompatible material in
requirement. same location and nearby each
other
2 Use Flameproof cabinets to store 2 Don't keep Glass bottles at height.
flammable material.
3 Use Fuming hood for addition of 3 Don't keep Solvent bottles below
chemical for testing. Electrical fixture.
4 Keep Compressed Gas Cylinder 4 Don't carry sample bottle in hand.
used for gas chromatography in (Use sample tray or bucket to carry
upright position only with properly the same.)
securing with Chain & with cap.
5 Keep all Fuming Hood in working 5 Don't Eat or Drink water inside the
condition effectively Lab
6 Use Apron / Safety Goggles / 6 Don't keep any chemical without
Surgical hand gloves & Safety Shoes labelling & identification location
7 Keep Access of Safety Shower & 7 Don't Handle broken Glassware
Eye Wash free from any Obstruction with bare Hand
8 Use Only Standard make Glassware 8 Don't store any material above the
cupboard
9 Use Equipment with 3 Pin plug
Socket & with proper Earthing
10 Always use Cut resistant Gloves
to Handle broken Glassware

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 Manufacturing Do's and Don'ts

Purchase

Sr. No. Dos Sr. No. Don't

1 Send SHE requirement of UPL 1 Don't deliver Material in
along with the Enquiry to all Unpalletised MS Drums / Barrels
Suppliers to understand UPL / HDPE.
Safety Requirement
2 Get MSDS of all the Chemicals 2 Don't Deliver Chemicals to the Units
along with the Consignment itself without prior intimation to the Unit
Stores to avoid overstocking & to
prevent creation of Unsafe situation
in the Unit
3 Ensure that no leaky Chemical
Tankers are delivered by the
Supplier to the Unit
4 Ensure that all Tankers are in
Road Worthy Condition duly certified
5 Ensure that all Fork Trucks are
Third Party Inspected and Certified
with Certificate available all the
time with the Fork Truck Pilots
6 Ensure that all Fork Truck Pilots
are Godrej or Equivalent Trained
& Certificate available
7 Ensure that all Tanker Drivers
are duly trained as per the legal
Statute - Motor Vehicle Act for
Transporting Hazardous Chemicals
and the Certificate is available with
the Tanker driver all the time.
8 Take declaration from all Contractors
as regards SHE requirement of UPL

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 Manufacturing Do's and Don'ts

Commercial

Sr. No. Dos Sr. No. Don't

1 Send the TREM Card of the 1 Don't allow Drivers who are Drunk
Chemical with each Consignment
2 Explain TREM Card to all Tanker 2 Don't allow Tankers which are not
/ Truck Drivers before dispatch road worthy and in fit condition
of the Consignment
3 Ensure that all Drivers are trained 3 Don't Hire any Fork Truck Pilots
as per the Legal Statute - Motor who are not Godrej or Equivalent
Vehicle Act and the Certificate Trained
available in possession of the
Driver at all times
4 Ensure that all Drivers have
License, PUC, Hazardous
Chemical Transportation
Training Certificate
5 Ensure that all Tankers have
a Road Worthiness Certificate
duly issued by RTO
6 Ensure that Daily checks of
Fork Truck is done as per
Operation and Maintenance
Checklist before start of use
of Fork Truck

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 KEY DEFINITIONS

ACUTE TOXICITY
Adverse health effects occurring within a short time period of exposure to a single dose of a
chemical or as a result of multiple exposures over a short time period, e.g. 24 hours.

AFFF, AQUEOUS FILM-FORMING FOAM

Fire-fighting foam which flows on burning liquid as a film, providing rapid knock-down.

ALCOHOL-RESISTANT FOAM
Foam for use against fires involving liquids miscible with water, e.g. alcohol, acetone.

ANOXIA
Deficient supply of oxygen to tissues.

ASPHYXIA
The result of a diminished supply of oxygen to the blood and tissues and interference with
the respiratory function. Simple anoxia may be caused by 'inert gases', e.g. Nitrogen and
some flammable gases, e.g. methane. Toxic anoxia may be caused by certain substances,
e.g. Carbon Monoxide and Hydrogen cyanide, which interfere with the body's ability to transfer
or utilize oxygen in the tissues. Rapid unconsciousness and death can occur in either case.

AUTO-IGNITION TEMPERATURE
The Minimum temperature required to initiate or cause self-sustained combustion of material
in the absence of any external source of energy. Any ignition source must be at a temperature
of, or greater than the ignition temperature of the specific substance. The Auto ignition
temperature is the temperature at which the chemicals formed by decomposition begin to
burn.

BASE
A Chemical Compound whose aqueous solution turns red litmus paper blue and is capable
of accepting or receiving a proton from another substance. They react with acids to form
salts and water.

BOILING LIQUID EXPANDING VAPOUR EXPLOSION (BLEVE)

Instantaneous release and ignition of flammable vapour upon rupture of a vessel containing
flammable liquid above its atmospheric boiling point.

BOILING POINT / RANGE

This is the temperature at which the vapour pressure of a liquid is equal to the external
pressure. Flammable or Toxic substances with low boiling point present greater Fire or Toxic
exposure hazards than substances with high Boiling Points.

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BLOWING AGENT
Chemical liable to decomposition at low temperature to produce a large volume of gas.

CARCINOGEN
An Agent (whether Chemical, Physical or Biological) capable of increasing the incidence of
malignant neoplasms. Simply put any agent which can cause Cancer.

CHRONIC TOXICITY
Adverse Health effects resulting from repeated daily exposures to a chemical for a significant
period.

CLASS A FIRE
A Fire involving solids, normally organic, in which combustion generally occurs with the
formation of glowing embers.

CLASS B FIRE
A Fire involving liquids or liquefiable solids.

CLASS C FIRE
A Fire involving gases or liquefied gases in the form of a liquid spillage, or a liquid or gas leak.

CLASS D FIRE
A Fire involving metals.

CNS DEPRESSANT
Substances, e.g. anesthetics and narcotics, which depress the activity of the central nervous
system. Symptoms following exposure include headache, dizziness, loss of consciousness,
respiratory or cardiac depression, death.

CONFINED SPACE
A Space which is substantially, although not always entirely, enclosed and where there is a
reasonably foreseeable risk of serious injury from hazardous substances or conditions within
the space or nearby. The risks may include Flammable substances; Oxygen deficiency or
enrichment; toxic gases, fume or vapour; ingress or presence of liquids; free-flowing solids;
presence of excessive heat. Or A 'Confined Space' means any place, including any chamber,
tank, vat, silo, pit, trench, pipe, sewer, flue, well or other similar space in which, by virtue of its
enclosed nature, there arises a reasonably foreseeable specified Safety risk.

CONTACT DERMATITIS
Inflammation of the skin due to exposure to a substance that attacks its surface.

CORROSIVE
A Substance that chemically attacks a material with which it has contact (body cells, Materials
of Construction).

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CHEMICAL STABILITY
This is a property which indicates whether the material remains in same form under expected
and reasonable conditions of storage and use.

CRYOGEN
A substance used to obtain temperatures far below freezing point of water, e.g. < - 78°C.

CONFINED VAPOUR CLOUD EXPLOSION (CVCE)

Explosion of a Gas or Vapour which is initially 'confined' within a vessel, building, piping, etc.

COMBUSTIBLE LIQUID
Any liquid which has a Flash Point of greater than 37.8 Degrees Centigrade but lower than
93.3 Degrees C.

DETONATION
Explosion in which the flame front advances at more than supersonic velocity.

DUST
Solid particles generated by mechanical action, present as airborne contaminant (e.g. <75
micron in size).

ECOTOXICOLOGY
The Study of toxic effects of chemical and physical agents on living organisms as well as
human beings, especially on populations and communities within defined ecosystems.

ENDOTHERMIC REACTION
A Chemical reaction resulting in absorption of heat.

EXOTHERMIC REACTION
A Chemical reaction in which heat is released and, unless temperature is controlled, may
lead to runaway conditions.

EXPLOSION SENSITIVITY TO MECHANICAL IMPACT

This is an indication whether or not the material will burn or explode on shock (for e.g.
Dropping a drum or container) or by friction

FIRE POINT
The Minimum temperature at which a mixture of Gas/ Vapour and Air continues to burn in an
open container when ignited. The value is generally above the flash point.

FLAMMABLE RANGE
The Concentrations of flammable gas or vapour between the LEL and UEL at a given
temperature.

FLAMMABLE LIQUID
Any liquid which has a Flash point of less than 37.8 Degrees C

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FLASH POINT
The Lowest temperature required to raise the vapour pressure of a liquid such that vapour
concentration in air near the surface of the liquid is within the flammable range, and as such
the Air / Vapour mixture will ignite in the presence of a suitable ignition source, usually a
flame. The Methods used to check the Flash Point are Open Cup Method and Closed Cup
Method. Open cup values are approximately 5.5° to 8.3°C higher than the Closed cup values.

FOG (MISTS)
Liquid Aerosols formed either by condensation of a liquid on particulate nodes in air or by
uptake of liquid by hygroscopic particles.

FUME
Airborne Solid particles (usually <0.1 micron) that have condensed from the vapour state.

HAZARD
The inherent property of a substance capable of causing harm (e.g.. Toxicity, Radioactivity,
Flammability, Explosivity, Reactivity, Instability). In a broader context anything that can cause
harm, e.g. electricity, oxygen-deficiency, machinery, extreme temperature.

HAZARDOUS POLYMERISATION
A reaction that takes place at a rate that releases large amounts of energy that can cause
Fire or Explosions or rupture reactors and containers.

HAZARDOUS COMBUSTION PRODUCTS

Hazardous combustion products are chemicals which may be formed when a material burns.
These chemicals may be Toxic, Flammable or have other Hazards.

INERTING
Depression of the Flammable limits of a flammable Gas/ Vapour-air mixture by the addition
of an inert gas, e.g. Nitrogen, Carbon dioxide, or similar mixtures, to render it nonflammable.

INCOMPATIBILITY (WITH OTHER MATERIALS)

These are materials that could cause dangerous reactions by direct contact with one another.
Incompatible materials may cause a Fire, Explosion or Violent reaction or can cause the
release of Hazardous Chemicals.

JET FIRE
Fuel burning as a flame when flammable gas or vapour issues from a pipe, or other orifice,
and burns on the orifice.

LC50
The calculated concentration of a substance that causes death to 50% of a test population
under prescribed conditions in a prescribed period of time (normally expressed as ppm or
mg/m3 for gases, mg/Litre for liquids).

24
LD50
The calculated dose of chemical (mg. per kg. body weight) causing death to 50% of test
population. (The species of animal, route of administration, any vehicle used to dissolve or
suspend the material and the time period of exposure should be reported)

LEL (LOWER EXPLOSIVE, OR FLAMMABLE LIMIT)

The Minimum Concentration of a gas, vapour, mist or dust in air at a given pressure and
temperature that will propagate a flame when exposed to an efficient ignition source. Generally
expressed as % by volume for gases and vapours, and as mg/m3 for mists or dusts.

LPG (LIQUEFIED PETROLEUM GAS)

Petroleum gas stored or processed as a liquid in equilibrium with vapour by refrigeration or
pressurization. The two LPGs in general use are commercial propane and commercial butane

MELTING POINT
The temperature at which the solid and liquid phases of a substance are in equilibrium at
atmospheric pressure.

MUTAGEN
A Chemical or Physical agent that can cause a change (mutation) in the genetic material of
a living cell.

NARCOSIS
Drowsiness or Sleepiness.

NATURAL GAS
Flammable gas consisting essentially of Methane with very minor proportions of other gases.
Flammable limits approximately 5-15%.

ODOUR THRESHOLD
This is the lowest concentration of a Chemical in air that is detectable by smell. This should be
considered as an estimate. The ability to detect the odour of a Chemical varies from person to
person and depends on conditions such as the presence of other materials. Odour cannot be
used as a warning of unsafe conditions since people may become used to the smell (Adaptation)
or the chemical may numb the sense of smell, a process called as Olfactory Fatigue. e.g. H2S
causes Olfatcory Fatigue. If the Odour threshold for a Chemical is well below its exposure limit,
odour can be used to warn of a problem with the respirator that is worn

OXIDIZING AGENT
Compound that gives up oxygen easily or removes hydrogen from another compound. It
may comprise a gas, e.g.. Oxygen, Chlorine, Fluorine, or a Chemical which releases Oxygen,
e.g.. a Nitrate or Perchlorate. A compound that attracts electrons.

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OXYGEN DEFICIENCY
Depletion of Oxygen content in an atmosphere to below the normal 21%. Exposure to <18%
must not be permitted. Concentrations 6% to 10% oxygen can lead to loss of consciousness.

OXYGEN ENRICHMENT
Increase in Oxygen content of air to above the normal 21%. Enrichment within a room to
>25% can promote or accelerate combustion.

PERCUTANEOUS ABSORPTION
Absorption via the skin, e.g.. due to local contamination or a splash of chemical.

PERMIT-TO-WORK
A document needed when the safeguards provided in normal production are unavailable and
the manner in which a job is done is critical to safety. Identifies conditions required for safe
operation.

PNEUMOCONIOSIS
A group of lung diseases of a chronic fibrotic character due to the inhalation and retention in
the lungs of a variety of industrial dusts. The main diseases are asbestosis, silicosis,
coalworkers' pneumoconiosis and mixed-dust pneumoconiosis; less common pneumoconiosis
are associated with talc, clay or aluminium.

POOL FIRE
A Fire involving a flammable liquid spillage onto ground or onto water, or within a storage
tank or trench. The pool size depends upon the scale and local topography. Fire engulfment
and radiant heat pose the main risks.

pH
The pH is a measure of the acidity or basicity (Alkalinity) of a material when dissolved in
water. It is expressed on a scale of 0 to 14. Materials with pH of 0 to 2 and 11.5 to 14 are
classified as Corrosive.

PULMONARY OEDEMA
Production of watery fluid in the lungs.

PYROPHORIC SUBSTANCE
These are substances which will ignite Spontaneously in air at a temperature of 54.4 Deg C
or below.

REDUCING AGENT
A Material that adds Hydrogen to an element or compound; a material that adds an electron
to an element or compound.

REACTIVITY
This is a property that describes tendency to undergo chemical reaction either by itself or
with other materials with release of energy.

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RESPIRABLE DUST
That fraction of total inhalable dust which penetrates to the gas exchange region of the lung
(usually considered to be in the range 0.5 microns -7 micron).

RESPIRATORY SENSITIZER (ASTHMAGEN)

A Substance which can cause an individual's respiratory system to develop a condition which
makes it 'over-react' if the substance is inhaled again. Such an individual is 'sensitized'; over-
reaction is then likely to occur at concentrations of the substance which have no effect on
unsensitized persons and lead to characteristic symptoms, e.g. rhinitis (a runny nose),
conjunctivitis or in severe cases asthma or alveolitis.

RISK
The likelihood that a substance will cause harm in given circumstances in combination with
the severity.

SENSITIZATION DERMATITIS
Inflammation of the skin due to an allergic reaction to a sensitizer.

SENSITIZER
A Substance that causes little or no reaction in a person upon initial exposure but which will
provoke an allergic response on subsequent exposures.

SMOKE
Particulate matter (usually <0.5 micron in diameter) in air resulting usually from combustion,
including liquids, gases, vapours and solids.

SOLVENTS
Liquids that dissolve other substances. Chemical solvents are used widely in industry: e.g..
by pharmaceutical makers to extract active substances; by electronics manufacturers to
wash circuit boards; by paint makers to aid drying. Solvents can cause air and water pollution
and some can be responsible for ozone depletion.

SPONTANEOUS COMBUSTION
Combustion that results when materials undergo atmospheric oxidation at such a rate that
the heat generation exceeds heat dissipation and the heat gradually builds upto a sufficient
degree to cause the mass of material to inflame.

STEAM EXPLOSION
Overpressure associated with the rapid expansion in volume on instantaneous conversion of
water to steam.

SYSTEMIC POISONS
Substances which cause injury at sites other than or as well as, at the site of contact.

TERATOGEN
A Chemical or Physical agent that can cause defects in a developing embryo or foetus when
the pregnant female is exposed to the harmful agent.
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TLV-C, THRESHOLD LIMIT VALUE - CEILING VALUE
A limit for the atmospheric concentration of a chemical which may not be exceeded at any
time, even instantaneously in workroom air.

TLV-STEL, THRESHOLD LIMIT VALUE - SHORT TERM EXPOSURE LIMIT

A Maximum limit on the concentration of a chemical in workroom air which may be reached,
but not exceeded, on up to four occasions during a day for a maximum of 15 minutes each
time with each maximum exposure separated by at least one hour.

TLV-TWA, THRESHOLD LIMIT VALUE - TIME WEIGHTED AVERAGE

A Limit for the atmospheric concentration of a chemical, averaged over an 8-hr day, to which
it is believed that most people can be exposed without harm.

UEL, UPPER EXPLOSIVE (OR FLAMMABLE) LIMIT

The Maximum concentration of gas, vapour, mist or dust in air at a given pressure and
temperature in which a flame can be propagated.

UVCE (UNCONFINED VAPOUR CLOUD EXPLOSION)

Explosion which may occur when a large mass of flammable vapour, normally >5 tonnes,
after dispersion in air to produce a mixture within the flammable range is ignited in the open.
Intense blast damage results, often causing 'domino effects', e.g. secondary fires.

VAPOUR DENSITY
This is a measure of a vapour's weight as compared to ambient air. The vapour density of air
is One. Vapours with densities greater than one will sink, Vapours with densities less than
one will rise. Vapours with densities greater than one present an increased Fire / Toxic Hazard
in confined Space.

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 Hazards of Chemical Industry

Various Hazards of a Chemical Industry:

A. Chemical Hazards :
a. Health Hazards
I. Toxicity
II. Corrosivity
III. Irritant
IV. Carcinogenicity
V. Mutagenicity
VI. Toxic to Reproduction
VII. Specific Substances Hazardous to Health
b. Other Hazards
I. Dust explosion
II. Reactivity
III. Flammability
B. Mechanical Hazards
I. Kinetic Hazards -
a. Rotating Parts
b. Moving Objects
c. Falling Objects

II. Potential Hazards

a. Compressed Fluid stored at elevated Pressure
b. Hanging Loads
c. Pressure Hazards
C. Biological Hazards
a. Bacteria
b. Virus
c. Fungus
d. Prions
e. Parasites

29
 D. Thermal Hazards
a. Hot Burns
b. Cold Burns
E. Radiation Hazards
a. Ionizing Radiations
i. Alpha
ii. Beta
iii. Gamma
iv. Neutron
b. Non Ionising Radiations
i. UV
ii. IR
iii. Radio wave
iv. Microwave
F. Electrical Hazards
G. Ergonomic Hazards
H. Vibration Hazards
I. Noise Hazards
J. Illumination Hazards
K. Vehicular Hazards

30
 Chemical Hazards - Health Hazards

a. Toxicity
b. Corrosivity
c. Irritant
d. Carcinogenicity
e. Mutagenicity
f. Toxic to Reproduction
g. Specific Substances Hazardous to Health
l The Toxicity of a substance is its capacity to cause injury once inside the body.
l A substance is said to be toxic if small doses cause death or serious Ill health when
inhaled, swallowed or absorbed via the skin. E.g. Potassium Cyanide
l Harmful Chemical - if large doses cause death or serious ill-health when inhaled,
Swallowed or absorbed via the Skin.
l Corrosive Chemical - if it destroys living tissue on contact with any part of the body
E.g. Concentrated Sodium Hydroxide (NaOH)
l Irritant- if it causes inflammation of the skin or mucous membranes (E.g. Eye and
Lungs) through immediate, prolonged or repeated contact.
l Carcinogenic- if causes Cancer (abnormal growth of cells in the body) when
inhaled, Swallowed or absorbed via the skin E.g. Asbestos.
l Mutagen -if it causes genetic mutations that can be inherited.
l Toxic to reproduction - If it causes sterility or affect an unborn child
l Skin Sensitizers - Can cause allergic dermatitis on contact with the skin E.g. Epoxy
Resin.
l Respiratory Sensitizer - Can cause asthma on inhalation into the lungs e.g.. Flour
dust and isocyanates.

ROUTES OF ENTRY INTO THE BODY:

l Inhalation - the substance is breathed in through the nose and mouth and down into
the lungs. This is a significant route of entry for many hazardous substances in the gas,
vapour, mist, fumes or dust form.
l Inhalable Dust - Particles of all sizes that can be inhaled into the nose and mouth.
l Respirable Dust - Particles less than 7 Micron that can travel deep into the Lungs
on inhaled breath.

31
l Ingestion - the substance is taken in through the mouth and swallowed down into the
stomach and then moves into the digestive system. This is less significant route of
entry since people are unlikely to deliberately swallow a hazardous substance. Ingestion
usually occurs through contaminated hands.
l Absorption - the substance passes through the skin and into the tissues beneath and
then into the blood stream. Only some substance can permeate through the skin in this
way, but when they can, this route can be very significant route since skin contact
allows absorption.
l Injection through the Skin - the substance passes through the skin barrier either by
physical injection e.g. needle stick injury or through damaged Skin (cuts and grazes).
This route is very significant for biological agents
l Factors to be considered when carrying out an Assessment of Hazardous
substance exposure:
l The Hazardous nature of the substance present - Is it toxic, corrosive,
Carcinogenic
l Potential ill Health effects - Will the substance cause minor injury or very serious
disease and will it result from short term or long term exposure.
l The Physical Form - that the substance takes in the workplace - Is it solid, Liquid,
Vapor, dust, fumes etc.
l The routes of Entry - the substance can take in order to cause harm - is it harmful
by inhalation, ingestion, skin absorption etc.
l The Quantity of the Hazardous substance present in the workplace
l The concentration of the substance - if stored or used neat or diluted, and the
concentration in the air if airborne.
l The number of People potentially exposed and any vulnerable groups or
individuals such as pregnant women or the infirm.
l The frequency of exposure - will people by exposed once a week, once a day or
continuously?
l The duration of exposure - will exposure be very brief, last for several hours or
last for all day?
l The control measures that are already in place such as ventilation systems and
PPE
l Work place exposure limits (For Airborne Contaminants) of the Hazardous
substance. Maximum concentrations of Airborne contaminants, normally measured
across a particular reference period of time, to which employees may be exposed.
l Short term exposure limits (STEL) - exposure for maximum of 15 minutes. Short
term exposure limits combat the ill health effects of being exposed to very high levels of
the substance for quite short periods of time.

32
l Long Term exposure limits (TLV) - 8 hours exposure. Long term exposure limits combat
the ill health effects of being exposed to relatively low concentrations of the substance
for many or all hours of every working day through an entire working lifetime.
l Ceiling TLV(C) - the concentration that should not be exceeded during any part of the
working exposure.
l Indicators of toxicity hazards for solids are LD50 & LC50. LD50 is the statistically
derived single dosage of a substance that can be expected to cause death in 50% of
the sample population like rats, mice.
l LD50 is also determined by other routes, e.g. by skin absorption in rabbits.
l Lower the value of LD50, higher is the toxicity. Higher the value of LD50, lower is the
toxicity. Unit of LD50 is mg/kg.
l LC50 is the lethal concentration of chemical (e.g. in air or water) that will cause the
death of 50% of the sample population.

Hazardous Substance Monitoring

l Stain Tube Detectors - Easy and useful for analyzing gas and vapour contamination in
air at one moment in time. The principle of operation is simple - a known volume of air
is drawn through a chemical reagent contained in a glass tube. The contaminant in the
sir reacts with the reagent and a coloured stain is produced. The degree of staining
gives a direct reading of concentration.
l Passive Samplers - These use absorbent chemicals to sample contaminants without
using a pump to draw air through the collector. They give a measure of concentration
over a period of time (Long term Sampling) and can be used for Gas and Vapor. The
sampler is designed to allow gas or vapor to diffuse to an absorbent surface. At the end
of the sampling period, the sampler is sent for laboratory analysis. It is expensive process.
l Smoke Tube / Sticks - These are simple devices that generate smoke in a controlled
Chemical reaction. Breaking the smoke tube open activates the chemical reaction,
then the bulb is used to puff the smoke as required. Smoke tubes are useful for visualizing
the movement of air currents in a workplace and in particular can be used to assess the
effectiveness of ventilation and extraction systems.
l Dust Monitoring Equipment - Dust exposure in the workplace can be quantified using
a sampling train made up of an Air pump, tube and sampling head. This equipment can
be worn by a worker, so gives an indication of personal exposure. A pre-weighed filter is
fitted into the sampling head, air is drawn through it by the pump for a chosen period of
time, then the filter is removed and re-weighted.
l Dust Lamp (Tyndall Light) - A strong beam of light is shone through the area where a
cloud of finely divided dust is suspected. The eye of the observer is shielded from the
light beam and the dust cloud is made visible. This method is used to determine how
exhaust ventilation systems are working.

33
 Control Measures for preventing Toxic Exposure:
l Principles of Good Practices:
1. Minimization of emission, release and spread of Hazardous substances
through design and operation of Process and task activities.
2. Effectiveness and reliability of Control options that minimize the escape and
spread of Hazardous substances.
3. Exposure control to be proportional to health risk
4. Personal Protective Equipments (PPE)
5. Other PPE and clothing
6. Personal Hygiene and Protection regimes.
7. Health and Medical Surveillance
8. Additional Controls
l Elimination and Substitution
l Process Change
l Reduce Exposure Time
l Enclosure & Segregation
l Local Exhaust Ventilation
l Dilution Ventilation

34
 Corrosivity

l The Globally Harmonized System (GHS) of classification and labeling of chemicals has
two separate classifications for corrosives. These are 'corrosive to metal' and 'skin
corrosion.' The two definitions are as follows:
l A substance or a mixture, which by chemical action will materially damage, or
even destroy, metals.
l A substance or mixture that will cause irreversible damage to the skin; namely,
visible necrosis through the epidermis and into the dermis.
l Common corrosives are either strong acids (extreme low pH ) or strong base (extreme
high pH ) or concentrated solutions of certain weak acids or weak base.
l They can exist as any state of matter including liquid, solids gases mists or vapours
l The pH is a measurement of the acidity or alkalinity of a material when dissolved in
water. It is expressed on a scale of 0 to 14.
pH 0 to 2 = Strongly acidic
pH 3 to 5 = weakly acidic
pH 6 to 8 = Neutral
pH 9 to 11 = weakly basic
pH 12 to 14 = Strongly basic
l Material with pH values of 0 to 2 or 11.5 to 14 are classified as corrosive.
l Corrosive substances are most hazardous to eyesight. A drop of a corrosive may cause
blindness within 2-10 seconds through opacification or direct destruction of the cornea.
l Ingestion of corrosives can induce severe consequences, including serious damage of
the gastrointestinal tract, which can lead to vomiting, severe stomach aches, and death.
l Strong acids and bases are so corrosive that even momentary exposure to the skin will
produce severe damage.
l Weak acids and bases can also produce severe corrosion of the skin, but generally
require higher concentrations or longer contact times.
l Acids and bases damage tissue in different ways. Acids generally damage proteins
while bases saponify (e.g., dissolve) both proteins and fats.
l Damage from acids is generally felt at the outset of exposure.
l Damage from bases may not become painful for some time. Because bases act on
both proteins and fats and are not as immediately painful, exposure to bases can cause
more damage.
l The two greatest exceptions to acids causing immediate pain are hydrofluoric acid (HF)
and trifluoroacetic acid. For both it can take several hours for any symptoms to develop
(e.g., pain, redness). By this time, significant tissue damage can occur as well damage
to bone tissue.
l Of internal injuries, inhalation is the greatest concern. Corrosives that damage lung
tissue will cause chemically induced pulmonary edema. The lungs can fill with fluids
making breathing difficult or even impossible.
35
 Odour

l The odour threshold is the lowest concentration of a chemical in air that is detectable
by smell.
l The odour threshold should be regarded as an estimate. This is because odour threshold
are commonly determined under controlled laboratory conditions.
l Some chemicals possess low odour thresholds: their smell gives warning of impending
danger.
l Others possess odour thresholds well in excess of the hygiene standard.
l Reliance on the nose as an indicator, however, can be hazardous since untrained
exposees may not understand the significance of an odour.
l Some materials with low odour thresholds may paralyses the olfactory nerves and cause
the sense of smell to be lost within minutes called olfactory fatigue (e.g. Hydrogen
Sulphide).
l Some materials are odourless (e.g. Nitrogen, Carbon Monoxide).
l Some materials, such as arsine, phosphine, toluene di-isocyanate and stibine, may be
present in concentrations in excess of their hygiene standards yet undetectable by
smell.
l The odour of a toxic chemical may be masked by the odour from another substance, or
a mixture.
l Workers may become acclimatized to a commonly-occurring odour, or be suffering
temporarily from an impaired sense of smell, e.g. due to cold.

Control of Carcinogens, Mutagens and Asthamgens

l Exposure to Carcinogens, Mutagens and Asthmagens should be prevented, but if this
is not possible then following controls to be adopted:
l Total Enclosure
l Prohibition of eating, Drinking & Smoking in Potentially contaminated areas.
l Regular Cleaning of floors, Walls and other surfaces
l Designation of areas that may be contaminated with the use of warning signs
l Safe Storage, Handling and disposal.

36
 Chemical Hazards - Other Hazards

I. Flammability
II. Dust Explosion
III. Reactivity
I. Flammability
Certain chemicals pose fire and explosion risks because:
l They ignite easily. Vapours often travel a considerable distance to an ignition source
remote from the point of chemical escape. Considerable heat is generated.
l Many volatile substances liberate heat at a rate some ten times faster than burning
wood.
l The fire spreads easily by, e.g., running liquid fire, a pool fire, a fire ball, heat radiation
or thermal lift (convection).
Important terminology for flammable chemicals
Flash point: The flash point of a liquid is the lowest temperature at which sufficient vapour is
given off to flash on the application of a flame in the presence of air. Liquids with low flash
points are greater fire hazards than liquids with high flash points.
Fire point: The lowest temperature of a liquid at which vapors evolved is fast enough to
support continuous combustion. This temperature is usually above the flash point
Auto ignition: The lowest temperature to which a solid, Liquid or gas requires to be raised to
cause self-sustained Combustion without initiation by a spark or flame.
Explosive limit / Flammability Range: Explosive limits (Flammability Range) are those
concentrations of a vapor or gas in air below or above which propagation of a flame does not
occur on Contact with source of ignition.
Lower explosive limit (LEL): It is the minimum concentration below which the vapor air
mixture is “too lean” to burn or explode. This limit is also known by 'Lean mixture'.
Upper explosive limit (UEL): It is the maximum concentration above which the vapor air
mixture is “too rich” to burn or explode.
Auto ignition temperature: Minimum temperature at which substance catch fire automatically
(without source of ignition)
Hazardous decomposition product: Describes the hazardous materials produced from a
chemical reaction.
Confined Vapour Cloud Explosion: (CVCE) can result from ignition of vapour within a
building or equipment. Gas or vapour burns in a confined volume and rapid expansion of the
combustion products is restrained until failure of the container or building occurs.
Boiling Liquid Expanding Vapour Explosion: (BLEVE) Instantaneous release and ignition
of flammable vapour upon rupture of a vessel containing flammable liquid above its
atmospheric boiling point. It can result when unvented containers of flammable chemicals
37
burst with explosive violence as a result of the build-up of internal pressure. It follows failure
of a pressurized container of flammable liquid, e.g. LPG, or a sealed vessel containing volatile
flammable liquids, under fire conditions. Ignition results in a fireball and missiles.
Unconfined Vapour Cloud Explosion: (UVCE) Explosion which may occur when a large
mass of flammable vapour, after dispersion in air to produce a mixture within the flammable
range is ignited in the open. Intense blast damage results, often causing 'domino effects',
e.g. secondary fires.
Spontaneous Combustion : Combustion that results when materials undergo atmospheric
oxidation at such a rate that the heat generation exceeds heat dissipation and the heat
gradually builds up to a sufficient degree to cause the mass of material to inflame
Pyrophoric Substance : A material that undergoes such vigorous oxidation or hydrolysis
(often with evolution of highly-flammable gases) when exposed to atmospheric oxygen or to
water, that it rapidly ignites without an external source of ignition. This is a special case of
spontaneous combustion.

38
 II. Dust explosion

What is a Dust Explosion

A dust explosion is the rapid combustion of fine particles suspended in the air, often but not
always in an enclosed location.
Consequences of Dust Explosion
A. Human Injury which could be even fatalities
B. Environment damage
C. Huge Property Damage

Operations susceptible to Dust Explosion can occur

l Drying of Powder
l Milling of Powder
l Micronisation of Powder
l Sieveing of Powder

Conditions that are required for Dust Explosion to occur

l Presence of Combustible Material / Dust / Vapour
l Ignition Source
l Oxygen
l Dispersion of Dust Particles in sufficient Quantity & Concentration (Between LEL
and UEL)
l Confinement of the Dust Cloud
Possible Ignition Sources
l Fire, Flames or smoldering Material
l Hot Surfaces
l Static Electricity
l Electrically generated Spark
l Mechanically generated Spark due to friction

Important Tests which are done for Dust Handling

l Burning Test
l For evaluating the combustibility of material (what extent a fire started by an
external source will propagate in a dust layer of a dried product.

39
 l Ignition Test for Airborne dust - BAM
l For determination of the minimum temperature at which a given dust cloud
auto ignites at a Hot surface
l Lutolf Oven - DTA Open Cup
l For determination of the lowest temperature at which a substance shows a
exothermic reaction.
l Grewer Oven
l For determination of the lowest temperature at which a substance shows an
exothermic reaction in a fresh air stream.
l Dust Explosion Test
l For determining explosiveness of dust and violence of explosion, It gives
explosion class (which is qualitative)
l Percussion test
l For evaluating the sensitivity of percussion (Impact sensitivity of a material
upon its exposure to impact energy)
l Gas Evolution test
l For determining the amount of gas evolved on decomposition along with
flammability of the gases of decomposition.
l Hot Storage Oven
l For determining the lowest temperature at which, a substance shows an
exothermic decomposition under insulated conditions (Accumulation of Heat)
l Minimum Ignition Energy MIKE
l For determining of the lowest energy required to ignite the dust / air mixture
l Powder resistivity
l For determining the importance of static charges as hazard

40
 l Deflagration Test
l For determining whether a sample, when subjected to a standard initiation
source, will deflagrate
l Dust Layer Ignition
l For determining the lowest temperature at which a substance of Dust Layer
shows an exothermic reaction
l Pmax
l Maximum Dust explosion pressure
l Kst
l Explosion severity The maximum value for the material-specific constant
“Kmax” that describes the rate of pressure rise, dP/dt, as a function of vessel
volume.
l Burning Numbers
l Every material has a burning number which is determined by conducting a
Combustion test and is expressed in Burning Number from 1 to 6 as below

Observation of Nature of Fire Burning Class Remarks

Combustion Test
No Ignition No Spreading of Fire 1
Brief Ignition and 2
Rapid Extinction
Localized Combustion or 3
glowing with practically
no spreading
Glowing without sparks Fire Spreads 4
(smoldering) or slow
decomposition w/o flame
Burning like fireworks 5
or slow, quiteburning
with flames
Very rapid combustion 6
with flame propagation or
rapid decomposition
without flame

41
Safety Class for Milling

[Link] SKM 0 SKM 1 SKM 2

Ignition Behaviour
1. Minimum Ignition Energy '> 1 J Upto 1 J '-
2. Minimum Ignition
Temperature '> 500 Deg C Upto 500 Deg C '-
Burning Behaviour
3. Burning Class 1-2 3-5 6
Thermal Stability
4. Auto Ignition / Exothermic '> 220 Deg C 90 to 220 Deg C '< 90 Deg C
Reaction in Fresh Air
Stream (Grewer)
5. Exothermicity in Open '> 220 Deg C 90 to 220 Deg C '< 90 Deg C
Vessel (Lutolf)
6. Flammable Solvent Upto 0.1 % Upto 0.5 % '> 0.5 %
Impact Testing
7. Deflagration at 100 Deg C Negative Negative Positive
8. Drop Hammer Test Negative Negative Positive

l A product is classed as SKM 0 if the corresponding conditions are fulfilled in all

criteria. Products which fall under SKM 0 can be milled / Dried without Special
Precautions
l A product is classed as SKM 1 if it can not be assigned to SCM 0 in at least one
criterion. Products which fall under SKM 1
l Technical Explosion Safeguards will be required and if necessary Fire
Extinguishing devices will be required.
l A product is classed as SkM 2 when the conditions of this class are reached in at
least one criterion. Products which fall under SKM 2
l Safe Handling is so delicate that Mechanical Milling / FBD would not normally
be acceptable.
Key Safety data required for Dust Explosivity
l Minimum Ignition Energy MIE in mJ
l Minimum Ignition Temperature in Deg C
l Specific Powder Resistivity in Ohm m
l Particle Size in Micron
l Volume and shape / Diameter of the silo or container (for filling and emptying operation).

42
Important Considerations of above parameters:
l If flammable content in the powder is more than 0.5%, powder to be handled with
precautions of Handling a Solvent.
l If the solvent content in the powder is between 0 to 0.5 % and if the product is stored for
period in large volumes in a silo or vessel without Special ventilation after size reduction
- then formation of Solvent / Hybrid mixture expected and must be inerted positively
l If particle size is more than 500 Micron and fines in it less than 10 gm / m3, then
presence of explosive atmosphere not expected
l If Particle size is less than 500 Micron and fines in it is more than 10gm / m3, then
check for its MIE, If the MIE is more than 1 J then ignition due to static is not expected.
However other sources of ignition needs to be controlled.
l If Particle size is less than 500 Micron and fines in it is more than 10gm / m3, then
check for its MIE, If the MIE is less than 1 J then Earth all conductive plant components,
vessels and containers including those capable of discharge.
l If Particle size is less than 500 Micron and fines in it is more than 10gm / m3, then
check for its MIE, If the MIE is less than 30 m J then Earth all conductive plant
components, vessels and containers including those capable of discharge. Also all
personnel must be grounded by means of conductive footwear and flooring where
explosive concentrations are present.
l As Particle size decreases, MIE also decreases
l As Temperature increases, MIE decreases
l If the powder resistivity is < 10 to the power 8 = It is Conductive
l If the powder resistivity is > 10 to the power 12, the powder is not conductive and there
are high chances of explosion if precautions are not taken
l If the Explosive atmosphere cannot be avoided, then
l Provide inerting
l Avoid ignition source
l In case of mixing operation and during emptying and filling, the tip speed of the ribbon
should not be more than 1 m/s
l If the MIE of the Powder is < 10 mJ, then provide additional constructional explosion
protection measures or inerting
l While charging a powder into a flammable solvent,
l Charge the material at below the Flash Point of the Solvent
l Purge the vessel with Inert gas and maintain Oxygen content below LOC
l Do earthing & bonding of the vessel & Charging system.
l Use closed Charging system

43
 Safety Class for Drying

[Link] SKD 0 SKD 1 SKD 2

1. Burning test at 100 0C in air Max 3 4 or 5 6
(Burning number)
2. Self propagating decomposition Negative Negative Positive
test at 100 Deg C
3. Impact sensitivity Negative Negative Positive
(for paddle dryers with
beaters only)
4. Test for volume of Max 10 ' > 10
decomposition gases
up to 220 0C
6. Content of flammable Max 0.1 % '> 0.1 %
solvent before drying
( % by weight)

l A product is assigned to SKD 0 if all five criteria for this class shown in table are fulfilled
l A product is assigned to SKD 1 if at least one of the criteria of SKD 0 is
l exceeded but non of the criteria of SCD 2 is fulfilled
l A product is assigned to SKD 2 if it fulfills at least one of the three criteria for this class

44
 III. Reactivity

l Reactivity is the tendency of a substance to undergo chemical reaction, either by itself

or with other materials, and to release energy.
l Many incidents have happened due to Run away reactions leading to Explosion, Toxic
release
l A runaway reaction is a chemical reaction over which control has been lost. It continues
to accelerate in reaction speed until it either runs out of reactants or the vessel containing
it overpressures, losing containment - frequently with high risk of injury, Environmental
damage and equipment damage.
l Exothermic runaway incidents are caused by poor understanding of the reaction
chemistry and thermo chemistry, under-rated control and safety back-up systems and
inadequate procedures and training continue
l Causes of Runaway in Industrial reactors and Storage Tanks
1. Accumulation of Reactants or intermediates
l Incorrect Kinetic Assumption
l Incorrect initiation
l Insufficient Mixing
l Temperature too low
l Impurities (inhibitors)
l Catalysts
l Feed rate too fast
2. Insufficient Cooling
l Incorrect assumption on Heat Balance
l Loss of Cooling or Stirring
3. Triggering of Undesired reaction
l Temperature of Heat Transfer Fluid too high
l Product Mixup
l From the above 3, if combination of 1 & 2 happens, it leads to Heat accumulation and
uncontrolled Temperature rise. Whereas if combination of 2 & 3 happens, it leads to
thermal runaway situation.
l Process Safety Tests which are normally done for Chemical Synthesis
l DSC (Differential Scanning Calorimetry)
l RC1 (Reaction Calorimetry)
l DSC : It is a method for thermal analysis using small samples of a few milligrams
(micro-thermal analysis).
l RC1 : This is a computer controlled laboratory reactor with balancing of heat and mass
flows. It is an excellent tool for studying the thermal characteristic of the desired reactions,
and for assuring safe process performance
45
Following information is required to study a Synthesis process in terms of
Process Safety

[Link] Information required Method

1 Can the process temperature be controlled?
Power of Cooling System : Heat of Reaction RC1, DSC
2. What temperature can be attained after run away of
desired reaction ?
Degree of Accumulation
MTSR : Max Temp of Synthesis reaction
3. What temperature can be attained after Runaway
of decomposition. Will give significance of Runaway DSC
4. At which moment cooling failure has worst consequence?
Degree of accumulation, stability of Reaction mass RC1, DSC
5. How fast is runaway of desired reaction?
How fast is increase in Temperature RC1, DSC
6. How fast is runaway of decomposition at MTSR.
Dynamics of Decomposition reaction DSC (TMR ad)

Following are the important parameters

1. Delta T ad : (Adiabatic Temp rise) - Measure of severity of an Incident
l The severity of a potential incident is linked to the amount of energy, which can be
releases. Therefore the adiabatic temperature rise is a direct measure of the
severity.
l If it is > 200 K, then it is high severity
l If it is < 200K but > 50 K, then it is medium severity
l If it is < 50 K, then it is low severity
2. TMR ad (Time for Maximum rate under adiabatic conditions - Time to the point of
maximum decomposition reaction at a given temperature) - Measure of Probability of
an incident.
l There is no direct measure for the probability of an incident, the induction time of
a thermal explosion can be used for the same. If the temperature increase is
sufficiently slow to allow for implementation of countermeasures, the probability
of the run away reaction can be considered to be low. In like manner, in the case
of a fast run away, where there is no possibility of recovering control of the reaction,
probability is considered high. Therefore the time to Maximum Rate under adiabatic
conditions TMR ad is used as a guide - value to assess the probability of an
incident
46
 l Probability is high if it is < 8 hrs
l Probability is medium if it is > 8 hrs and < 24 hrs
l Probability is low if it is > 24 hrs.
3. MTSR = Maximum Temperature of Synthesis Reaction in case adiabatic conditions
occur

47
 Biological hazards

1. Bacteria
l These are single celled organisms that are found in vast numbers in and on the
human body. Some are harmless, some are beneficial and some cause disease
(eg. Legionnaire's disease, leptospirosis)
l Bacteria are ten to 100 times larger than viruses.
l They acquire energy from the same essential sources as humans, including sugars,
proteins, and fats.
l Some bacteria live and multiply in the environment while others are adapted to life
within human or animal hosts.
l Some bacteria can double in number every fifteen minutes while others take weeks
or months to multiply.
l Bacteria cause many types of diseases, ranging from mild skin irritation to lethal
pneumonia.
2. Viruses
l Viruses are very small infectious organisms that reproduce by hijacking living cells
to manufacture more viruses. Many cause disease eg. Hepatitis
l Viruses are different from all other infectious microorganisms because they are
the only group of microorganisms that cannot replicate outside of a host cell.
l Because viruses do not eat food - instead they seize materials and energy from
host cells by hijacking cellular machinery.
l Viruses are known to infect nearly every type of organism on Earth. Some viruses,
called bacteriophages, even infect bacteria.
3. Fungi
l Fungi are diverse in terms of their shape, size and means of infecting humans.
l Eg of Fungi are Moulds, yeast and Mushrooms. Most are harmless to humans but
some can cause disease such as Fungal infections (e.g. Athlete's foot) and Framer's
Lung (an allergic irritation caused by inhaling mould spores.
l Fungi most often cause skin infections and pneumonia. Fungal diseases are
particularly dangerous to immune compromised people, such as those suffering
from AIDS.
4. Prions
l Prions (the name is derived from proteinaceous infectious particle) is the name
used by many scientists to describe the pathogen that causes transmissible
spongiform encephalopathies (TSE) which are neurodegenerative diseases in
mammals.

48
 l Prions are abnormal, transmissible agents able to induce abnormal folding of
normal cellular Prion Proteins in the brain, leading to brain damage eg. Creutzfeldt
- Jakob Disease (CJD or “Mad Cow Disease”)
l Prions are a disease-causing form of a normal protein called cellular prion protein
(PrPC) that is located primarily on the surface of central nervous system cells but
also in other tissues of the body in mammals.
l Prions are unique pathogens in that they appear to have no nucleic acid and
thereby differ from viruses, bacteria, fungi and other pathogens.
l Prions are resistant to procedures that break down nucleic acid and destroy
biological forms of pathogens.
l Prions are responsible for genetic, sporadic and acquired forms of
neurodegenerative disease.
l Prions are an abnormal form of a normal protein that is genetically encoded, they
do not produce an immune response in the host as would a foreign infectious agent.
5. Parasites
l Parasites are part of a large group of organisms called eukaryotes.
l Parasites are different from bacteria or viruses because their cells share many
features with human cells including a defined nucleus.
l Some parasites only replicate within a host organism, but some can multiply freely
in the environment.
l In developing countries unicellular parasites, such as Plasmodium, the cause of
malaria, are a major sources of disease.
l Waterborne parasites, such as Giardia and Cryptosporidium are the most common
causes of parasitic disease in the United States.
Control of Biological Hazards
l Sterilisation & Disinfection - This process removes the biological agent and
therefore the Hazard. Disinfection of workrooms and benches is an important
control to minimize the spread of Infectious Materials.
l PPE : PPE can be used to prevent contamination of clothing (e.g. Lab Coat) or to
prevent material entering the body (e.g. Respiratory and Eye protection to prevent
entry via inhalation or absorption, gloves to prevent contact with broken skin ).
Those handling biological agents should ensure that open wounds are covered at
all times.
l Spill Containment Methods: Spill trays may be used in Laboratories. Uncontrolled
release of body fluids such as blood may be treated with a Chemical to contain
and disinfect. High Standards of personal hygiene are essential. Smoking, Drinking,
Eating and applying Cosmetics should all be banned in the workplace and clothing
should be changed (eg Lab Coats removed) before entering uncontaminated areas.
l Vaccination should be used to prevent infection.

49
 Specific Substances Hazardous to Health

1. Asbestos
2. Blood borne Viruses
3. Carbon Mono oxide
4. Cement
5. Legionella Bacteria
6. Leptospira Bacteria
7. Silica
8. Wood Dust

Asbestos :
Hazards of Asbestos:
l Asbestosis : Asbestos fibers lodge deep in the lungs and cause scar tissue
formation if enough of the lung is scarred then severe breathing difficulties occur,
Can prove fatal, Increase risk of Cancer.
l Lung Cancer : Asbestos fibers in the lung trigger the development of cancerous
growths in the Lung tissue. Usually fatal
l Mesothelioma : Asbestos fibers in the lung migrate through the lung tissue and
into the cavities around the lung and trigger the development of cancerous growths
in the lining tissue. Always fatal.
l Diffuse Pleural Thickening : Thickening of the lining tissue of the lung (known
as pleural plaques) that causes breathing difficulties. Not Fatal.
Controls for Working in areas where Asbestos is present:
l The work area must be sealed to prevent the escape of air contaminated with
asbestos dust.
l Workers entering the sealed area must wear protective clothing and respiratory
protective equipment to prevent dust inhalation.
l The sealed area must be ventilated by a negative pressure ventilation system
with high efficiency particulate air filers (HEPA)
l All ACM's removed must be securely double bagged, labelled and disposed of as
hazardous waste at a site licensed to receive it.
Hazards of Blood borne Viruses
Hepatitis A - Contracted orally by cross contamination with faecal material containing the
hepatitis A virus. Sewerage workers are at risk of contracting Hepatitis A.
Hepatitis B - Transmitted by body fluids such as blood. Health care workers (Nurses, Doctors),
Fire Fighters, Police and Waste disposal workers are at risk. Contaminated body fluids can
50
cause infection by contact with damaged skin, needle stick injury and even splashing to the
eyes and mouth. Symptoms of the disease include Jaundice and Liver damage.
Controls to prevent Blood Borne Viruses:
l Use of PPE such as Gloves and Eye protection when handling potentially
contaminated material.
l Correct disposal of potentially contaminated material such as clinical waste
l Prevention of needle stick injuries by correct disposal of sharps in a sharp bin
l Decontamination and disinfection procedures
l Vaccination where appropriate
l Procedures to deal with accidental exposures

Carbon Mono oxide

l Colorless, odourless gas usually encountered as a by-product of partial combustion
(e.g. poorly maintained heating boiler).
l CO interferes with the Oxygen carrying process by binding onto the haemoglobin
molecule at the same place where the Oxygen should be present.
l Prevents oxygen transportation and can lead to death by asphyxiation
l Levels of 13% will cause immediate unconsciousness and death within 3 minutes.
This can happen even though Oxygen concentration are normal at 21%.
Controls to prevent CO exposure:
l Restricting work on gas systems to competent engineers only
l Maintenance and testing of boilers and flues
l Good General work place ventilation
l LEV for vehicle exhausts in workshops
l Care in the siting of equipment containing combustion engines
l Carbon monoxide alarms
l Confined Space entry control.

Cement
Hazards of Cement
l Cement is an irritant dust easily inhalable and blown into eyes.
l Once mixed with water it is corrosive on skin and eye contact.
l Irritation or corrosive burns to the eyes
l Irritation of the respiratory tract
l Irritant dermatitis on skin contact

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 l Allergic dermatitis on repeated skin contact
l Corrosive burns to the skin on prolonged contact.
Controls to Prevent
l Eliminating or reducing exposure
l Use of work clothing and PPE such as Gloves, Dust masks and eye protection.
l Removal of contaminated clothing
l Good Hygiene and washing on skin contact

Legionella Bacteria
l Water loving Soil bacteria
l Hazardous when inhaled into the lungs
l Causes a disease called Legionnaire's disease
l Can occur when water systems in a workplace become contaminated with the
bacteria and that contaminated water is then sprayed to create a mist (with living
bacteria inside the droplets)
l Most common sources for outbreaks of the disease are outdoor cooling tower.
Water containing the bacteria is sprayed inside the cooling tower, then drifts out of
the top of the cooling tower and is inhaled by passerby. These people may develop
this disease. It starts with flu like and then develops to pneumonia and it can prove
to be fatal.
Controls to prevent
l Enclosing water systems to minimize risk of contamination
l Water treatment like chlorination to kill the bacteria
l Operating hot water systems > 60 Deg C as the bacteria is temperature sensitive
and is killed above 60 Deg C.
l Use of Biocides
l Prevention of limescale buildup (Limescale can harbor the bacteria)
l Routine cleaning of cooling towers
l Water sampling and analysis
Leptospira Bacteria
l Commonly infects animals such as rats, mice, Cattle and Horses.
l Infected rats can pass the bacteria in their urine onto wet surfaces or into water
where the bacteria can stay alive
l If contaminated water comes into contact with cuts or graces or is ingested, then
infection may occur.
l Occupation at risk are dairy farmers who work with infected animals

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 l Causes disease called Leptospirosis which starts with flu like symptoms and then
progresses to more serious stage of jaundice causing damage to liver (Weil's
disease)
l If not diagnosed early, can be fatal.
Controls to prevent
l Preventing rat Infestation by good Housekeeping and Pest Control
l Good Personal Hygiene (Hand Washing)
l PPE (Especially Gloves)
l Covering cuts and grazes
l Issuing workers with an “at Risk” card to be shown to the worker's doctor
(physicians) to allow early diagnosis.

Silica
l Silica is hazardous if inhaled.
l If inhaled, respirable crystalline silica dust is deposited deep into the lungs where
it causes scar tissue to form Silicosis.
l Progressively it leads to breathlessness and chest pain and can prove extremely
disabling and fatal by heart and lung failure.
Control to prevent:
l Prevention of exposure by use of alternative work methods
l Dust suppression by water jet / Spray
l Local exhaust ventilation
l Respiratory protective equipment
l Health Surveillance (Lung Function test and Chest X Ray)

Wood Dust
l Wood dust is Hazardous on inhalation and causes asthma
l Certain wood dust are more likely to cause asthma and hence categorized as
asthmagens.
l Hardwood dusts can cause cancer usually of nose and hence categorized as
Carcinogens.
Controls to Prevent
l Local Exhaust Ventilation Systems
l Use of Vacuuming to cleanup dust (not sweeping)
l Respiratory Protective equipment
l Health Surveillance

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 Mechanical Hazards

l A wide variety of mechanical motions and actions may present hazards to the
worker.
l These can include the movement of rotating members, reciprocating arms, moving
belts, meshing gears, cutting teeth, and any parts that impact or shear.
l Mechanical Hazards can be broadly divided into 2 types
l Kinetic
l Potential
Kinetic
The basic types of hazardous mechanical motions and actions are:
Motions
l Rotating (including in-running nip points)
l Reciprocating
l Transversing
Actions
l Cutting
l Punching
l Shearing
l Bending
Motion
l Rotating motion can be dangerous; even smooth, slowly rotating shafts can grip
clothing, and through mere skin contact force an arm or hand into a dangerous
position.
l Injuries due to contact with rotating parts can be severe.
l Collars, couplings, cams, clutches, flywheels, shaft ends, spindles, meshing gears,
and horizontal or vertical shafting are some examples of common rotating
mechanisms which may be hazardous.
l The danger increases when projections such as set screws, bolts, nicks, abrasions,
and projecting keys or set screws are exposed on rotating parts.
l In-running nip point hazards are caused by the rotating parts on machinery. There
are three main types of in-running nips.
l Parts can rotate in opposite directions while their axes are parallel to each
other. These parts may be in contact (producing a nip point) or in close
proximity.
l In the latter case the stock fed between the rolls produces the nip points.

54
 This danger is common on machines with intermeshing gears, rolling mills,
and calendrers.
l Nip points are also created between rotating and tangentially moving parts.
Some examples would be: the point of contact between a power transmission
belt and its pulley, a chain and a sprocket, and a rack and pinion.
l Nip points can occur between rotating and fixed parts which create a shearing,
crushing, or abrading action. Examples are: spoked hand wheels or flywheels,
screw conveyors, or the periphery of an abrasive wheel and an incorrectly
adjusted work rest.
l Reciprocating motions may be hazardous because, during the back-and-forth or
up-and-down motion, a worker may be struck by or caught between a moving and
a stationary part.
l Transverse motion (movement in a straight, continuous line) creates a hazard
because a worker may be struck or caught in a pinch or shear point by the moving
part.
Actions
l Cutting action may involve rotating, reciprocating, or transverse motion.
l The danger of cutting action exists at the point of operation where finger, arm and
body injuries can occur and where flying chips or scrap material can strike the
head, particularly in the area of the eyes or face. Such hazards are present at the
point of operation in cutting wood, metal, or other materials.
l Examples of mechanisms involving cutting hazards include band saws, circular
saws, boring or drilling machines, turning machines (lathes), or milling machines.
l Punching action results when power is applied to a slide (ram) for the purpose of
blanking, drawing, or stamping metal or other materials.
l The danger of punching type of action occurs at the point of operation where
stock is inserted, held, and withdrawn by hand.
l Typical machines used for punching operations are power presses and iron workers.
l Shearing action involves applying power to a slide or knife in order to trim or shear
metal or other materials.
l A hazard occurs at the point of operation where stock is actually inserted, held,
and withdrawn.
l Examples of machines used for shearing operations are mechanically, hydraulically,
or pneumatically powered shears.
l Bending action results when power is applied to a slide in order to draw or stamp
metal or other materials. A hazard occurs at the point of operation where stock is
inserted, held, and withdrawn.
l Equipment that uses bending action includes power presses, press brakes, and
tubing benders

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Potential hazards
l Any load that is suspended above ground level is a hazard.
l A load that is above people's heads, and is moving, presents even greater hazards.
l If the load falls or tips it could cause serious harm to personnel and equipment
below it and around it.
l Loads can fall as a result of incorrect attachment methods (rigging)
l Faulty equipment such as strops, lifting eyes, crane wires, and hooks
l Using equipment that is not rated for the weight of the load.

High pressure hazards

l Pressure vessels are air-tight containers used mostly in process industry, refinery
and petrochemical plant to carry or hold liquid, gases or process fluids.
l The potential danger associated with pressure vessels failure if not properly
designed, constructed, operated, inspected, tested, or repaired are:
l Blast Effects
l Fragmentation damage
l Suffocation
l Poisoning
l Fire Explosion
l Chemical burns
l The catastrophic disasters caused by pressure vessel accidents could be totally
prevented by;
l Designing, fabricating and constructing pressure vessels to comply with
applicable codes and standards, and where no pressure vessel law exists,
to internationally recognized pressure vessel safety codes.
l Operating the vessel at pressure below the maximum allowable working
pressure with proper pressure setting of relief devices, to handle design
pressures and temperatures.
l Periodically testing and inspecting the vessel as well as the relief devices in
order to detect corrosion or erosion of the vessel that can cause holes, leaks,
cracks, general thinning of the vessel walls or any other defects. Safety relief
valves must be taken off during safety inspection to verify whether their
settings are correct.
l Keeping records of inspection reports and monitoring potential problem, so
that the vessel may be taken out of service before it becomes dangerous.
Also, having all information displayed prominently.
l Ensuring that alterations or repairs of vessels are only done by competent

56
 and authorised persons and the repair must meet the accepted industry
quality standards for pressure vessel repair.
l Providing safety training for employees on job hazard and anticipated
conditions that could jeopardize their safety or the safety of others.
l Periodically provide training for operators on vessels operating procedures
to avoid over pressurizing, as well as providing them with adequate and
suitable instructions for vessel safe operations.

High pressure water jetting hazard

l High pressure water jetting is a process using a stream of pressurized water to
remove material, coatings or contamination and debris from the surface of a work
piece or material substrate including:
l High pressure water jetting systems pressurized by positive displacement pumps
with an output capability 100 to 1000 bar liters per minute where there is a
foreseeable risk of injury to operators or other people.
l High pressure water jetting systems consist of an energy source like an electric
motor or internal combustion engine, a pump, control mechanism, hoses, pipes,
nozzles and various other components necessary for the equipment to function
as a system.
l Common hazards and risks include the water jet piercing the skin, being hit by
flying debris and exposure to noise.

Anyone using high pressure water jetting equipment should follow these safety
recommendations:
l Where necessary equipment near jetting operations should be shielded or protected
from debris and the ingress of water from operating the jetting equipment.
l Any essential electrical installation should meet the required protection levels
against the ingress of water vapour or overspray.
l People other than the operating team should be kept out of barricaded work areas.
l Work activities should be planned to provide safe access to the equipment and
item or surface being jetted.
l Overhead work should be avoided where possible as this may cause unstable
worker positioning and increase the risk of musculoskeletal disorders.
l Operators using manually operated jetting systems should be in a safe and well-
balanced position before starting jetting operations.
l Jetting operations should not be performed from ladders or other surfaces not
intended for use by workers as this can lead to loss of control of the jetting
equipment.
l Operators should check there is no interruption or interference to the release
57
 mechanism of hand or foot controls that could stop the equipment operating safely
and consistent with the manufacturer's specifications.
l Jetting operations should stop when:
l conditions change or new hazards are introduced
l unauthorized people enter the barricaded area
l recommended safe work practices are not being followed, or
l A malfunction occurs.
l Jetting systems should be depressurized and secured when:
l not in use and left unattended, and
l Components are being replaced or repairs are being made to the
system.

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 Thermal Hazards

l Many processes and equipment in chemical plant operate at high temperature and
directly expose hot environment, hot surface and high temperature radiation.
l Extreme cold temperature hazard cannot be neglected because it is able to present
real hazard to workers.
l Steam, hot-water pipes or any other heating media lines. All exposed steam, Hot-water
pipes or any other heating media lines within 7 feet of the floor or working platform or
within 15 inches measured horizontally from stairways, ramps, or fixed ladders shall be
covered with an insulating material, or guarded in such manner as to prevent contact.
l Serious injuries could occur from coming in contact with hot surfaces without hot surface
signs.
l Hot/ Cold surfaces warning signs “Hot Surface Do not Touch” to be provided to alert
workers around them.

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 Radiation Hazards

1. Categorized into 2 types :

l Ionizing Radiations - Radiation that caused ionization in the material that
absorbs it
l Non Ionizing Radiations - Radiation that does not cause ionization in the
material that absorbs it
2. Types of Ionizing Radiation
l Alpha Particles
l Sub atomic particles emitted by some radioactive substances.
l Do not have penetrating power and are stopped by thin material like Paper
and the dead layers of cells on the surface of the skin.
l Not considered hazardous provided they are outside the body
l but very hazardous if the source gets into the body by ingestion or
inhalation.
l Beta Particles
l Sub atomic particles emitted by some radioactive substances.
l More penetrating power and can penetrate through the skin into living
tissues.
l Considered hazardous when outside the body
l X Rays -
l A form of High energy electromagnetic radiation (light) emitted by some
radioactive substances and X Ray generators.
l High penetrating power
l Can shine right through the Human Body (though not through dense bone
tissue)
l Considered very hazardous
l Gamma Rays-
l A form of very high energy electromagnetic energy (light) emitted by some
radioactive substances.
l Very High penetrating power
l Can shine through the human body (even the bones) and through solid
objects like steel
l Considered very Hazardous

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 l Neutrons -
l Sub atomic Particles emitted by some radioactive substances
l Very High Penetrating power
l Can penetrate through the body
l Considered very hazardous
Sources of Ionizing Radiations:
l Alpha Particles - Smoke Detectors and science labs
l Beta Particles - Science labs and thickness gauges
l X Rays - Medical radiography and baggage security scanners
l Gamma Rays - Industrial radiography
l Neutrons - Nuclear Power Stations
Health Effects of exposure to Ionizing Radiation
l Acute effects of exposure to high doses
l Radiation sickness - Nausea, Vomiting & Diarrhoea
l Blistering and ulceration of the skin
l Hair Loss
l Dermatitis
l Cataracts
l Anaemia, due to red blood cell damage
l Reduced immune system due to white blood cell damage
l Infertility
l If the dose is large enough, even death can happen
l Chronic Effects of exposure
l Cancer
l Genetic Mutations
l Birth Defects

Protection from Ionizing Radiation

l Time
l Minimize the time of exposure
l Half the duration, half the dose
l Distance
l Reduce the distance from the radiation source.

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 l Alpha and Beta Particles cannot travel long distances and small distance
separation can have significant effect.
l X Ray and Gamma rays travel greater distances but obey inverse square
law.
l If the distance from source to person is doubled, the dose of radiation is
decreased by Quarter.
l Shielding
l Type of Shield will depend upon the type of radiation.
l Thin shields are sufficient for shielding from Alpha and Beta Rays
l For X Ray and Gamma Rays, thicker shields are required such as Lead
l Safe Exposure Limits
l As per ICRP the general public shall not be exposed to more than 1mSv Per
year
l Occupational exposure shall not exceed 20 mSv per year.
3. Types of Non Ionizing Radiation
l Ultra Violet Rays
l High Frequency electromagnetic radiation (light) emitted by white hot materials
such as the arc produced during arc welding or excessive exposure to sun.
l Visible Light
l Electromagnetic radiation between the UV and IR frequencies and visible to
the human eye, arising from artificial lighting and display screens.
l Infra Red Light
l Lower frequency electromagnetic radiation (light) emitted by red hot materials
such as Molten metal being poured into castings
l Microwaves
l Lower Frequency electromagnetic radiation emitted by a microwave
generator.
l Radio waves
l Lower frequency electromagnetic radiation emitted by an antenna

Sources of Non Ionizing Radiations:

l UV - Sunlight, Arc Welding
l IR - Red Hot Steel in a rolling mill, Glass Manufacturing
l Visible Light - Laser leveling device, laser pointer
l Microwaves - Industrial microwave oven in a food factory, telecommunication
equipment (e.g. Mobile Phone antenna)
l Radiowaves - Radio, TV or Radar Antenna

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Health Effects of exposure to Non Ionizing Radiation
l UV - Redness and burns to the skin e.g. Sunburns, pain and inflammation to the
surface of the eye leading to temporary blindness known as photokeratitis (often
called as Arc Eye or snow - Blindness), increased risk of Skin cancer, premature
aging of the skin.
l Visible Light - Temporary Blindness if intense or eye damage if very intense (high
powered laser)
l IR - Redness and burns to the skin, retinal burns, development of eye cataracts
l Microwaves - Causes internal heating of the skin. High doses cause internal
organ damage and could be fatal.
l Radiowaves - Cause internal heating. Lasers are classified according to intrinsic
safety and power output. A Class 1 laser presents little risk to workers but a Class
4 laser can cause instant skin burns and eye damage.

Protection from Non Ionizing Radiation

l UV
l Cover the exposed Skin
l Protect the eyes e.g. Welder should wear overalls with full length sleeves to
cover forearms, gauntlets and a full face welding visor with dark filter to
protect the eyes from UV and intense visible light.
l IR
l Cover exposed Skin
l Protect the eyes - Metal worker to wear overalls, Gauntlets, Face Visor,
goggles or safety spectacles to protect the eyes.
l Microwave
l Maintain a safe distance from the source of radiation (Generator or Antenna)
l This radiation obey the inverse square law, so intensity levels drop off very
rapidly as distance from the source is increased.
l Isolate (disconnect power) and lock off the source if workers have to approach
inside safe distances.
l Provide interlocked gates so that when the door is open, the power will get
cut off.
l Lasers
l Degree of Protection will depend on class of laser.
l For Class 1 laser, prevent shining of the light into people's eyes.
l High Class lasers, eye protection (dark goggles) shielding is required
to prevent escape of the beam, use of non-reflective surfaces

63
 Electrical hazards

l Electricity has become such an integral part of our society that it is often taken for
granted. Yet, electricity remains a very dangerous hazard for people working on or near
it.
l The basic parameters of an Electrical circuit is defined by
l V = I X R, Where
l V = Voltage = a Measure of the Potential difference or Electrical driving force
/ Pressure that is forcing electricity through the conductor Unit = Volts
l I = Current = a measure of the rate of flow of electricity through a conductor
Unit = Amperes
l R = Resistance = a measure of how much a component in the circuit resists
the passage of electricity Unit = Ohm

l Hazards of Electricity
l Electric Shock
l Severe shock can cause involuntary muscle grip, heart fibrillation, respiratory
failure and cardiac arrest.
l Electrical shock occurs when a person touches a live surface and current
passes through their body using the body as a conductor.
l Most important factor that determines what the effects will be is the amount
of current
l Burns
l Direct Electrical burns
l where current causes overheating as it passes through the skin and
the internal tissues of the body.
l There may be entry and exit burns and these will be full skin thickness
l Internal tissue burns can be very serious and may prove fatal.
l Indirect Electrical burns
l This does not occur as a result of current passing through the body, but
when an electrical accident causes something to overheat and explode.
l e.g. dropping of a spanner onto a high voltage cable can cause a
short circuit which results in a flash of radiant heat and an explo
sion of molten metal.

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l Fire and Explosion
l Electrical equipment may be faulty and overheat as a result, leading to a fire.
l The system may be overloaded, as too much current is passing through it
overheats.
l Misuse of equipment - e.g. connected into mains supply by pushing bare
wires into the socket rather than using the proper plug.
l Wrong type of electrical equipment is brought into flammable atmosphere.
l A flammable atmosphere is accidently created in an area where it would not
be expected
l Electrical equipment may produce heat or sparks as a part of its normal
operation
l Poor internal connections
l Arcing
l Arcing is where electricity jumps across an air gap.
l High voltage Power lines can arc across distances of over 10 meters through
air.
l Risks associated with arcing
l Electric shock as a result of being struck by the arc
l Direct burns as a result of being struck by the arc.
l Indirect burns from the radiant heat given off by the arc and from the
melting of any equipment struck
l Damage to the eyes as a result of the Ultraviolet light that is emitted by
the arc.
l Secondary Effects
l Any sort of injury that results indirectly from receiving an electric shock
l Secondary effect injuries occur when people undergo violent muscle
contractions during an electric shock accident.
l Thrown across a room and receive cuts, bruises and broken bones as
a result of fall from height
l Factors that influence the severity of injury on receiving a shock
l Voltage - Higher the voltage, greater the current
l Duration - the length of time that a person is exposed to the flow of
electricity is critical
l Frequency - of the AC current
l Current Path - the route that the electricity takes as it flows through the
body is also critical. If it runs through the chest, it is likely to affect the

65
 heart.
l Resistance - The higher the resistance, the lower the current. Dry skin
will have resistance of 100,000 Ohms whereas a wet skin will have
1000 Ohm resistance only.
l Contact Surface area - the more skin that is in contact with the live
surface, the lower the resistance and the more severe the injury
l Environment- Any environmental factors that reduce resistance will
cause an increase in current flow
l High Risk Activities
l Use of Poorly Maintained Electrical Equipment
l Work Near Overhead Power Lines
l Contact with underground Power Cables
l Work on live supplies
l Use of Electrical Equipment in Wet Environment
l Control Measures
l Various Protective systems
l Fuses -
l A device used to prevent current overload. A simple fuse is made
up of two metal caps joined by a thin piece of fuse wire.
l Fuse will become hot and will melt in case the current through the
Fuse is more than the rating of the fuse
l Very Cheap and reliable
l Offers good level of protection to the equipment
l Protects equipment and does not protect people
l A fuse does not stop current flow quickly enough to prevent
ventricular fibrillation.
l The current flow must be above the fuse rating for the fuse to
operate and this may be above the 60mA capable of causing
fatal injury
l Very easy to bypass
l MCB - Miniature Circuit Breaker
l Does not melt in response to current overload, it trips out and can
be reset by pressing a button
l Earthing
l Is a way of protecting equipment so that in the event of an electrical
fault, current flows safely to earth rather than flowing through a
person who might be touching the equipment.
66
 l Electricity will flow through path of least resistance and since the
earth wire will have very low resistance the majority of the fault
current will flow safely to earth through the wire.
l Any person touching the casing will receive minor shock
l It protects the person form fatal electric shock
l Provides secondary protection to the equipment
l A poor broken earthing connection will prevent the earth from
working properly and since earthing does not take part in the
normal functioning of the equipment this fault can go completely
undetected,
l Easy to disconnect and disable.
l Isolation
l Isolation by Switching off makes the circuit dead and safe to work
on.
l To be done by padlocking isolators for positive isolation
l System to be tested to prove that it has become dead.
l Very effective form of protection of the People from Electrical shock
l Does not allow certain types of testing, fault finding and repair
work which needs the circuit to be live.
l Reduced and Low Voltage
l Lower the Voltage, lower is the risk of injury associated with electric
Shock
l As Voltage is reduced, shock current is also reduced and hence
severity of injury reduced
l Low Voltage system is inherently safer
l Limitation is low voltage systems are inefficient at transmitting
power and hence cannot be used for industrial applications
l Residual current devices
l Specially designed to protect Human Life in the event of Electric
Shock
l Very Sensitive to small current imbalance in a circuit and able to
break the circuit very quickly
l Constantly compares the amount of current flowing down the live
and neutral lines and if an imbalance is detected, it trips the circuit
l Provides excellent protection to people in the event of a Shock
l Does not provide over current protection
l Needs to be tested periodically

67
 l Can cause repeated circuit tripping if there is a fault and can
encourage people to bypass the same
l Double Insulation
l Two layers of insulation between the user and any live conductor.
l Eliminates the need to provide Earth protection
l Relies on insulation rather than on Electrical System itself for safety
l Limitation is that Insulation must be routinely visually inspected
as there is no earth protection
l Work of Electrical Systems to be restricted to competent person only
l Knowledge of Electricity
l Experience of Electrical Work
l Understanding of the System to be worked on
l Ability to recognize whether it is a safe for work to continue
l Safe System of Work for:
l Work on or near Live Electrical Systems
l Isolation
l Striking buried cables
l Contact with overhead power lines

l Emergency Procedure in case of Electrical Incident

l Do not touch the person
l Call for help
l Switch off the Power Supply
l Call for ambulance
l If power cannot be switched off, push or pull them away from the live
part using Non Conducting Material such as timber or dry clothing
l If breathing, place in recovery position
l If not breathing, perform CPR (Cardio pulmonary resuscitation)
l Treat any obvious burns
l Treat for Physiological shock
l Make sure they get professional medical treatment
l Careful assessment of the situation when approaching the casualty is
important for 2 reasons as below:
l The Casualty may still be receiving an electric shock, in which
case touching them will involve their potential helper in the shock
as well
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 l High Voltage conductors can arc electric current through the air
over large distances (Over 10 Mtrs)

Effect of Different Magnitude of Current on Human body

Magnitude of current Effect on human body

1 mA No sensation
1- 3 mA Sensation, no pain
3 - 15 mA Pain, most people can get away
15 - 30 mA Pain, half of people freeze
30 - 75 mA Pain, breathing difficult, asphyxiation
75 - 200 mA possible ventricular fibrillation
200 - 300 mA certain ventricular fibrillation
300 + mA severe burns, heart stops

Static Electrical hazards

l Static electricity is the Electric charge generated when there is friction between
two things made of different materials or substances, like clothes tumbling in your
dryer.
l Static electricity is what causes the sparks when you comb your hair or touch a
metal object, like a doorknob, after walking across a carpet on a cold, dry day
l It can also be generated by repeated contact and separation between unlike
materials, like a flat belt on a rotating pulley.
l Electric charges can build up on an object or liquid when certain liquids (e.g.,
petroleum solvents, fuels) move in contact with other materials.
l This can occur when liquids are poured, pumped, filtered, agitated, stirred or flow
through pipes. This buildup of electrical charge is called static Electricity.
l Even when liquids are transported or handled in non-conductive containers,
something rubbing the outside surface of the container may cause a static charge
to build up in the liquid.
l The amount of charge that develops depends, in part, on how much liquid is
involved and how fast is it flowing or is being agitated or stirred
l Flammable and Combustible liquids can present a static Electricity hazard
depending on their ability to generate static electricity, how well they conduct
electricity (conductivity), and their flash point.

69
 l Solvents and fuels produced from petroleum (e.g., benzene, toluene, mineral spirits,
gasoline, jet fuel) can build up a charge when they are poured or flow through
hoses.
l They tend to hold a charge because they cannot conduct electricity well enough
to discharge when in contact with a conducting material, like a metal pipe or
container, which is grounded.
l When enough of a charge is built up, a spark may result. If the vapour concentration
of the liquid in air is in the “flammable range” and the spark has enough energy, a
fire or explosion can result.
l Transferring a liquid from one metal container to another may result in static
Electrical sparks. To prevent the buildup of static electricity and prevent sparks
from causing a fire, it is important to bond metal dispensing and receiving containers
together before pouring.
l Bonding is done by making an Electrical connection from one metal container to
the other. This ensures that there will be no difference in Electrical potential between
the two containers and, therefore, no sparks will be formed.
l All grounding and bonding connections must be bare metal to bare metal. Remove
all dirt, paint, rust or corrosion from points of contact.

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 Ergonomic hazards

l Ergonomics is the study of the relationship between the worker, the work that they are
doing and the environment in which they are doing it.
l Ergonomics is concerned with the interaction between people and
l The tools, equipment or machinery that they are using (eg the ease of use of
control panels)
l The workplace environment (eg Suitability of Lighting)
l Organizational factors (eg Shift Patterns, Hours of Work)
Typical ill health associated due to ergonomic issues are and they are called Musculoskeletal
Disorders. They are mainly caused due to repetitive tasks, activities done in awkward position
l Back Injuries and back pain
l Work related upper limb disorders (WRULD's)
l Other chronic soft tissue injuries

High Risk Activities

l Display screen equipment use (Computers)
l Factory Assembly of small components
l Bricklaying
l Supermarket checkout operation.

Ergonomic Factors that determine the risk

Task Factor :
l Repetition - the need for repetitive movements when carrying out the task (e.g.
Typing for several hours)
l Force - the physical force required to perform the task and the strain this puts on
the body (eg Closing stiff catches on a machine)
l Posture - any requirement to adopt an awkward posture (e.g. Stooping over into
a bin to pick out contents)
l Twisting - any twisting action required by the task (e.g. twisting the wrist when
using a screwdriver)
l Rest - the potential for the worker to rest and recover from any fatigue (e.g. a
worker on a production line cannot stop the line, they have to keep working even
when fatigued)

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Environment Factors:
l Lighting - the availability of natural & artificial light and the effect on the worker's
ability to see the work clearly. The presence of glare may also cause a problem.
l Other Environmental parameters - in particular temperature, humidity and ventilation
will directly affect the worker's ability to perform the task and their comfort.
Equipment Factors
l Equipment Design - the shape of the equipment and how this affects ease of use
(e.g. a Large shaped handle on a scraper makes it easier to hold and use)
l Equipment Adjustability-the scope there is for the user to adjust the equipment
to suit their personal requirements (e.g. the height of the seat for a computer user)
Control of Ergonomic Risks can be reduced by making changes to below so as to suit
the individuals carrying the work:
l The Task and the way that it is done
l The tools, equipment and machinery
l The Workplace environment

Control Measures for computer users (DSE)

l Carry out a workstation assessment of the user's workstation to ensure that the
equipment and environment meet minimum standards and that the workstation
can be adjusted to suit the user.
l Provide basic DSE that meets minimum standards in terms of good ergonomic
design.
l Plan the user's work routine so that they can take short frequent breaks from
screen and keyboard use.
l Provide Computer users with a free eye test and if required spectacles for screen
use.
l Provide training on potential health risks of DSE use and the preventive measures

Control Measures for Factory Assembly Line :

l Carry out ergonomic risk assessment to ensure it is appropriate and can be adjusted
to suit the worker's needs.
l Plan the worker's work routine so that they can take recovery breaks
l Provide training to workers on potential MSD health risks and the preventive
measures
l Automate the process to eliminate the MSD risk entirely
l Re-Layout the workstation to allow comfortable posture and to minimize
overreaching, stooping, twisting

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 l Provide comfortable shoes and floor mats to relieve foot pressure if sitting is not
possible
l Allow short, frequent breaks from the production line or introduce job rotation to
prevent long duration on one task.
l Ensure lighting is appropriate to the task (Brightness or lux levels should be relatively
high for fine detail work)
l Introduce ergonomically designed hand tools
Manual Handling
l Manual handling is a common cause of MSD such as injury to the back, tendons,
Ligaments, muscles, Hernia, Cuts, burns, dislocations, broken bones and WRULD's
l The lifting, carrying, pushing and pulling of a load by bodily force is called manual
handing.
Control Measures for reducing the risk of Manual Handling
l Eliminate Manual Handling
l Assess the manual handling that cannot be eliminated
l Use Handling aids
l Modify the task, Load or Environment
l Ensure individual capabilities are matched to the activity.
Modify the Task:
l Control repetitive handling by introducing frequent rest breaks or job rotation to
minimize the length of time that an individual worker has to perform the task.
l Eliminate stooping and twisting by changing the layout of the workstation
l Use a table or lift to bring the load to waist height to eliminate picking up from floor
level.
Modify the Load
l Break down a heavy load into smaller parts
l Use several workers to handle a large, bulky load rather than jut one
l Stabilise an unstable load by securing it or putting it into a container.
l Markup a load with an off centre C of G so that workers can see where the C of G
is
l Attach Handles to a load that is difficult to grasp.
Modify the Environment
l Rearrange the workspace to allow more space for the handling activities
l Level an uneven floor
l Supply additional lighting in a poorly lit location
Apart from the above, ensure individual capabilities are matched to the activity.

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 Vibration Hazards

l The health effects associated with vibration exposure falls into 2 main categories:
l Hand Arm Vibration Syndrome (HAVS) -
l Whole Body Vibration effects.

l Hand Arm Vibration Syndrome (HAVS)

l Specifically affects the hands and arms as a result of significant vibration dose to
the hands.
l Vibration White Finger (VWF) - the blood supply to the fingers shuts down and the
fingers turn white (known as blanching) and become numb. The blood supply
returns after a time and the fingers become red and painful.
l Nerve Damage - the nerves carrying sensory information from the fingers stop
working properly resulting in a loss of pressure, heat and pain sensitivity and
feeling.
l Muscle Weakening - Grip Strength and manual dexterity is reduced
l Joint Damage - Abnormal bone growth at the finger joints can occur.
l HAVS normally results from long term exposure ( 5 to 10 years)
l Normally incurable
l Irreversible condition and any further exposure will further worsen the situation

l Whole Body Vibration effects

l Health effects can result from a significant vibration dose to the body normally
through the buttocks (sitting) eg Dumper Truck driver) or the feet and legs (standing
e.g. Aircraft Cabin crew).
l The most significant health effect is damage to the soft tissues of the spine

Vibration Exposure Standards

l Determined by
l Vibration Magnitude measured in m.s
l Duration of Exposure (in hours and minutes)
l Daily exposure - 2.5 m/s2 for Hand Arm Vibration
l Action Value - 0.5 m/s2 for Whole Body Vibration
l Daily Exposure - 5.0 m / s2 Hand Arm Vibration
l Limit Value - 115 m/s2 - Whole Body Vibration

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Vibration Exposure control measures
l Reduce the vibration at source
l Interrupt the pathway from source to receiver
l Limit the duration of exposure
l At Source
l Eliminate the source by mechanizing the tools
l Substitute the source with a tool which generates less vibration
l Change the work technique - doing work in ways by which the work does not give
as much vibration (e.g. cutting holes in masonry using a diamond tipped drill rather
than a tungsten hammer drill). Also consider modifying the equipment to improve
the grip on the tools.
l Do regular maintenance to reduce the vibration
l Pathway
l Vibration is transmitted through solid materials by direct contact.
l Isolation involves separation of the vibrating parts from the user's hand using anti
vibration mountings which will break the transmission pathway.
l Duration
l There is a direct relationship between the vibration dose and duration of the
exposure.
l Reducing the duration to half will reduce the vibration exposure to half.
l Limit the duration of exposure by calculating how long a worker might use a
particular tool before they approach a relevant action or limit value
l Change the work schedules through job rotation / rest periods so that the vibration
exposure is shared between several workers with no one worker receiving above
the relevant action or limit value

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 Noise Hazards

l Exposure to excessive noise causes induced hearing loss as well as other health &
safety risks
l Health Effects
l Temporary reduction in hearing sensitivity as a result of short duration exposure
to excessively loud noise
l Temporary ringing in the ears as a result of short duration exposure to excessively
loud noise
l Noise induced hearing loss (NIHL) - permanent loss of hearing as a result of
repeated exposure to excessively loud noise.
l Tinnitus - Persistent ringing in the ears as a result of repeated exposure to
excessively loud noise.
l Stress effects - caused by irritating nuisance / background noise
l Safety Effects
l Inability to hear
l hazards such as vehicles
l alarms and warning sirens
l conservation and spoken instructions as a result of background noise.

Sound Terminology
l Sound Pressure Level - A measure of the intensity of the pressure wave moving
through the air and normally expressed in Decibel (dB) scale
l Decibel (dB) - the unit of sound pressure level (loudness of sound). The decibel
scale is logarithmic scale. i.e. relatively small increases in decibel value actually
represent very large increases in intensity. E.g. an increase of just 3 dB represents
a doubling of sound intensity.
l Frequency - a measure of the number of pressure waves that pass a fixed point
in one second, the unit is hertz
l A - Weighting - during noise assessment A weighting is applied to the decibel
scale to give a sound pressure expressed as dB (A). This A weighting converts the
decibel value to take into account the sensitivity of the human ears across a range
of frequencies. It is the decibel value corrected for the human ear.
l C - Weighting-during noise assessment C Weighting may be applied to the decibel
scale to give a sound pressure level expressed as dB(C). This C weighting gives
a more accurate reading for impulse noise - single loud bangs that would not be
properly recorded using the dB(A) scale.

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Noise Assessment
Different types of Noise meter that are used:
l Simple Sound Level meter - measures instantaneous noise levels and can be
used for spot checks or for very simple surveys.
l Integrating sound level meter - measures noise over a period of time and gives
a time weighted average over that time period; useful for most noise surveys.
l Dosimeters - integrating sound level meters, worn by the worker to give a measure
of personal noise exposure, useful for work areas where people move around a
lot.
Noise Exposure Standards :
l Lower Exposure Action Value = 80 dB (A) daily Personal Noise Exposure
l Upper Exposure Action Value = 85 dB (A) Daily Personal Noise Exposure
l If the Noise Level is continuously above 85 dB (A),
l Establish Mandatory hearing protection zones
l Provide Training
l Provide hearing protection and enforce its use.
l Provide health Surveillance
Noise Exposure Controls :
l Reduce the Noise at source (through equipment selection or Engineering
Controls).
l Interrupt the pathway from source to receiver (through Engineering controls)
l Protect the receiver (through Engineering controls or PPE)
At Source
l Eliminate the source - completely remove the noise source - not practical
l Substitute the source - Change the noise source which does the same job
but generates less noise.
l Modify the process - e.g. by changing from glass to plastic bottles, noise
from packing line can be reduced, or by replacing a compressed air rivet gun
with a screw fixing manufacturing noise can be reduced.
l Maintenance - Do regular maintenance as machinery produces noise as it
needs maintenance.
l Damping -Machine parts (especially metal surfaces) can sometimes resonate
in harmony with noise being produced by the machine (like a cymbal that
rings when hit) This exaggerates the noise generated. Damping changes
the resonance. Damping achieved by changing the part, stiffening it or even
adding material to one side of it.
l Silencing -Fit silencer on the exhaust to suppress noise.
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 Pathway
l Insulation - Build acoustic enclosure around the noise source.
l Isolation - Noise is often transmitted in the form of mechanical vibration
from machinery into supporting structures (eg from a compressor into the
floor it is mounted on). Isolation involves separating the machines from any
supporting structure using vibration absorbent mats or springs which will
break the transmission pathway.
l Absorption - Involves putting sound absorbing material in the workplace to
absorb these sound waves before they can reach the receiver, eg sound
absorbent material might be used to line a wall, preventing reflection of sound
waves.
Receiver
l Acoustic Haven - If the workplace is inherently very noisy and it is not possible
to apply the above controls, then an acoustic haven might be built that workers
can retreat into to escape the noisy environment
l Hearing Protection - If none of the above works, the last resort is providing
protection which will reduce the amount of noise that penetrates to the worker's
ear. Like Ear Defenders / Ear Muffs or Ear Plugs

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 Illumination

The Major hazards associated with lighting include:

l Illumination levels can be too little or too much light. If there is too little light,
employees can't see well. This can result in an error occurring because a dangerous
situation may not be recognized with a corresponding decrease in an individual's
reaction time.
l If there is too much light, bright lights can injure receptor cells in the eye. Bright
lights can cause after-images that can obscure an individual's visual field until
their receptor cells can recover. (The after image from a camera flashbulb is a
common example.)
l Changes in illumination levels can interfere with the ability of the eye to adjust
quickly enough to permit seeing without error. Examples of changing light levels
are the transition from bright outdoor light to dark interiors or from a bright area of
a building to a dark one.
l Glare is the presence of a bright light in the visual field. Direct glare occurs when
the light in the visual field is a source light. An example of direct glare is the
headlight of an oncoming car at night.
l Reflected glare occurs when a bright light reflects from a surface, such as water
or metal. Glare can lead to errors in perception and detection that result in accidents
and may produce after-images or delay visibility due to adaptation.
l Ideal Conditions of Illumination
l Minimum Light levels (Lux Levels) should be achieved as per the local laws
l Natural light should be used in preference to artificial lights
l Light levels should be adjusted to suit the level of detail required and the visual
acuity of the workers
l Local Lighting such as spotlight positioned above machinery, might be required to
give higher levels of light on critical areas.
l Lighting must be arranged to avoid reflections and glare that might dazzle or
temporarily disable.
l Lighting must be arranged to avoid the creation of shadows that might obscure
areas and create risk.
l Flickering should be avoided to prevent nuisance and in particular the “Stroboscope
effect”.
l Lighting must be suitable for the environment (e.g. Intrinsically safe lighting used
in a flammable atmosphere)
l Emergency lighting should be provided to allow safety in the event of mains supply
failure.

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 Stress

l Stress is the adverse reaction that people have to excessive pressure or other demands
placed on them.
l Causes of Stress
l Demands - Excessive demands of the job in terms of workload (too much or too
little), Speed of work, Deadlines as well as working hours, Nature of job - inherently
difficult, exposure to high emotional situations.
l Control - Lack of control over work over - what work to be done, how it is to be
done, priorities, work environment
l Support - Lack of support in terms of information, instruction and training to do
the work and having no one to turn to when pressure increases.
l Relationship - Poor workplace relationship and in particular bullying and
harassment (by Managers, peers or even subordinates)
l Role - Lack of clarity about an individual's role, responsibilities and accountabilities,
how they fit in to the larger organizational structure.
l Change - threat of change, change process itself, whether the change will affect
one person (eg demotion, re-assignment) or the whole organization eg.
Redundancies, Management take over)
l Effects of Stress
l Psychological anxiety, Low self esteem, depression
l Physical sweating, Fast Heart Beat, High Blood Pressure, Skin Rashes, muscle
tension, headache, dizziness
l Behavioral : sleeplessness, inability to concentrate, Poor decision making ability,
Mood swings, irritability, increased alcohol consumption, drug misuse, increased
absence from workplace.
l Prevention Strategies for stress
l Demands - Remove pressure from the workplace by giving Reasonable workload,
set targets in consultation, Allow Flexible working, select workers based on
competency, skills and ability to cope with difficult or emotionally demanding work,
arrangement to be made to allow workers to recover from high stress situations
without fear of punishment.
l Control - Give as much control of their work as possible , especially when the
work is demanding, encourage to take control over what and how the work is to be
done, priorities and control over their working environment where possible.
l Support - Provide adequate training, instructions and information, should have
access to additional information.
l Relationships - Clear Policies on acceptable standards of behavior in the
workplace. Bullying and harassment not to be tolerated.
l Role - Clarify role, responsibilities and accountabilities, authorities, how they fit
into the larger organizational structure, should be clearly communicated to the
employees.
l Change-There should be careful planning and preparation of the change process.
The reasons for change should be clearly explained and workers consulted where
possible.
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 Vehicle Operation Hazards

Hazards of Vehicle operation in a site to Vehicle drivers, pedestrians, other drivers

l Loss of Control and Vehicle Overturning
l Driver Error (e.g. Driving too fast)
l Environmental Conditions (e.g. Mud on the road)
l Mechanical Failures (e.g. Brake fail)
l Vehicle Collision with pedestrians, other vehicles or fixed structures
l Other vehicles e.g. between 2 vehicles maneuvering
l Fixed Objects e.g. between a vehicle and a structure
l Collision with a Pedestrians
l Non Movement related hazards
l Loading - both manual and mechanical loading of vehicles can create risk e.g.
The manual handling risk associated with lifting crates into the back of a truck, or
the risk of collision when loading a flat bed truck using a Fork Truck.
l Unloading - Both manual and mechanical unloading can create risk, e.g. tipping
operations can result in the vehicle overturning or people being struck by the
material being tipped.
l Securing - When workers have to climb onto a vehicle in order to secure the load
e.g. a driver might have to climb onto the top of a vehicle to cover the load or climb
onto the top of a road tanker to close hatches.
l Coupling - When vehicles are attached to trailers or other towed equipment there
is potential for collision and crushing
l Maintenance Work - When Technicians have to access various parts of the vehicle
and may have to work at height or under the vehicle.
Control Measures
The control measures can be divided into 3 categories
l The workplace Environment
l The Vehicle
l The Driver
l The Workplace Environment
l Vehicle free zones
l Pedestrian free zones
l Vehicle Traffic route Layout - Good Design of roads and Routes can be used to
keep vehicles at a distance from pedestrian's walkways and other vehicles. One
way traffic can be implemented. No reversing by introducing One way Systems

81
 and turning circles where appropriate.
l Segregation of vehicles and pedestrians
l Marking Pedestrians walkways
l Speed Limits and proper signage
l Banksmen to guide the traffic
l Good visibility and provision of mirrors on blind turns
l Eliminate Blind Spots
l Good Standards of Lighting
l Appropriate Signage
l Barriers to protect the pedestrians from vehicles
l Good Road Surface - strength, stability, grip Characteristics
l Preferably no gradients in the road.
l The Vehicle
l Suitable for intended use
l Suitable for the environmental and conditions in which they are used.
l Maintained in Safe working Conditions
l Only driven by suitably trained & Qualified Driver
l Inspected routinely before use
l Fitted with Safety Belt
l Roll bar or roll cage to protect the driver in the event of Overturn.
l Guard to protect the driver in the event of falling objects
l Horn
l Audible Reverse alarm to warn pedestrians
l Beacon or flashing light to warn of an approaching vehicle
l Control Measures to prevent accidents while reversing
l Avoidance of reversing by implementing one way traffic System
l Segregation of pedestrians and vehicles or the provision of refuges.
l Good vehicle selection so that drivers have adequate visibility.
l Provision of Audible reversing alarms and flashing beacons.
l Provision of mirrors at blind spots to see approaching Pedestrians
l Use of high visibility clothing
l Ensuring that the area is well lit
l Provision of Banksmen
l Training for drivers and pedestrians working in the area
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l The Driver
l Competent to drive the vehicle
l Proof of Qualification (Driver's License)
l Driver trained and assessed.
l Refresher training and recertification
l Check Driver's license periodically to ensure that the driver does not have
undisclosed penalties or disqualification for road traffic offense.
l Medically Fit to Drive
l Medical examination to assess driver's health and fitness during selection
l On going Training and Information
l Driver Specific Induction Training
l Appropriate to the workplace and site
l Supervised
l To ensure they follow procedures
l To ensure they follow site safety rules
l To ensure they do not get into bad practices
l Fork Truck Pre-Use Checks
l Tyre Pressure
l Parking brakes and service brakes
l Steering
l Fuel, Oil and water system for leaks
l Batteries, to ensure they are charged, leak free, chargers are off and leads
are stored and that the battery retention device is secured.
l Lifting and tilting systems (including hydraulics) are working, are leak free
and hydraulic fluid levels are correct.
l Audible warning
l Lights
l Mirrors
l Any defects reported to the supervisor

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 Fire & Safety

l Fire is not, in fact, a substance, but a process - a chemical reaction.

l It's the same chemical reaction that occurs when a cut apple left on the counter turns
brown, when silver tarnishes or when an iron nail rusts. That process is oxidation:
combining oxygen with another substance.
l Fire is an oxidation process that happens very fast, so that light, heat and sound are
released - often with enough force.
l The sudden release of energy causes temperatures to rise, sometimes by thousands
of degrees. And it also results in smoke, the toxic waste of fire's leftovers.
The Fire Triangle identifies the three needed components of fire:
l Fuel (something that will burn) Vapour/ Gas Mist/ Froth Dust of combustible solid
l Heat (enough to make the fuel burn) Ignition source, Flames, Sparks (of sufficient
energy), Self-heating etc.
l and Air (Oxygen, oxidizing agent including e.g. chlorine)
l All three components must be present to have a fire.
l Fire will burn until one or more of the components are removed.
l Traditional fire extinguishing methods involve removing the fuel, heat, or oxygen.
l In more recent years, a fourth component - the uninhibited chain reaction - has
been added to explain fire.
l This chain reaction is the feedback of heat to the fuel to produce the gaseous fuel
used in the flame. In other words, the chain reaction provides the heat necessary
to maintain the fire.

FIRE DRAWING

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Stages of fire
l Ignition: Fuel, oxygen and heat join together in a sustained chemical reaction. At
this stage, a fire extinguisher can control the fire.
l Growth: With the initial flame as a heat source, additional fuel ignites. Convection
and radiation ignite more surfaces. The size of the fire increases and the plume
reaches the ceiling. Hot gases collecting at the ceiling transfer heat, allowing all
fuels in a room to come closer to their ignition temperature at the same time.
l Fully developed: Fire has spread over much if not all the available fuel;
temperatures reach their peak, resulting in heat damage. Oxygen is consumed
rapidly.
l Decay (Burnout): The fire consumes available fuel, temperatures decrease, fire
gets less intense.
How fire spreads
Fire spreads by transferring the heat energy from the flames in three different ways.
l Conduction: The passage of heat energy through or within a material because of
direct contact, such as a burning wastebasket heating a nearby couch, which
ignites and heats the drapes hanging behind, until they too burst into flames.
l Convection: The flow of fluid or gas from hot areas to cooler areas. The heated
air is less dense, and rises, while cooler air descends. A large fire in an open area
produces plume or column of hot gas and smoke high into the air. But inside a
room, those rising gases encounter the ceiling. They travel horizontally along the
ceiling forming a thick layer of heated air, which then moves downward.
l Radiation: Heat traveling via electromagnetic waves, without objects or gases
carrying it along. Radiated heat goes out in all directions, unnoticed until it strikes
an object. Burning buildings can radiate heat to surrounding structures, sometimes
even passing through glass windows and igniting objects inside.
Fire classifications based on Fuel type:
l Class A: Ordinary combustible materials, such as wood, cloth, paper, rubber and
many plastics. They burn with an ember and leave an ash. Extinguished by cooling
the fuel to a temperature that is below the ignition temp. Water and other
extinguishing agents are effective.
l Class B: Flammable liquids (burn at room temperature) and combustible liquids
(require heat to ignite). Petroleum greases, tars, oils, oil-based paints, solvents,
lacquers, alcohols, and liquefiable solids. High Fire hazard; water may not
extinguish. Extinguish by creating a barrier between the fuel and the oxygen, such
as layer of foam.
l Class C:This type of fires is possible in storage tanks and chemical stores. These
are fires involving gases or liquefied gases such as Propane, Butane, etc. This
type of fire is expected in LPG, Hydrogen storage Electrical fires also comes under
this type. Special techniques and agents required to extinguish, most commonly
carbon dioxide or dry chemical agents. Use of water is very dangerous because
water conducts electricity.
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 l Class D: Combustible metals, such as magnesium, titanium, zirconium, sodium,
lithium and potassium. Because of extremely high flame temperatures, water can
break down into hydrogen and oxygen, enhancing burning or exploding. Extinguish
with special powders based on sodium chloride or other salts; also clean dry sand.
l Class K: Fires in cooking appliances that involve combustible cooking media
(vegetable or animal oils and fats).
Electrical Fires:
l In India, till recently, the electrical fires were Class 'E' fires.
l However, as per latest classification of Bureau of Indian Standards, the electrical
fires do not constitute a particular Class.
l Any fire involving or started by electrical equipment must in fact be a fire of Class
A, B or C.
l The normal procedure is to cut off the electricity and use an extinguishing method
appropriate to the burning material.
l Special extinguishing agents which are non-conductors of electricity and non-
damaging to the equipment should be used in case of any doubt about positive
isolation of electric supply.
Methods of Extinguishing Fires :
l Fire extinguishment usually consists of removal/limiting of one or more of three
factors of fire triangle.
l However, a fourth way i.e. chemical interference has also been identified. This
converts the 'Fire Triangle' into a 'Pyramid'.
The different ways to extinguish fire are:
a) Starvation: Elimination of fuel
b) Smothering: Elimination of oxygen
c) Cooling: Removal of Temperature (Heat)
d) Chemical interference: Interrupt chain reaction
e) Blanketing: Elimination of oxygen
f) Beating out: Elimination of oxygen
Starvation:
The extinguishment of fire by starvation is brought about in the following three Ways:
l By removing combustible material from the neighborhood of the fire, Such as the
transfer of fuel from burning oil tanks, taking out of cargo at a ship fire, cutting of
branches around forest fires, closing the valve on gas/fuel etc.
l By removing material on fire from the neighborhood of combustible material. For
example isolating a burning material from the one safe nearby.
l By sub-dividing the burning material into small sized isolated fires to break continuity.

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Smothering:
l If the oxygen content of the atmosphere in the immediate neighborhood of Burning
material can be sufficiently reduced, combustion will cease.
l The General procedure of this type is to prevent or impede the access of Fresh air
to the seat of fire and allow the combustion to reduce the oxygen content in the
confined atmosphere until it extinguishes itself.
l The principle Is ineffective in the cases where the burning material contain within
itself the oxygen it requires for combustion in a chemically combined form, such
as Celluloid.
Cooling:
l If the rate which heat is generated by combustion is less than the rate at which it
is dissipated through various agencies, the combustion cannot persist.
l In applying this principle of fire extinction, the first step is to accelerate the cooling
with which heat is removed from the fire, thus reducing the temperature of the
burning mass and as a consequence the rate at which heat is produced.
l In due course the rate at which heat is lost from the fire exceeds the rate of Heat
production and the fire dies away.
Chemical Interference:
l The combustion process actually takes place between free radicals and not
between molecules as is usually depicted.
l Fire is an example of a free radical change reaction. Some chemicals, the bromo-
chloro-fluoro-hydrocarbons, have a great affinity for free radicals and so injecting
these into the fire has the effect of preventing the propagation of the chain reaction.
Blanketing:
l Other method by which fire may be extinguished especially on persons whose
clothing is in fire is by blanketing.
l The persons should be laid down and covered or rolled in a coat, jacket, woolen/
asbestos blankets, etc.
l Fire blankets can also be used in other small class 'A' fires if no fire extinguisher is
available.
l It may also be used to prevent sparks from reaching combustibles around cutting
and welding operations.
Beating out:
l Small fires in materials such as grass etc. may often be extinguished by beating
them out or by rolling up the burning materials tightly to exclude air.

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MANAGEMENT OF FIRE RISK:
l FIRE RISK, conveniently defined as the chance or possibility of loss due to fire,
may cause heavy loss to the plant and life.
l The Management of Fire - Risk, therefore, basically deals with three aspects:
l Fire Prevention
l Fire Protection
l Fire Fighting
l All these three distinct aspects are very closely related to each other but are
completely separate in their individual scope.
Fire Prevention:
l It means adoption of safe practices initially at the design stage and subsequently
in the day to day operations. It is the concern of everybody working in the
chemical plant.
Fire Protection:
l It involves provision of different facilities, which shall help in immediate handling
of fire effectively.
Fire Fighting:
l It is the physical phenomenon of handling the fire with the use of protection
equipment, facilities as well as with the help of firefighting personnel who have
been specially trained for this job.
Control of Ignition Sources
Sources of ignition can be controlled by taking suitable safety measures as enumerated
below:
A. Electrical Oriented Sources of Ignition
l Only approved type of Electrical equipment should be used.
l Temporary or make shift wiring, particularly if defective or overloaded, is an
important source of ignition. It should not be used unless absolutely necessary
and should be removed as soon as possible.
l Portable Electrical tools and extension cords should be inspected frequently
and repaired promptly.
l Water proof cords and sockets should be used in damp places and explosion
proof lamps and fixtures should be used in classified areas.
l All Electrical equipment should be grounded.
l Lamp bulbs should be protected by lamp guards or adequately sealed
transparent enclosures and kept away from sharp objects and from falling.
l Bare bulb should never be used where flammable dusts or vapours are likely
to be present.

88
 l Employees should be instructed in the use of Electrical equipment and should
be prohibited from tampering, blocking circuit breakers, using wrong fuses,
by-passing fuses and installing equipment without authorization.
l Electrical installation and equipment should be periodically inspected and
tested to ensure continued satisfactory performance and detect deficiencies.
B. Smoking
l Carelessly discarded cigarette or beedi butts are a major source of fire.
l Smoking should be permitted at specific safe places.
l “No Smoking” areas should be marked with conspicuous signs and “no
smoking” should be rigidly enforced.
l Personnel should not be allowed to carry with them matches, cigarettes and
beedies when they enter the “No Smoking” areas.
C. Friction
l Excessive heat generated by friction causes a very high percentage of
industrial fires.
l Inadequate lubrication, misaligned bearing, choking/jamming of materials,
poor adjustment of power drives and broken or bent equipment are some of
the causes for the source of ignition.
l A program of preventive maintenance on plant machinery can avert fires
due to this source of ignition.
l Fire frequently results from overheated transmission bearings and shafts in
buildings where the dust accumulation takes place, such as coal plant, grain
elevators, cereal, textile, wood working, plastic and metal working plants.
l Frequent inspection and oiling of bearings should be done.
l Accumulation of dusts should be kept to a minimum. Dust suppression system
be installed to minimize dust generation in coal plants.
D. Foreign Objects
l Every precaution should be taken to keep foreign objects entering the running
machines.
l On entering so, the foreign objects can strike against moving machine parts
and create sparks.
l Such sparks can ignite flammable dusts, vapours or combustible materials
such as combustible lints or dusts.
E. Open Flames
l Open flames are probably the most obvious source of ignition for ordinary
combustible materials.
l Many think that open flames can be easily controlled. Still they account for a
large percentage of industrial fires.

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 l Use of open flames in the factory should be discouraged. If at all necessary,
work with open flames should only be permitted under the authority of safety
work permit.
F. Boilers and Gas or Fuel Oil Fired Heaters.
l Boilers and gas or oil fired heaters have open flames inside and any flammable
vapor entering inside can get ignited. So, care should be exercised to avoid
flammable vapors or gases reaching them.
l Boilers and gas or oil fired heaters can cause fires in any combustible/
flammable materials kept nearby, by heat transfer by conduction or radiation,
So such materials should not be kept near boilers and gas or oil fired heaters.
G. Torches
l When acetylene or LPG torches are used they should be placed so that
flames are at least 25 cms away from wood surfaces. They should not be
used around flammable liquids, papers or any other combustible material.
H. Welding and Cutting
l When possible, welding and cutting should be done in special fire safe areas
or rooms with concrete or metal plate floors.
l Flame impingement on concrete may cause damage to it. Consequently
work should be kept off the floor or else the floor should be protected by a
metal shield.
l In cases where welding and cutting operations are performed outside the
special fire safe areas, Hot Work Permit System should be adopted.
l When welding is done outside a shop or area designated for welding,
observers should be stationed to prevent sparks or molten slag from starting
fires or to extinguish fires.
l The observer should remain at the work location for at least one-hour after
the welding or cutting is completed, because some fires escape detection at
the time of their inception.
l However, it will be better to pour buckets of water in the areas where welding
or gas cutting jobs have been carried out.
l Shield or fire resistant blankets should be installed around welding spot, to
prevent hot welding slugs coming in contact with combustible / flammable
materials lying in the nearby areas.
I. Spontaneous Ignition
l Spontaneous ignition results from a chemical reaction in which there is a
slow generation of heat from oxidation of organic compounds that, under
certain conditions, is accelerated until the ignition temperature of fuel is
reached.
l This condition is reached when there is sufficient air for oxidation but not
enough ventilation to carry away the heat as fast as it is generated.
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 l This is a condition usually found in the bulk storage of combustible materials
like coal, sulfur etc. In such storage large amount of surface gets exposed
for oxidation, yet without adequate air circulation to dissipate heat. This leads
to heat accumulation leading to development of high temperature and
spontaneous ignition.
l The presence of moisture is conducive for spontaneous heating unless the
material is wet beyond a certain limit.
l A temperature of 60 deg C is considered dangerous for coal piles. If
temperature rapidly rises it is advisable to rearrange the pile for better
circulation of air.
l The best prevention against spontaneous ignition is either total exclusion of
air or good ventilation.
J. Housekeeping
a) Collection and Storage of Combustibles
l Many fires are direct result of accumulation of oil and paint saturated
clothing, rags, waste and combustible refuse.
l Such materials should be deposited in non-combustible receptacles
having self-closing covers that are provided for this purpose and
removed daily from the work area.
l Cotton, jute and other highly combustible fibrous materials should be
stored in covered and non-combustible containers.
l If they are to be stored in large quantities in rooms then the latter should
be of fire resistant type equipped with fire doors and automatic sprinklers.
l Accumulation of all types of dust on beams, machines (particularly on
bearings and other hot surfaces), overhead pipes etc. should be
prevented by cleaning at regular intervals.
l It must be understood that all organic as well as many inorganic
materials, if ground finely enough, will burn and propagate flame.
l Such materials should not be allowed to accumulate in stairs, shafts,
out of way corners, near electric motors, or within 25 cms of any stove,
furnace or boiler.
b) Rubbish Disposal
l Fires are often caused by burning rubbish in yard areas near combustible
buildings, sheds, lumber piles, fences, dry grass or other combustible
materials.
l If it must be burnt, the best and safest way to burn it in a well-designed
incinerator which meets the requirement of the environment pollution
controls laws.

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 K. Explosive Atmosphere- Dusts
l A dust explosion hazard exists when a material that can burn or oxidize
readily, is available in powder form, as the surface area of each particle is
very large in relation to its mass.
l There are two ways to prevent dust explosion.
l Prevent the formation of explosive mixture of dust in air.
l Prevent ignition of an explosive mixture of dust and air by control of
ignition sources, by increased humidity or by using inert gas.
l Adequate precautions should be taken to prevent the accumulation of dust,
which may cause explosive mixture formation.
l Extensive use of local exhaust and frequent cleaning will do much to minimize
the hazard.
l Where possible, dust operations should be segregated and dust-producing
equipment should be totally enclosed and exhausted to prevent leakage of
dust in the general work area.
L. Gases and Vapours
l Gases and vapours that produce flammable mixture with air or oxygen are
common in industry.
l For example acetylene, propane, hydrogen, carbon monoxide, methane,
natural gas etc. can form flammable mixture with air or oxygen.
l Highly flammable liquids which emit flammable vapours include gasoline,
benzene, naphtha, cyclohexane etc.
l Flammable liquids must be handled and used only in minimum quantities
and in safety containers.
l Other precautions are providing explosion proof fittings, effective exhaust
system and frequent testing of atmosphere to check the formation of explosive
mixtures.
M. Static Electricity
l Spark resulting from accumulation of static electricity is one of the common
causes for accidental fires and explosions.
l Static charge may develop while handling solids, liquids or gases or during
the operation of equipment such as the belts.
l The flow of an organic liquid of low conductivity in a pipeline generates static
electricity.
l The discharge of the static electricity in the presence of flammable mixtures
(vapours, dusts and gases) may result in fires / explosions.
l To avoid static charges, necessary bonding and grounding should be
incorporated.
l Jumpers should be provided over the flanged joints of solvent storage and
handling equipment and pipelines.
l The bonding and earthing systems should be inspected and tested periodically
to ensure electrical continuity of the system.
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 WORK PERMIT SYSTEM

What is Work Permit

l A Work Permit is an approved document (approved by one or more authorities as
specified by the organization) that permits the receiver of the permit to perform the jobs
mentioned in the permit.
l The Permit includes the precautions taken by the permit issuer for the safe handing
over of the equipment & additional precautions to be taken by the permit receiver, so
that the job can be carried out safely by the permit receiver.
l Written Work Permit systems are required to prevent miscommunication between two
or more departments.
l A Chemical plant should develop & implement safe work practices (SWP/Permit system)
to provide for the control of hazards during operations such as Confined Space Entry,
Lock out / Tag out, opening process equipment or piping etc.
The various kind of work permits being followed in UPL are:
Hot Work Permit - Class A Permit :
1. Hot work permit is necessary for welding & cutting, working with open flames, or
sparks due to grinding, chiseling etc. or where hot work is dangerous or may catch
fire.
2. The area must first be made free from fire hazards and explosion. Test for explosive
air mixture or possibly should be carried out by combustible gas detector if the
area has any flammable substance stored in vicinity. Sufficient vents, lights should
be provided. Any hazardous storage in the vicinity will be covered with fire retardant
tarpaulin.
Vessel Entry Permit - Confined space entry - Class B Permit:
1. No person in any factory shall enter or be permitted to enter any confined space
like chamber, tank, pit etc. having dangerous fumes likely to involve risk. Until all
practicable safety measures have been taken to remove any fumes which may be
present (unless certified by Safety Officer) & based on a test carried out by himself
that the space is free from dangerous fumes and fit for person to enter, work
should not commence.
2. Isolation of the vessel from source of energy or harmful substance by way of
disconnection, blinding, blanking etc. draining, cleaning, washing and purging to
make free from toxic gases, testing the air for oxygen or Toxicity content, providing
two man holes for ventilation, lighting, wearing helmet, safety belt, airline mask
and if required low voltage (24 volts) flameproof lights as standby arrangement
are essential. This is applicable even for new vessels.

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Cold Work Permit - Class C Permit :
1. Cold work permit is mainly used at site, to carry out jobs like, working at height,
any equipment / pipelines to be opened.
2. Any work to be carried out above 2 mtrs height, the person should use safety belt
and PPE like Helmet, Safety goggles, etc. The person who is using scaffolding
should get it checked by Contract Safety Supervisor before giving the permit. He
should go through check list given in Class 'C' Permit and check that the person's
health who is going to work above 02 mtrs his is Ok or not, whether he can work
above 02 mtrs or not.
3. For doing height work at open area, vertigo testing of the person going to work at
height needs to be done.
Electrical Lock Out & Tag Out (LOTO) Permit - Class D Permit:
1. Part 1: Whenever a maintenance activity of any equipment is to be done where
there is a chance of incidents due to any kinetic energy, LOTO of the equipment is
done.
2. Part 2: This permit is taken whenever a maintenance activity is to be done in HT
panels. Concerned Electrical dept. i.e. Engg. / Electrical Supervisor should fill
such type of permits. Before issuing the permit it should be ensured that the
instrument is made dead, earthed and isolated from all like connections by opening
all relevant switches. Circuit breakers, fuses, isolators etc.
3. Fuses also should be removed from the panel and should be kept with Wireman
or with Elect. Supervisor till the work is completed. On completion of job, person
engaged in the work must remove temporary wiring & tags and put the fuses back
in the system before handing over.
Temp. Elect Connection Class 'E' Permit:
1. Such kind of permit is used for getting approval of temporary electrical connection
wherever required. For example
l Hand lamp (Flame proof / Non flame proof)
l Welding machine
l Grinder Machine
l Drill Machine
l Vacuum Cleaner
l Spare Pump etc.
2. The user has to fill the format then it will be sent to Elect Dept. Elect. Dept. will get
the required materials, will go to the place and will check all parameters. No loose
wiring, unsafe condition like no plug or unhealthy cable condition should be allowed.
Before doing any work it should be checked whether Earthing is proper or not, any
open wire is there or not. After the work is completed then all temporary Electrical
connections will be removed by wireman and will check that nothing is left

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Permit extension & Closing: The permit automatically expires at 17:30, so for working
beyond 17:30 up to 23:00 hrs is possible only if the permit is extended. The authority to
extend the permit lies only with the Unit Head. The permit has to be closed by the before next
permit is taken.
DEFINITION:
l Hot Work means welding, gas cutting, soldering, drilling, and grinding using non-
flameproof electrical equipment. This also includes concrete breaking, chiseling,
hammering, chipping using iron tools like Chisel, Hammer, Spanner, Hacksaw
etc.
l Originating Department: means Department / Personnel operating or In charge
of the equipment. They will plan, prepare and take all required steps mentioned in
the description and prepare the permit.
l Receiving Dept.: means Department / Personnel carrying out repair, adjustment,
cleaning.
l Issuing Authority: means the authorized signatory without his signature the permit
is invalid and the work cannot be started.
l Confined Space: A confined space means a space covered from all the sides
with a small opening at one end to enter inside the space. Also, it has poor air
circulation.
l A space having the possibility of the presence of toxic gases and/or Oxygen
deficiency eg. Tanks, Pit of 1 mtr. depth, Sump, Server Pit, Reactor, Vessel, Column,
Chimney manhole, Boiler etc.
l Height job means working at height more than 2 mtr on scaffolding, temporary
platform, fragile roof etc.
Role & Responsibility during Permit System Implementation
l Originating Department: (Where work is carried out) must fill part-A of the permit
with compliance.
l Executing Department: (Responsible for completion of work) must fill part-B of
the permit with compliance.
l HOD should approve the permit before starting the JOB.
l Safety department is to cross check as applicable for the compliances.
l Permit is valid for 8 hrs. and extension must be taken if work is extended beyond
that period. However same permit is valid for day only.
l All the Permits are automatically cancelled in case of any emergency.
l Permits are to be closed by Originating & Executing deptt after completion of job.
Advantages of Work Permit System:
l To minimize Accident / incident during hazardous work.
l Work is also completed in the time frame.
l Continuous work monitoring ensured.
l Quick response on leakages or spillages or to handle any type of an emergency.
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 CHEMICAL TANKERS TRANSPORTATION SAFETY

l Transportation of hazardous chemicals has the accident potential during transit.

l In transit, the goods would subject to impact, vibration, compression and other adverse
effects and exposure to harmful environment.
l The other factors such as improper packing of the contents, poor storage may also lead
to release of chemicals to the environment resulting in emergencies like fire, explosion,
toxic release, etc
l Apart from pollution of land, water and air, such emergencies have potential to cause
injuries and death, property damage.
l Availability of information on the hazards of goods and control measures at the time of
emergency is vital for minimizing the effect of such accidents. Security is a concern
throughout.
l Irrespective of the mode of carriage, the safe transport of chemicals is the responsibility
of:
l the producer;
l any transporter/ haulers involved; and
l the recipient, e.g. during unloading.
l Effective communication between them is a vital consideration.
Classification of Dangerous Goods
The Dangerous Goods have been classified into nine classes as per Central Motor Vehicle
rules, 1989. This classification of chemical hazards is recommended by the UN Committee
of Experts on the Transport of Dangerous Goods.
Class 1. Explosives
Class 2. Gases, compressed, liquefied, dissolved under pressure or
deeply refrigerated.
2.1 Non-flammable gases
2.2 Inflammable gases
2.3 Poison (toxic) gases
Class 3. Inflammable Liquids
Class 4. Inflammable solids
4.1 Inflammable solids
4.2 Substances liable to spontaneous combustion
4.3 Substances which, on contact with water, emit inflammable gases

96
Class 5. Oxidizing substances and organic peroxides.
5.1 Oxidizing substances
5.2 Organic peroxides
Class 6. Poisonous (toxic) substances and infectious substances.
6.1 Poisonous (toxic) substances
6.2 Harmful substances
6.3 Infectious substances
Class 7. Radioactive substances
Class 8. Corrosives
Class 9: Miscellaneous dangerous substances and articles
Rule no 129 to 137 of CENTRAL MOTOR VEHICLE RULES, 1989 for transportation of
dangerous goods
129. Transportation of Goods of Dangerous or Hazardous nature to human life.-(1)
Every owner of a goods carriage transporting any dangerous or hazardous goods shall,in
addition to complying with the provisions of any law for the time being in force in relation to
any category of dangerous or hazardous goods, comply with the following conditions, namely:-
l Every such goods carriage, carrying the same type of dangerous or hazardous
goods (whether in bulk or in packages), shall display a distinct mark of the class
label appropriate to the type of dangerous or hazardous goods specified in column
3 of the Table I to rule 137;
l Every package containing dangerous or hazardous goods shall display the distinct
class labels appropriate to the type of dangerous or hazardous goods specified in
column 3 of the Table I to rule 137;
l in the case of packages containing goods listed in Table 111 in rule 137 and which
represents two hazards as given in column 2 thereof, such packages shall display
distinct labels to indicate both the hazards
l Every goods carriage carrying any dangerous or hazardous goods shall be
equipped with Safety Equipment for preventing Fire, Explosion or escape of
hazardous or dangerous goods.
l One year from the date of commencement of Central Motor Vehicles(Amendment)
Rules, 1993, every goods carriage carrying goods of dangerous or hazardous
nature to human life, shall be fitted with techograph (an instrument to record the
lapse of running time of the motor vehicle; time speed maintained, acceleration,
deceleration, etc.) conforming to the specifications of the Bureau of Indian
Standards.
129-A. Spark arrester.-Six months from the date of commencement of Central Motor
Vehicles (Amendment) Rules, 1993, every goods carriage carrying goods of
dangerous or hazardous nature to human life shall be fitted with a spark
arrester.
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130. Manner of Display of Class labels.-
(1) Where a class label is required to be displayed on a vehicle, it shall be so positioned
that the size of the class label is at an angle of 45 degrees to the vertical and the
size of such label shall not be of less than twenty-five millimeters square which
may be divided into two portions, the upper half portion being reserved for the
pictorial symbol and the lower half for the text: Provided that in the case of smaller
packages a suitable size of the label may be adopted.
(2) Where the class label consists of adhesive material, it shall be waterproof and
where it consists of metal or other substance on which the pictorial symbol and
the text are printed, painted or affixed, they shall be affixed directly on such material
and in every case, the surface of the vehicle surrounding the label shall be of a
colour that contrasts vividly with the background of the class label.
(3) Every class label displayed on a vehicle shall be positioned in such a manner that
it does not obscure other markings required to be displayed under any other law.
(4) Every goods carriage carrying any dangerous or hazardous goods shall display
the class label on the places shown in the Table in rule 134.
131. Responsibility of the consignor for safe transport of dangerous or
hazardous goods.-
(1) It shall be the responsibility of the consignor intending to transport any dangerous
or hazardous goods listed in Table III, to ensure the following, namely:-
l The goods carriage has a valid registration to carry the said goods;
l The vehicle is equipped with necessary first-aid, safety equipment and
antidotes as may be necessary to contain any accident;
l That the transporter or the owner of the goods carriage has full and adequate
information about the dangerous or hazardous goods being transported; and
l That the driver of the goods carriage is trained in handling the dangers posed
during transport of such goods.
(2) Every consignor shall supply to the owner of the goods carriage, full and adequate
information about the dangerous or hazardous goods being transported as to
enable such owner and its driver to,-
l comply with the requirements of rules 129 to 137 (both inclusive) of these
rules; and
l be aware of the risks created by such goods to health or safety of any person.
(3) It shall be the duty of the consignor to ensure that the information is accurate and
sufficient for the purpose of complying with the provisions of rules 129 to 137(both
inclusive) of these rules.]

98
132. Responsibility of the transporter or owner of goods carriage.-
(1) It shall be the responsibility of the owner of the goods carriage transporting any
dangerous or hazardous goods to ensure the following, namely:-
l That the goods carriage has a valid registration to carry the said goods and
the said carriage is safe for the transport of the said goods; and
l The vehicle is equipped with necessary first-aid, safety equipment, tool box
and antidotes as may be necessary to contain any accident.
(2) Every owner of a goods carriage shall, before undertaking the transportation of
dangerous or hazardous goods in his goods carriage, satisfy himself that the
information given by the consignor is full and accurate in all respects and correspond
to the classification of such goods specified in rule137.
(3) The owner of a goods carriage shall ensure that the driver of such carriage is
given all the relevant information in writing as given in Annexure V of these rules in
relation to the dangerous or hazardous goods entrusted to him for transport and
satisfy himself that such driver has sufficient understanding of the nature of such
goods and the nature of the risks involved in the transport of such goods and is
capable of taking appropriate action in case of an emergency.
(4) The owner of the goods carriage carrying dangerous or hazardous goods, and the
consignor of such goods shall lay down the route for each trip which the driver
shall be bound to take unless directed or permitted otherwise by the Police
Authorities. They shall also fix a time table for each trip to the destination and
back with reference to the route so laid down.
(5) It shall be the duty of the owner to ensure that the driver of the goods carriage
carrying dangerous or hazardous goods holds a driving license as per provisions
of rule9 of these rules.
(6) Notwithstanding anything contained in rules 131 and 132, it shall be sufficient
compliance of the provisions of these rules if the consignor transporting dangerous
or hazardous goods and the owner of the goods carriage or the transporter, abides
by these conditions within six months after the date of coming into force of the
Central Motor Vehicles (Amendment) Rules, 1993.]
133. Responsibility of the driver.-
(1) The driver of a goods carriage transporting dangerous or hazardous goods shall
ensure that the information given to him in writing under sub-rule (3) of rule 132 is
kept in the driver's cabin and is available at all time while the dangerous or
hazardous goods to which it relates, are being transported.
(2) Every driver of a goods carriage transporting any dangerous or hazardous goods
shall observe at all times all the directions necessary for preventing fire, explosion
or escape of dangerous or hazardous goods carried by him while the goods carriage
is in motion, and when it is not being driven, he shall ensure that the goods carriage
is parked in a place which is safe from fire, explosion and any other risk, and at all
times the vehicle remains under the control and supervision of the driver or some
other competent person above the age of 18 years.
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134. Emergency Information panel.-
(1) Every goods carriage used for transporting any dangerous or hazardous goods
shall be legibly and conspicuously marked with an Emergency Information Panel
in each of the three places indicated in the Table below so that the emergency
information panel faces to each side of the carriage and to its rear and such panel
shall contain the following information, namely:-
l The correct technical name of the dangerous or hazardous goods in letters
not less than 50 millimeters high;
l The United Nations class number for the dangerous or hazardous goods as
given in Column 1, Table 1 appended with rule 137, in numerals not less
than 100 millimeters high;
l The class label of the dangerous or hazardous goods of the size of not less
than 250millimetres square;
l The name and telephone number of the emergency services to be contacted
in the event of fire or any other accident in letters and numerals that are not
less than 50millimetres high and the name and telephone number of the
consignor of the dangerous or hazardous goods or of some other person
from whom expert information and advice can be obtained concerning the
measures that should be taken in the event of an emergency involving such
goods.
(2) The information contained in sub-rule (1) shall also be displayed on the vehicle by
means of a sticker relating to the particular dangerous or hazardous goods carried
in that particular trip.
(3) Every class label and emergency information panel shall be marked on the goods
carriage and shall be kept free and clean from obstructions at all times.

Location for display of EIP & Class labels

TRUCK PANEL LABEL POSITIONING

DRAWING

100
TRUCK PANEL LABEL
DRAWING WITH SIZE

EIP dimensions (in mm)

101
 HAZCHEM CODE
l The HAZCHEM CODE or Emergency Action Code (EAC) is a three character code
displayed on all dangerous goods classed carriers.
l It provides a quick assessment to first responders and emergency responders (i.e. fire
fighters and police) of what actions to take when the carrier carrying such goods become
involved in an incident (traffic collision, for example).
l EAC's are characterized by a single number (1 to 4) and either one or two letters
(depending on the hazard).
l The first digit is a numeric which signifies the extinguishing media to be applied at the
time of an emergency as per given below:
1 ------ Water Jet
2 ------ Water fog
3 ------ Foam
4 ----- Dry chemical agent
l 2nd digit will be at least one letter, which determines which category the chemical falls
under, and which also highlights the violence of the chemical (i.e. likelihood to react
violently), what personal protective equipment to use during emergency, what action to
take when disposing of the chemical (whether spill can be diluted with water or should
be contained)
P,R,S,T ------------- Spill can be diluted
W,X,Y,Z ------------ Spill should be contained, dilution with water not allowed.
P,S,W,Y ------------- Violently reactive
P,R,W,X ------------- Full protection needed.
S,T,Y,Z -------------- Full body protective cloth with SCBA
S,T,Y,Z (In black background) --- SCBA needed for fire only.
l If the 3rd digit is E ------- Indicates the consideration of evacuation.

NFPA CODE
l NFPA code should be displayed on the every storage of hazardous & flammable
chemicals.
l It looks like a diamond shape.
l There are four colour codes used in this diamond.
l The NFPA diamond is designed to give general hazard information for chemicals.
l A grading system in each section is given in numbers of 0 to 4.
l Digit 4 means extreme or severe hazard & digit 0 means minimum or no hazard.

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 NFPA CODE
DRAWING

Red: Fire Hazard

0 : Will not burn
1 : Must be preheated for ignition; flashpoint above 2000F (930C)
2 : Must be moderately heated for ignition, flashpoint above 1000F (380C)
3 : Ignition may occur under most ambient conditions,
flashpoint below 1000F (380C)
4 : Extremely flammable and will readily disperse through air under standard
conditions, flashpoint below 730F (230C)
Blue: Health Hazard
0 : Hazard not greater than ordinary material
1 : May cause irritation; minimal residual injury
2 : Intense or prolonged exposure may cause incapacitation; residual injury may
occur if not treated
3 : Exposure could cause serious injury even if treated
4 : Exposure may cause death
Yellow: Reactivity Hazard
0 : Stable
1 : May become unstable at elevated temperatures and pressures, may be mildly
water reactive
2 : Unstable; may undergo violent decomposition, but will not detonate.
May form explosive mixtures with water
3 : Detonates with strong ignition source
4 : Readily detonates

103
White: Special Hazard
OX : Strong Oxidizer
W : water reactive

TREM CARD
l A TREM card is a Transport Emergency Card.
l It must be carried in the cab of the vehicle that is transporting dangerous goods by
road.
l It contains instructions and information that the driver can refer to in the event of
an incident involving the hazardous load.

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 CONSTRUCTION SAFETY
Various Hazards of Construction
[Link] Trade Activity Hazard
1 Civil Excavation l Fall hazard
l Caving in of soil & entrapment.
l Stability problem to nearby structure.
Shoring & l Failure of shore due to improper calculation.
strutting
Shuttering l Fall from height
l Injury due to nails
Slab casting l Fall from height
l Fall while transferring concrete.
l Failure of material handling devices
l Concrete making machine hitting some one
Bar bending l Sharp pieces/ portions piercing
& cutting l Electric shock
Scaffolding l Fall hazard
l Fall of objects from height
Civil Others Roof Fixing l Fall from height
l Medically unfit person working at height.
2 Mechanical Cutting l Burn injury
Fabrication l Back fire or explosion of torch
l Falling compressed gas cylinder
l Fall of heavy object
l Flying objects
Welding l Electrocution
l Burn
l Toxic fume
l High intense light
l Fire
Grinding l Flying objects
l Electrocution
Drilling l Mechanical injury
l Flying objects
Mechanical Structure l Fall from height
Erection erection l Mechanical injury
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 l Fall of objects above head
l Crane/ hydra toppling
l Fall from ladder
Equipment l Fall from height
erection l Mechanical injury
l Fall of objects above head
l Crane/ hydra toppling
l Failure of lifting tools & tackles
Mechanical Pressure l High pressure line getting burst
others testing
Material l Failure of material movement equipment
movement l Failure of lifting tools and tackles
l Slips, trips and falls
Insulation l Fall from height
l Fall of object above head.
l Burn Injury due to hot bitumen
l Cut injuries
l Respiratory illness
Painting l Fall from height
l Fall of object above head.
l Respiratory illness
l Fire
3 Electrical Cable l Cut injury
laying l Fall from height
l Falling of object above head.
Fabrication l Same as mechanical fabrication
Panel erection l Same as equipment erection
Provision l Electrocution
of supply l Arc flash explosion
4 InstrumentationCable laying l Cut injury
l Fall from height
l Falling of object above head.
Fabrication l Same as mechanical fabrication
Panel erection l Same as equipment erection
5 House Cleaning l Lacerated wounds
keeping l Respiratory problem
l Slip & trip hazard
Scarp removal l Same as above

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 EXCAVATION & TRENCHING SAFETY

l Excavations of 5ft. or more in depth must be shored or sloped in an approved

manner.
l Excavated or other material must not be stockpiled closer than 1mtr from the
edge of any excavation. Surface encumbrances that create a hazard must be
moved or supported as necessary.
l All excavations should be barricaded with hard barricading along with warning
signage.
l Protection should be provided to existing structure during excavation besides them.
l Protection should be provided at the edge or face of excavation to eliminate the
possibility of loose rock or soil that could fall or roll into the excavation.
l No person is permitted under loads handled by lifting or digging equipment. When
mobile equipment operates adjacent to or approaches the edge of an excavation,
a warning system such as barricades, hand or mechanical signals must be used.
l A designated competent person must monitor the construction and maintenance
of the recommended protective systems and their use in excavations.
l Safe access and egress should be provided to all excavations and trenches.
l A stairway, ladder, or ramp should be provided for egress from all trenches over 5
ft in depth.
l Means of egress should be provided so that employees do not have to travel
more than 25 ft laterally to exit the excavation.
l When ladders are used as a means of egress, they should extend 3 ft above the
top of the excavation and be secured at the top.
l All ladders, and/or means of access and egress, must be located within the confines
of the shoring or shielding.
l Underground utilities and other obstructions present a very real danger. The
locations of any underground installations such as sewer lines, electric lines, etc.,
shall be determined before excavation. All such installations must be appropriately
identified for the safety of persons working nearby.
l All excavations are to be performed with extreme caution to prevent injury or
damage to underground piping, electrical wiring, etc.
l If there are known underground obstacles, a pre-excavation meeting to be
conducted to define appropriate protective measures.
l When excavations occur within 3 ft, vertically or horizontally, of an active direct
buried electrical or communication cable, exploratory hand trenching must be done
to authenticate the actual location of the cable.
l During hand excavations, if a person's head is below the top of the excavation or
if the trench is greater than 5 ft deep, adequate shoring or sloping is required.
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 l Excavation tools with wooden handle to be used during hand excavation.
l If any utilities or underground installations are close to, or disturbed by excavation,
then each should be protected, supported, or removed prior to the start of the
excavation.
l During excavations with a backhoe, there must be an observer at all times to
watch the backhoe bucket. This observer should be stationed adjacent to the
excavation to avoid the operations of the hoe. The observer is responsible for
visually identifying any obstruction while the bucket is excavating, and alerting the
operator immediately if any obstructions are observed.
l If the observer leaves the excavation area, excavation efforts must be stopped
immediately until the observer returns.

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 Working at height
l 'Work at height' means work in any place where, if there were no precautions in
place, a person could fall a distance liable to cause personal injury (for example a
fall through a fragile roof).
l Working at height remains one of the biggest causes of fatalities and major injuries.
Common cases include falls from ladders and through fragile surfaces.
l Before working at height work through these simple steps:
l avoid work at height where it's reasonably practicable to do so
l where work at height cannot be easily avoided, prevent falls using either an
existing place of work that is already safe or the right type of equipment
l minimize the distance and consequences of a fall, by using the right type of
equipment where the risk cannot be eliminated
l For each step, always consider measures that protect everyone at risk (collective
protection) before measures that only protect the individual (personal protection).
l Collective protection is equipment that does not require the person working at
height to act for it to be effective. Examples are permanent or temporary guardrails,
scissor lifts and tower scaffolds.
l Personal protection is equipment that requires the individual to act for it to be
effective. An example is putting on a full body safety harness correctly and
connecting it, with an energy-absorbing lanyard, to a suitable anchor point above
the working platform.
Do's and don'ts of working at height
Do….
l As much work as possible from the ground
l Ensure workers can get safely to and from where they work at height
l Ensure equipment is suitable, stable and strong enough for the job, maintained
and checked regularly
l Take precautions when working on or near fragile surfaces
l Provide protection from falling objects
l Consider emergency evacuation and rescue procedures
Don't…
l Overload ladders - consider the equipment or materials workers are carrying before
working at height. Check the pictogram or label on the ladder for information
l Overreach on ladders or stepladders
l Rest a ladder against weak upper surfaces, e.g. glazing or plastic gutters
l Use ladders or stepladders for strenuous or heavy tasks, only use them for light
work of short duration (a maximum of 30 minutes at a time)
l Let anyone who is not competent (who doesn't have the skills, knowledge and
experience to do the job) work at height
l Don't allow anybody to work at height without having undergone Vertigo test

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 Portable Powered Tools

l Tools are such a common part of our lives that it is difficult to remember that they may
pose hazards. Tragically, a serious incident can occur before steps are taken to identify
and avoid or eliminate tool-related hazards.
l Employees who use Hand and Power tools and are exposed to the hazards of falling,
flying, abrasive, and splashing objects.
l Five basic safety rules can help prevent hazards associated with the use of hand and
power tools:
l Keep all tools in good condition with regular maintenance.
l Use the right tool for the job.
l Examine each tool for damage before use and do not use damaged tools.
l Operate tools according to the manufacturers' instructions.
l Provide and use properly the right personal protective equipment.
l Use required Personal Protective Equipment safety glasses, safety goggles and face
shields, etc. when operating or working near hand or power tools.
l Power tools shall be maintained in safe operating condition.
l Power operated tools and equipment guards shall be inspected before each use and
shall not be removed or tampered with.
l Portable electric power tools shall be double insulated or grounded, using a three
conductor cord and a three prong plug.
l ELCB should be provided in power supply board with rating of 30mA.
l Electric on/ off switches shall operate properly.
l Any damaged, defective, or unsafe plug, cord or tool shall be reported to your supervisor
immediately.
l Tools and other materials shall not be left on stepladders, scaffolds, roofs or other
places where they may be dislodged and fall. Floor and bench mounted abrasive wheels
shall be provided with safety guards (protection hoods), maximum exposure shall be
not more than 90 degrees.
l All bench grinders shall contain a safety guard and grinding wheel maintained for safe
operation.

Portable Hand Tools

l Hand tools are tools that are powered manually. Hand tools include anything from axes
to wrenches.
l Employees should be trained in the proper use and handling of tools and equipment.
l The greatest hazards posed by hand tools result from misuse and improper maintenance.
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 Some examples include the following:
l If a chisel is used as a screwdriver, the tip of the chisel may break and fly off,
hitting the user or other employees.
l If a wooden handle on a tool, such as a hammer or an axe, is loose, splintered, or
cracked, the head of the tool may fly off and strike the user or other employees.
l If the jaws of a wrench are sprung, the wrench might slip.
l If impact tools such as chisels, wedges, or drift pins have mushroomed heads, the
heads might shatter on impact, sending sharp fragments flying toward the user or
other employees.
l Iron or steel hand tools may produce sparks that can be an ignition source around
flammable substances.
l Where flammable gases, highly volatile liquids, and other explosive substances are
stored or used, spark-resistant tools made of non-ferrous materials should be used.

SCAFFOLDING SAFETY
Safety during use of All Types of Scaffolds
l Before you use the scaffold, a competent person must:
l Inspect the scaffold assembly to be sure that
l it has not been altered;
l is assembled correctly;
l is level and plumb;
l all base plates are in firm contact with sills;
l all bracing is in place and securely tightened
l all platforms are fully decked;
l all guardrails are in place;
l safe access is provided;
l it is properly tied and/or guyed;
l there are no overhead obstructions;
l there are no energized electric power lines within 12 feet of the scaffold
assembly and;
l any deficiencies found are corrected prior to use.

Precautions When Using Scaffold

l Use only proper access. Do not climb cross braces. Do not climb any scaffold component
unless it is specifically designed for that purpose. Do not stand on platform overhangs.

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l Climb safely!
l Face the rungs as you climb up or down.
l Use both hands.
l Do not try to carry materials while you climb.
l Be sure of your footing and balance before you let go with your hands. Keep one
hand firmly on frame or ladder at all times.
l Clean shoes and rungs to avoid slipping.
l DO NOT work on slippery platforms.
l DO NOT overload platforms with materials. Special care must be taken when putlogs
are used.
l DO NOT store materials on platforms supported by putlogs. They are designed for
personnel ONLY.
l DO NOT extend working heights by standing on planked guardrails, boxes, ladders or
other materials on scaffold platforms.
l DO NOT loosen, detach, or remove any component of a scaffold assembly except
under the supervision of a competent person. Components that have been removed
must be replaced immediately.
l DO NOT erect scaffolding on wagons, trucks, or other wheeled vehicles.
l Stand only within the platform area; do not try to extend work area by leaning out over
guard railing.

Precautions When Using Rolling Towers

l DO NOT RIDE MANUALLY PROPELLED ROLLING SCAFFOLD. NO ONE MUST BE
ON A ROLLING TOWER WHILE IT IS BEING MOVED.
l Lock all casters before getting on a rolling tower. Casters must be locked at all times the
scaffold is not being moved.
l DO NOT bridge between rolling towers.
l Remove all materials from scaffolding before moving a rolling tower.
l Be sure floor surface is clear of obstructions or holes before moving scaffold.
l Be sure there are no overhead obstructions or energized electric power lines in the
path when moving a rolling tower.
l Rolling towers must only be used on level surfaces.
l Move rolling towers from the base level only. DO NOT PULL OR PUSH from the top.

Erection of Scaffold.
l Scaffold must be erected, moved, or disassembled only under the supervision of
competent persons. PPE's including full body harness, safety helmets must be worn by
all persons erecting, moving, dismantling or using scaffolding.
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l Base plates must be centered on the sills, and be in firm contact with both sills and
frame legs. Be especially careful when scaffolds are to be erected on soft or frozen
ground. Any part of a building or structure used to support the scaffolding must be
capable of supporting the load to be applied.
l Compensate for uneven ground by using screw jacks and base plates, and sills if required
by ground conditions. DO NOT USE unstable objects such as blocks, loose bricks, and
similar objects or materials.
l Plumb and level scaffolding. Be sure scaffold stays plumb and level as erection
progresses.
l Ties, guys, bracing, and/or outriggers may be needed to assure a safe, stable scaffold
assembly. The height of the scaffold in relation to the minimum base width, wind loads,
the use of brackets or cantilevered platforms, and imposed scaffold loads determine
the need for sway and stability bracing.
The following general guidelines apply:
l A scaffold must always be secured when the height of the scaffold exceeds four (4)
times the minimum base width.
l Ties must be placed as near as possible to horizontal members. The bottom tie must be
placed no higher than four (4) times the minimum scaffold base width.
l Subsequent vertical tie placement will depend upon the scaffold width.
l Scaffolds three (3) feet and narrower must be tied at vertical intervals no more than 20
feet apart.
l Scaffolds wider than three (3) feet must be tied at vertical intervals no more than 26 feet
apart.
l The uppermost tie should be placed as close to the top as possible and, in no case,
more than four (4) times the minimum base width from the top.
l Vertical ties must be placed at the ends of the scaffold runs and at no more than 30 feet
horizontal intervals in between.
l Ties must be installed as the erection progresses, and not removed until scaffold is
dismantled to that height.
l Side brackets, cantilevered platforms, pulleys, hoist arms, enclosed scaffolds, sloped
surfaces, and windy conditions introduce overturning and uplift forces which must be
considered and compensated for. These situations require additional bracing, tying, or
guying.
l Circular scaffold erected completely around or within a structure may be restrained
from tipping by use of “stand off” bracing members.
l A free standing tower must be guyed at the intervals outlined above or otherwise
restrained to prevent tipping or overturning.
l Outrigger frames or outrigger units can be used to increase the minimum base width. If
used, they must be installed on both sides of the tower.

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l Work platforms must be fully decked with platform units in good, sound condition.
l Platform units may be individual fabricated metallic planks.
l Scaffold platforms and walkways must be at least 18 inches wide.
l Each end of each plank must overlap its support by a minimum of 6 inches or be
cleated.
l Each end of each platform 10 feet long or less must overhang its supports by no more
than 12 inches.
l Each end of each platform longer than 10 feet must overhang its supports by no more
than 18 inches.
l Larger overhangs must be guarded to prevent access to the overhang.
l Materials must not be stored on overhangs. Do not stand on overhangs.
l Each plank on a continuous run scaffold must extend over its supports by at least 6
inches and overlap each other by at least 12 inches.
l Secure platform units to scaffolding to prevent uplift caused by high winds or other job
site conditions.
l Use latches, if supplied by platform manufacturer or other suitable means.
l Guardrails must be used on all open sides and ends of scaffold platforms. Both top and
midrails are required.
l Toe boards must be installed whenever people are required to work or pass under a
scaffold platform.
l When materials are to be stacked higher than the toe board, screening is required from
the toe board or platform to the top guardrail.
l Access must be provided to all work platforms.
l If access is not available from the structure, access ladder units, or stairways must be
provided.
l Attachable ladder units must extend at least three (3) feet above platforms.
l Install access ladder units as scaffold erection progresses.
l Use fabricated decks or cleated planks to minimize platform interference in access
areas.
l DO NOT store materials on side or end bracket platforms.
l Cantilevered platforms must be specifically designed for that purpose, the frames pinned
to prevent uplift and adequate ties provided to prevent overturning.
l Materials must never be placed on cantilevered platforms unless the assembly has
been designed to support material loads by a qualified person. These types of platforms
cause overturning and uplift forces which must be compensated for.
l After erecting scaffold, be sure screw jacks are in firm contact with frame legs.
l Special care must be taken when putlogs are used:

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l Putlogs must only be mounted using putlog hangers, with all bolts and nuts installed
and tightened.
l Putlogs must overhang their supports by at least 6 inches.
l Lateral bracing and knee bracing are both required for putlog spans greater than 10
feet.
l Putlogs used as side or end brackets require special mountings and special bracing.
l DO NOT install platforms between free standing towers.
l Material hoists and derricks should not be mounted on a scaffold unless the scaffold is
specifically designed for that purpose.
l CHECK THE ENTIRE SCAFFOLD ASSEMBLY BEFORE USE. Thoroughly inspect the
completed assembly to see that it complies with all safety codes, all fasteners are in
place and tightened, it is level and plumb, work platforms are fully decked, guardrails
are in place, and safe access is provided.
Erection of Rolling Scaffolds
The following additional precautions apply to the erection of rolling towers:
l The height of the rolling tower must not exceed four (4) times its minimum base width.
l WARNING: The load rating of the casters used will limit the size, configuration, and
load capacity of the rolling tower.
l Secure all casters to frame legs or screw jacks with a nut and bolt or other secure
means.
l Screw jacks must not increase the height of the scaffold by more than 12 inches.
l Towers must be kept level and plumb at all times.
l Horizontal diagonal bracing must be used at the bottom and top of rolling towers where
the top work platform is more than 9 feet above the surface.
l When rolling towers are to be erected higher than 9 feet, the first brace must be no
more than 2 feet above the casters, the others at no greater than 21 foot intervals
above. Fabricated planks with hooks may be used as diagonal braces.
l All frames must be fully cross-braced.
l Platform units with hooks, or cleated planks, must be used on rolling towers.
Dismantling Scaffolds
The following additional precautions apply when dismantling scaffolding:
l PRIOR TO REMOVAL OR LOOSENING of any component, consider the effect the
removal of the component, or the loosening of a joint, will have on the strength of the
remaining assembly.
l Check to see if scaffolding has been altered in any way which would make it unsafe. If
so, reconstruct where necessary before beginning the dismantling process.
l Use only proper access. Do not climb braces or vertical members. Do not climb scaffold
components unless they are specifically designed for that purpose.
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l Do not remove ties until scaffold above has been removed.
l Visually inspect each plank to be sure it is supported on both ends and is safe to work
on.
l Do not accumulate removed components or equipment on the scaffold.
l Lower components in a safe manner as soon as dismantled. Do not throw components
off scaffold.
l Stockpile dismantled equipment in an orderly manner.
l Remove scaffold components immediately after detaching from scaffold.
l Understanding and following these safety guidelines will increase your personal safety
and the safety of your fellow workers.

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 LADDER SAFETY

A. Inspections
l Ladders shall be maintained in good condition at all times.
l All ladders must be inspected prior to each use. The inspection shall include, but
not be limited to:
l The joint between the steps and side rails shall be tight;
l All hardware and fittings should be securely attached;
l Movable parts shall operate freely without binding or undue play;
l Frayed or badly worn rope shall be replaced;
l Check for missing steps, rungs, or cleats, broken side rails, or other faulty
equipment;
l Check for proper bases or feet.
B. Safety Precautions
The following safety precautions shall be observed in connection with the use of
ladders;
l Portable rung and cleat ladders shall be used at such a pitch that the horizontal
distance from the support to the foot of the ladder is one-quarter (1/4) of the
working length of the ladder;
l The ladder shall be placed as to prevent slipping;
l Ladders shall not be placed on boxes, barrels, or other unstable bases to obtain
additional height;
l Ladders shall not be placed in front of doors opening toward the ladder unless the
door is blocked open, locked, or guarded;
l Ladders shall be tied off at the top;
l Ladders used to gain access to roof shall extend at least three (3) feet above the
point of support;
l While climbing a ladder, both hands should be used to hold onto the side rails;
l Do not carry tools or other objects in your hands. Use a hand line, if necessary to
raise or lower tools;
l Do not work from the top three rungs of single or extension rung ladders;
l Do not stand on the top two rails of step ladders;
l When working from a ladder, both feet must be kept on the ladder rungs or steps;
l Your waist must be kept within the boundary of the side rails;
l Check for overhead power lines or obstructions before erecting a ladder.
l Do not use ladders on or near power lines or other electrical devices.
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 l Trained personnel shall use only listed fiberglass ladders for limited authorized
electrical Work
l Use only FRP Ladder for doing Electrical Work
C. Loads
l Self-supporting (foldout) and non-self-supporting (leaning) portable ladders must
be able to support at least four times the maximum intended load, except extra-
heavy-duty metal or plastic ladders, which must be able to sustain 3.3 times the
maximum intended load.
D. Angle
l Non-self-supporting ladders, which must lean against a wall or other support, are
to be positioned at such an angle that the horizontal distance from the top support
to the foot of the ladder is about 1/4 the working length of the ladder.
E. Rungs
l Ladder rungs, cleats, or steps must be parallel level, and uniformly spaced when
the ladder is in position for use. Rungs must be spaced between 10 and 14 inches
apart.
l For extension trestle ladders, the spacing must be 8-18 inches for the base, and
6-12 inches on the extension section.
l Rungs must be so shaped that an employee's foot cannot slide off, and must be
skid resistant.
F. Slipping
l Ladders are to be kept free of oil, grease, wet paint, and other slipping hazards.
G. Other Ladder Requirements
l Foldout or step ladders must have a metal spreader or locking device to hold the
front and back sections in an open position when in use.
l When two or more ladders are used to reach a work area, they must be offset with
a landing or platform between the ladders.
l The area around the top and bottom of ladder must be kept clear.
l Ladders must not be tied or fastened together to provide longer sections, unless
they are specifically designed for such use.
l Never use a ladder for any purpose other than the one for which it was designed.

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 Arc Welding & Cutting Safety

l Arc welding is a safe occupation when sufficient measures are taken to protect the
welder from potential hazards.
l When these measures are overlooked or ignored, however, welders can encounter
such dangers as electric shock, overexposure to fumes and gases, arc radiation and
fire & explosion; which may result in serious or even fatal injuries.
The main hazards are:
l Electric shock during arc welding
l fire caused by heat, welding sparks;
l explosion when welding tanks or drums which contain or may have contained
flammable materials;
l fumes created during arc welding;
l arc rays may burns eyes & skin;
l burns from contact with the welded part.
Following precautions to be taken during arc welding:
l Insulate welder from work piece and ground using dry insulation. Rubber mat or
dry wood.
l Wear dry, hole-free gloves. (Change as necessary to keep dry.)
l Do not touch electrically live parts or electrode with bare skin or wet clothing.
l Welding machine should have ELCB of 30mA rating. Test ELCB daily before use.
l Keep electrode holder and cable insulation in good condition. Do not use if insulation
damaged or missing.
l Use ventilation or exhaust to keep air breathing zone clear & comfortable.
l Use helmet and positioning of head to minimize fume in breathing zone.
l Read warnings on electrode container and material safety data sheet (MSDS) for
electrode,
l Provide additional ventilation / exhaust where special ventilation requirements
exist.
l Use special care when welding in a confined area. Do not weld unless ventilation
is adequate.
l Provide welder helper and method of welder retrieval from outside enclosure.
l Do not weld on containers which have held combustible materials Check before
welding.
l Remove flammable materials from welding area or shield from sparks, heat.
l Keep a fire watch in area during and after welding at least for half an hour.

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 l Keep a fire extinguisher in the welding area.
l Wear fire retardant clothing and hat.
l Select a filter lens which is comfortable for you while welding.
l Always use helmet when welding.
l Provide non-flammable shielding to protect others.
l Wear clothing which protects skin while welding.
l Connect work cable as close as possible to area where welding is being performed.
l Do not allow alternate circuits through scaffold cables, hoist chains, ground leads,
structures
l Use only double insulated or properly grounded equipment.
l Always disconnect power to equipment before servicing.
l Never touch cylinder with the electrode.
All welders should use the following procedures in order to minimize exposure to
Electric and Magnetic Fields (EMF) from the welding circuit:
l Route the electrode and work cables together - Secure them with tape when
possible.
l Never coil the electrode lead around your body.
l Do not place your body between the electrode and work cables. If the electrode
cable is on your right side, the work cable should also be on your right side.
l Connect the work cable to the work piece as close as possible to the area being
welded.
l Do not work next to welding power source.

Gas cutting & Welding Safety

l Oxy/ fuel gas equipment has many uses - welding, cutting, heating, straightening,
and descaling. The equipment is versatile, easy to move and cheap.
l It is so widely used that sometimes people forget about the dangers.
The main hazards are:
l Fire caused by heat, sparks, molten metal or direct contact with the flame;
l Explosion when cutting up or repairing tanks or drums which contain or may have
contained flammable materials;
l Fire/ Explosion caused by gas leaks, backfires and flashbacks;
l Fumes created during flame cutting;
l Fire/ Burns resulting from misuse of oxygen;
l Burns from contact with the flame or hot metal;
l Crushing or impact injuries when handling and transporting cylinders.

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No one should use oxy/fuel gas equipment unless they have received adequate
training in:
l the safe use of the equipment;
l the precautions to be taken;
l the use of fire extinguishers;
l the means of escape, raising the fire alarm and calling the fire deptt.
The following precautions will be taken during gas cutting & welding :
l Work in a safe location away from other people;
l Wear protective clothing, gauntlets and eye protection;
l Shut off the blowpipe when not in use. Do not leave a lighted blowpipe on a bench
or the floor as the force of the flame may cause it to move;
l Clamp the work piece, do not hold it by hand;
l Keep hoses away from the working area to prevent contact with flames, heat,
sparks or hot spatter;
l Move the work piece to a safe location for carrying out the hot work process;
l Remove any combustible materials (such as flammable liquids, wood, paper,
textiles, packaging or plastics) from within about 10 meters of the work;
l Ventilate spaces where vapours could accumulate, such as vehicle pits or trenches;
l Protect any combustible materials that cannot be moved, from close contact with
flame, heat, sparks or hot slag. Use suitable guards or covers such as metal
sheeting, mineral fibre boards or fire retardant blankets;
l Use guards or covers to prevent hot particles passing through openings in floors
and walls (doorways, windows, etc);
l Maintain a continuous fire watch during the period of the work, and for at least an
hour afterwards;
l Keep fire extinguishers nearby
l Keep hoses clear of sharp edges and abrasive surfaces or where vehicles can
run over them;
l Do not allow hot metal or spatter to fall on hoses;
l Handle cylinders carefully. Keep them in an upright position and fasten them to
prevent them from falling or being knocked over. For example, chain them in a
wheeled trolley or against a wall;
l Always turn the gas supply off at the cylinder when the job is finished;
l Maintain all equipment and keep in good condition;
l Regularly check all connections and equipment for faults and leaks.
l Avoid taking gas cylinders into poorly ventilated rooms or confined spaces

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 l Never allow oil or grease to come into contact with oxygen valves or cylinder
fittings;
l Never use oxygen with equipment not designed for it. In particular, check that the
regulator is safe for oxygen and for the cylinder pressure.

Backfires
A backfire is when the flame burns back into the blowpipe often with a sharp bang. This may
happen when the blowpipe is held too close to the work piece, or if the nozzle is blocked or
partly blocked.
If a backfire does occur:
l Shut off the blowpipe valves, oxygen first and then the fuel gas;
l Shut off the oxygen and fuel gas cylinder valves;
l Cool the blowpipe with water, if necessary;
l Check the equipment for damage or faults, particularly the nozzle.

Flashbacks
Flashbacks are commonly caused by a reverse flow of oxygen into the fuel gas hose (or fuel
into the oxygen hose), producing an explosive mixture in the hose. The flame can then burn
back through the blowpipe, into the hose and may even reach the pressure regulator and the
cylinder. The consequences of a flashback are potentially very serious. They can result in
damage or destruction of equipment, and could even cause the cylinder to explode. This
could end in serious injury to personnel and severe damage to property.
The following precautions will help to prevent flashbacks:
l Use the correct lighting up procedure. Purge the hoses before lighting the blowpipe
to remove any potentially explosive gas mixtures.
l Use a spark igniter and ignite the gas quickly after turning it on;
l Ensure the blowpipe is fitted with spring-loaded non return valves to prevent a
backflow of gas into the hoses;
l Use the correct gas pressures and nozzle size for the job. In particular, the acetylene
pressure must not exceed 0.62 bar (9 psi);
l Maintain the equipment in good condition.
If a flashback does occur:
l Immediately close the cylinder valves, both fuel gas and oxygen, if it is safe to do
so. The flame should go out when the fuel gas is shut off. If the fire cannot be put
out at once, evacuate the area and call the emergency fire services;
l The blowpipe, hoses, regulators, flashback arresters and other components may
have been damaged. Check carefully and replace if necessary before reuse. If in
doubt, consult the supplier.
Power Drill Safety:
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 l When it comes to using power tools, a little knowledge goes a long way toward
preventing injuries and prolonging the life of tools.
l Avoid baggy clothing. Loose sleeves, jewelry and hair can be a hazard when
operating a power drill.
l The spinning action of a cordless drill can catch and tangle any loose objects.
l While operating any power tools, wear short sleeves, remove jewelry and tie hair
back if necessary.
l Wear protective gear. Safety goggles are always a good idea when using a power
drill.
l Breathing mask to be used if the material drilling produces a lot of dust or shavings.
l Gloves can help protect hands, but only if they are form-fitting and not baggy.
Loose gloves can get caught in the drill.
l Secure the work piece. Clamp the work piece down or secure it in a vice before
applying the power drill to it.
l Drill pilot holes. It's much easier to insert a screw into a pre-drilled pilot hole in a
piece of wood. Less pressure will be applied to the power drill as the screw goes
in, reducing the chances of slip.
l Use a drill stand. A drill stand acts as a guide or a frame for power drill. A stand
prevents the power drill from slipping and scratching the work piece as well.
l Properly set the drill bit. Make sure the drill bit is properly inserted into the chuck
and tighten it firmly with the chuck key. With a loose bit, power drill won't make
straight holes and could slip.
l Use a center punch to start holes. A center punch makes an indentation on the
wood, giving power drill a target for starting perfect holes and avoiding slippage.
l Apply proper pressure to the drill. Power drill should do most of the work, so don't
apply too much force. If drill push too hard, the power drill can slip or it can strain
the motor.

Grinding Safety
l Grinders and sanders are highly versatile tools capable of accepting a variety of
attachments and accessories that allow the tool to be used for grinding, sanding,
polishing, wire brushing or cutting-off operations.
l The proper guarding and safety devices must be used with the accessories (e.g.,
the proper type of guard used with a certain grinding wheel).
l Always read and understand the tool's operator's manual, tool markings and the
instructions packaged with the accessory before starting any work.
l Always wear safety goggles or safety glasses with side shields complying with
current national standards, and a full face shield when needed.

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 l Use the appropriate mask or respirator in dusty work conditions.
l Wear proper hearing protection, as needed.
l Wear gloves and a shop apron capable of stopping small abrasive or work piece
fragments.
l Dress right. Do not wear loose clothes or jewelry. Contain long hair. Loose clothes,
jewelry, long hair can be caught in moving parts.
l Crowded, cluttered work areas that can cause tripping or loss of balance are
particularly dangerous.
l Do not operate the power tool near flammable materials. Sparks could ignite these
materials.
l Choose the Right Tool and Accessory. Choosing the correct tool and the proper
accessory for specific application can help to reduce the risk of serious injury.
l When used according to the manufacturer's instructions, the proper tool and
accessory will do the job safer and faster.
l When it is recommended to use a guard with a wire brush, do not allow the wire
brush to rub against the guard. The wire wheel or brush may expand in diameter
due to work load and spinning.
l Wheels must be used only for their recommended jobs. For example, do not grind
with the side of a cut-off wheel. It will shatter.
l The outside diameter and the thickness of accessory must be within the capacity
rating of power tool (e.g., don't use an 8x wheel on a 7x grinder).
l Incorrectly sized accessories cannot be adequately guarded or controlled.
l Use the correct accessory for tool. Check this carefully: Does it fit the spindle of
the power tool.
l Be careful not to over-tighten the spindle nut. Too much pressure will deform the
flanges and stress the wheel.
l Accessories with arbor holes that do not match the tool will wobble, vibrate
excessively and may cause loss of control.
l Always use undamaged wheel flanges that are the correct size and shape to
properly support the accessory.
l Make sure the speed marked on the accessory is at least as high as the no load
RPM marked on the tool. Accessories running faster than their rated speed can fly
apart.
l Do not use accessories that require liquid coolant, unless your tool has been
specifically designed for operations with liquid coolant.
l Using water or other liquid coolants may result in electrocution or shock.
l Do not use a grinder that is too heavy to easily control.
l When sanding, do not use excessively oversized sanding disc paper.

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l Avoid working on small pieces of material which can't be properly secured. Injury
could result from small pieces being thrown by the spinning accessory.
l Know what is behind a work piece before doing the job. Do not cut into existing
walls or other blind areas where electrical wiring, water, or gas pipes may exist. If
this situation is unavoidable, disconnect all fuses/circuit breakers, and shut off
any water and gas lines feeding this work site.
l Before working with a grinder, make sure the tool and its accessories are in proper
working order. Failure to do so may increase your risk of injury.
l Handle accessories carefully to prevent damage or cracking. Do not use a damaged
accessory.
l Before each use, inspect abrasive wheels for chips and cracks, backing pad for
cracks, tear or excess wear, wire brush for loose or cracked wires.
l Test grinding wheels before mounting. Tap the wheel lightly with a nonmetallic
implement such as the handle of a screwdriver. If it produces a ringing sound, it is
in good condition. If it sounds dull, replace the wheel. DO NOT USE A CRACKED
WHEEL.
l Tuck away or trim any loose portion of a polishing bonnet or its attachment strings.
l After inspecting and installing an accessory, position yourself and bystanders away
from the rotating accessory and run the power tool at maximum no load speed for
one minute. Damaged accessories will normally break apart during this test time.
l Keep bystanders a safe distance away from the work area. Anyone entering the
work area must wear personal protective equipment. Pieces of a work piece or a
broken accessory may fly away.
l Be sure the tool switch works properly. Do not use a tool if the switch does not turn
it off when returned to the off position.
l Be sure the guard is securely attached to the tool and positioned for maximum
safety, so the least amount of wheel is exposed toward the operator during use.
l Position the cord away from the spinning accessory. If person lose control, the
cord may be cut or snagged and person hand or arm may be pulled into the
spinning accessory.
l Bench grinder wheels should be trued and dressed when worn out of round, or
the surface face is clogged or worn smooth. This provides a clean sharp grinding
surface and rebalancing of the wheel.
l New bench grinder wheels should be balanced by dressing and truing to eliminate
vibration and possible mishap.
l Check operator's manual. Don't operate a grinder unless it is ensured that the
grinder, its base and/or stand are securely mounted.
l While grinding concentrate on job and be aware of kickback (a sudden reaction to
a pinched or snagged accessory).
l Pinching or snagging causes rapid stalling of the rotating accessory. This forces

125
 the uncontrolled power tool in the direction opposite the accessory's rotation at
the point of binding. It can also cause an uncontrolled work piece to be thrown.
l For example, when using a portable grinder, if an abrasive wheel is snagged or
pinched by the work piece, the edge of the wheel entering the pinch point can dig
into the surface of the material causing the wheel to climb or kick out of the work
piece. The wheel may either jump toward or away from the operator, depending
on direction of the wheel's movement at the point of pinching. Abrasive wheels
may also break under these conditions.
l Kickback is the result of power tool misuse and/or incorrect operating procedures
or conditions, and can be avoided by taking proper precautions.
l Never place your hand near the rotating accessory. The tool may kick back.
l Use special care when working on corners, sharp edges, etc. Avoid bouncing and
snagging the accessory. Corners, sharp edges or bouncing have a tendency to
snag the rotating accessory and cause loss of control or kickback.
l Do not attach a saw chain, woodcarving blade, or toothed saw blade. Grinders
are not designed for these types of blades.
l Do not “jam” a cut-off wheel or apply excessive pressure. Do not attempt to make
an excessive depth of cut.
l When using wire brushes, wire bristles are thrown during ordinary operation. Do
not overstress the wires by applying excessive load to the brush
l When stopping a cut, switch off the tool and hold the tool motionless until the
wheel comes to a complete stop.
l Never attempt to remove the cutoff wheel from the cut while the wheel is in motion.
l Do not restart the cut in the work piece. Let the wheel reach full speed and then
carefully reenter the cut.

Precautions using Portable grinders

l Maintain a firm grip on the power tool and position your body and arms to allow
you to resist kickback forces.
l Always use an auxiliary (side) handle, if provided, for maximum control over
kickback or a torque reaction during startup.
l The operator can control torque reactions or kickback forces, if proper precautions
are taken.
l Do not position your body in the area where the power tool will move if kickback
occurs. Kickback will propel the tool in the direction opposite to the wheel's
movement at the point of snagging.
l Support panels or any oversized work piece to minimize the risk of wheel pinching
and kickback.
l Large work pieces tend to sag under their own weight. Supports must be placed
under the work piece near the line of cut and near the edge of the work piece on
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 both sides of the wheel.
l When it is recommended to use a guard with a wire brush, do not allow the wire
brush to rub against the guard. The wire wheel or brush may expand in diameter
due to work load and spinning.

Precautions using Bench Grinders:

l On bench grinders, tool rests and spark guards are adjustable to compensate for
wheel wear. They must be reset when anew wheel is installed or after a wheel has
been worn or dressed.
l The distance between the spark guard and the wheel should be within 1/16x.
l The tool rest should be slightly below the center of the wheel with 1/8x or less
clearance from the wheel. This prevents accidental jamming between tool rest
and the wheel.
l When job done unplug, clean and store the tool in a safe, dry place after use.
l Never lay the power tool down until the accessory has come to a complete stop.
The spinning accessory may grab the surface and pull the power tool out of your
control.
l Do not run the power tool while carrying it at your side. Accidental contact with the
spinning accessory could snag your clothing, pulling the accessory into your body.
l Regularly clean the power tool's air vents. The motor's fan will draw the dust inside
the housing and excessive accumulation of powdered metal may cause electrical
hazards.
l Store accessories with care.

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 CRANE SAFETY

A. General Requirements
l Only certified and licensed personnel shall be permitted to operate a crane.
l A substantial and durable load rating chart with clearly legible letters and figures
shall be provided with each crane and securely fixed to the crane cab in a location
visible to the operator while seated at his control station.
l All cranes and similar equipment shall have been inspected and certified within
one year prior to using such equipment in the Job Site.
l All certification and inspection documents must be made available to the Safety
Deptt upon request.
l Cranes moving into, within, and out of operating units must have a spotter present
to ensure that operating equipment is not accidentally struck.
l All guards and other load limiting devices specified by the crane manufacturer
shall be in place and fully operational.
B. Handling the Load
l No crane shall be loaded beyond 75% of its rated load with all outriggers used
unless a critical lift plan has been completed and enacted.
l The hoist rope shall not be wrapped around the load.
l The load shall be attached to the hook by means of slings or other approved
devices.
l Hooks shall be equipped with safety latches
l Only properly trained personnel shall rig loads.
C. Moving the Load
l The crane should be level and properly blocked or balanced during all lifting and
moving operations.
l The load should be well secured and properly balanced in the sling or lifting devices.
l Before starting to lift and move a load, the hoist rope shall be checked to ensure
that it is not kinked and multiple hoist lines are not twisted around each other.
l The hook shall be brought over the load in such a manner as to prevent swinging.
l During hoisting, there shall be no sudden acceleration or deceleration of the moving
load.
l Care shall be taken to prevent the load from contacting any obstructions.
l No personnel shall be on the load or the hook during any hoisting, lowering,
swinging, or traveling,
l The load shall not be positioned over any personnel.

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 l Outriggers shall be used in accordance with the Manufacturer's specifications
when the load radius dictates.
l Neither the load nor the boom shall be lowered below the point where less than
two full wraps of rope remain on their respective drums.
l When two or more cranes are used to lift one load, one designated person shall
be responsible for the operation. He shall be required to analyze the operation
and instruct all personnel involved in the proper positioning, rigging of the load,
and the movements to be made.
l During transit, the following additional precaution shall be taken:
l The boom shall be carried in line with the direction of motion;
l The superstructure shall be secured against rotation, except when negotiating
turns and the boom is properly supported on a dolly.
l An empty hook shall be lashed or otherwise restrained so that it cannot
swing freely.
l Before traveling, with or without a load, a designated person shall be responsible
for determining and controlling safety. Decisions such as position of load, boom
location, ground support, travel route, and speed of movement shall be controlled
by the designated person.
l When rotating the crane, sudden starts and stops shall be avoided.
l A tag or restraint line shall be used to control the movement and location of the
load.
l At no time shall personnel be positioned where the load could possibly crush
them against a stationary object.
D. Holding the Load
l The operator shall not be permitted to leave their position at the controls while the
load is suspended.
l No person is permitted to stand or pass under a suspended load.
l If the load must remain suspended for any considerable length of time, the operator
shall hold the drum from rotating in the lowering direction.
E. Personnel Lifts.
l Hoisting personnel by crane should be granted with following rules:
l There is no safe alternative available and the requirements described below
are met;
l Cranes used to hoist personnel must be placed on firm ground and the crane
must be leveled.
l The crane operator must always have full control over the movement of the
personnel platform.
l Wire rope used for personnel lifting must be capable of lifting seven times
the maximum permitted load.
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 l The combined weight of the loaded personnel platform and its rigging must
not exceed 50 percent of the rated chart capacity of the crane.
l The crane must be equipped with:
l An anti-two-blocking device that prevents contact between the load block or
overhaul ball and the boom tip; or
l A two-block damage feature that deactivates the hoisting action before
damage occurs.
l The platform used for lifting must be capable of lifting five times the maximum
permitted load.
l Each personnel platform must be provided with a standard guardrail system that
is enclosed from the toe board to the mid-rail to keep tools, materials, and equipment
from falling on personnel below.
l The platform must have a grab rail, overhead protection, when needed, adequate
headroom and a plate or other permanent marking that clearly indicates the
platform's weight and rated load capacity or maximum intended load.
l A trial lift must be made before any personnel are allowed to be hoisted:
l The personnel platform must be loaded to its anticipated lift weight;
l The trail lift must start at ground level or at the location where personnel will
enter the platform, and proceed to each location where the personnel platform
is to be hoisted and positioned.
l The crane operator must check all systems, controls, and safety devices to ensure
that:
l They are functioning properly;
l There are no interferences; and
l All configurations necessary to reach work locations will allow the operator
to remain within the 50 percent load limit of the hoist's rated capacity.
l After the trial lift, the personnel platform must be hoisted a few inches and inspected
to ensure that it remains secured and is properly balanced.
l A pre-lift meeting must be held with all personnel involved in personnel hoisting
(crane operator, signal person, workers to be lifted, and the person responsible
for the hoisting operation) to review the requirements and the procedures to be
followed.
l Other Requirements include but are not limited to:
l All other requirements relative to crane safety must be followed;
l Personnel are forbidden to “ride the load”, only platforms (or baskets
specifically designed for personnel lifting shall be used to hoist personnel;
l Use tag lines where practical;

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 l All personnel shall keep all body parts inside the platform during raising,
lowering, and positioning activities;
l The platform shall be secured before exiting or entering;
l Safety belts or harness systems with lanyards must be used. The lanyard
must be attached to the lower load block or overhaul ball or to a structural
member within the personnel platform.
l All hoisting operations must cease if there are signs of a severe storm or other
impending danger.
F. Lifting over Process Lines and Equipment
l In general, lifting heavy objects over live electrical or operating lines or equipment
should be avoided whenever possible.
l When such activities cannot be avoided the methods, procedures and guidelines
set forth above for personnel lifts are applicable for all loads.

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 Concrete Mixer Safety

l Construction machinery frequently has pinch and nip point hazards including gear,
belts, chain drives, sprockets, and rotating parts.
l Portable cement mixers can be hazardous due to the rotating mixing drum or
rotating paddles inside the drum.
l A body part can be caught between the rotating drum and a stationary part of the
mixer.
l Electrical power can also be a potential hazard.
l Observe work area conditions. Work areas should be clear of debris and
obstructions which could cause the operator to slip, trip or fall into the mixer.
l The cement mixer should be on a flat and level surface to prevent tipping, rolling
or falling. Do not use in wet locations.
l Dress properly. Do not wear loose clothing or jewelry as they can be caught in
moving parts. Wear proper Personal Protective Equipment (PPE) and wear
restrictive hair covering to contain long hair.
l Check for wear and damaged parts. Before using, check to determine that the
mixer will operate properly. Any broken or missing parts must be repaired or replaced
before using.
l Check for proper machine guarding and assure the electrical power cord is in
good condition.
l Use ELCB protection when using an electric powered mixer outdoors or in damp
locations to prevent a shock hazard. Do not use cement mixer if it is not in proper
working order.
l Always earth the cement mixer when using ELCB.
l For diesel engine powered mixers, always shut off engine before fueling.
l Be aware of hot exhaust and do not use diesel engine powered mixer indoors as
carbon monoxide may accumulate and cause breathing hazard. Make sure all
tools and other equipment are removed from the cement mixer prior to turning it
on.
l The cement mixer should be rotating when filling or emptying the mixer.
l Do not overload mixer. An overload could damage the mixer.
l Never leave the mixer running unattended.
l Do not move the cement mixer during operation. The mixer could tip over or the
motor could be damaged.
l When transporting the mixer, disconnect the power cord or shut off the engine
and make sure the drum is empty of all material.
l Keep guards in place during operation.
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 l Only use accessories that are recommend by the manufacturer.
l Disconnect the power or shut off the engine from the mixer and place the switch in
the locked or off position before servicing, adjusting, installing accessories or
attachments. Such preventive safety measures reduces the risk of starting the
cement mixer accidentally.

Dumper Safety
l Rear-tipping Lorries/ dumpers can overturn during tipping operations.
l To prevent overturning:
l Always tip on firm level ground;
l Never tip on a slope;
l Never tip during high winds;
l Ensure the load is evenly distributed in the body of the truck;
l For articulated vehicles, ensure that the tractor is in line with the trailer body;
l Ensure a competent signaler is on hand to supervise tipping operations;
l Tip the load gradually so that it is discharged in a controlled manner; and
l Watch out for loads sticking, which could cause instability during tipping.
l Visibility from the driving position during reversing operations can be improved by
fitting visibility aids such as convex mirrors and CCTV. Warning devices, e.g. alarms
and lights, should operate when Lorries and lorry loaders are reversing.
l During maintenance operations under tipper-lorry bodies or cabs, proprietary props
designed to withstand the lowering forces should be used to secure them in the
raised position and prevent their collapse.
l Lorry drivers should only stay in their cabs during loading operations if it is safe for
them to do so, eg when loose pea gravel is being loaded, rather than when
demolition debris is being loaded. The safety of tipper-lorry cabs is increased
when there is an extension of the tipper body over the cab.

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 ELECTRICAL SAFETY

l Do not interfere with electrical connections including fuses. Call an electrician for
electrical breakdowns. No one other than an authorized electrician will work on
electrical equipment.
l All electrical connections must be properly insulated. If the insulation requires
attention, it must be expedited. A spark from an exposed live wire will lead to an
explosion and fire in a hazardous area.
l Employees finding sparking or smoking motors or other electrical equipment must
switch off immediately and report to the supervisor.
l Fuses blow when there is an overload or short circuit. The electrician must be
called to mend the fuses.
l All electrical equipment and power tools must be earthed before they are used.
The non-current carrying metal parts of portable and/or plug connected equipment
shall be grounded or protected by an approved system of double insulation.
l Extension cords used with portable electric tools and appliances shall be three-wire
grounded type and protected by ELCB (Earth Leak Circuit Breaker) of 30mA rating.
l Double insulated power hand tools to be used.
l Don't operate electrical equipment with wet hands or on wet ground.
l In a hazardous area, all electrical installation and fittings must be of explosion
proof type, except for all stores and warehouses. For all spark producing activity
in stores and warehouse, a HOT WORK permit is required.
l Do not use 2 core cables where 3 core cables are necessary. The additional
connection is for earthing and safety.
l Do not start repairing electrical equipment without final switching off the power at
mains and locking it, as per ELECTRICAL LOCK OUT procedure. Put a tag
indicating “DO NOT START”.
l Don't use Water, Soda-acid or Foam type fire extinguishers on electrical fires as
they may result in a fatal shock. Switch off power and use only Dry chemical /
Carbon Dioxide fire extinguishers.
l Keep Emergency Lights at hand in order to facilitate repair work in case of power
failure, in the night shift. Do not use these lights in the explosion proof area.
l No digging is allowed unless authorized by Engineering Division on a work permit,
due to the hazard of underground electrical cables.
l Worn, frayed or damaged electric cords or connectors shall not be used and shall
be tagged, “Danger, Out of Service, Do Not Use”.
In case of any emergency
l For any electrical accident of fire, switch off the power supply immediately.
l Give artificial respiration to the victim of an electric shock and immediately call for
a Doctor.
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 HYDRA SAFETY

l Hydra can be used for shifting material/ equipment within 100 mtr of site only.
l Hydra driver should be trained and have valid Heavy Vehicle Driving Licenses.
l Tyre of hydra should be in good condition without cut, crack, low air pressure etc.
l There should be a safety latch in lifting hook.
l SWL of hydra should be clearly marked on hydra.
l There should be hoist limit switch or a plate for the same.
l Wire rope & slings should be free from damage (No kinks, broken wire not more
than 10%)
l No leakage in hydraulic system. Hydraulic oil level be in recommended range.
l All front & rear lights to be in working condition during night working.
l Reverse & front horn should be in working condition.
l Fire extinguisher to be available in hydra cabin.
l Boom structure condition during full extension should be free from any damage
and no jamming while extending.
l No person should present below the hanging load.
l Hydra should be checked as per checklist before using the same.

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 FORKTRUCK SAFETY

Hazards of Fork Truck Operation

l Fork Truck Overturn
l Collision with Pedestrians
l Collision with other Vehicle
l Collision with a fixed structure
Factors that can cause Fork Truck to Overturn
l Cornering whilst being driven too fast
l Uneven loading of the Forks
l Driving over Potholes
l Driving with the load elevated, especially cornering
l Uneven tyre Pressure
l Driving across a slope (rather than straight up / down the fall line)
l Excessive braking
l Collisions especially with curbs
Factors that can cause Collisions
l Driving too fast
l Inadequate lighting
l Reversing without the help of a banksmen
l Blind spots, such as corners and entrances
l Bad weather conditions (e.g. Rain)
l Obstructed visibility (e.g. Overloaded Fork Truck driving forward)
l Poor design of pedestrian walkways and crossing points
l Lack of vehicle Maintenance (e.g. Brake failure)
General Requirements
l Only a trained and authorized forklift operator to drive a forklift.
l A substantial and durable load rating chart with clearly legible letters and figures
shall be securely fixed to the forklift in a location easily visible to the operator.
l Approved forklifts shall bear a label of Safe Working Load (SWL)

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Pre-Use Inspections
l The forklift operator must inspect the forklift at the beginning of each shift before using.
l The inspection shall include, but not be limited to:
l Tyre Pressure
l Parking brakes and service brakes
l Steering
l Fuel, Oil and water systems for leaks
l Batteries, to ensure they are charged, leak free, chargers are off and leads
are stored and that the battery retention device is secured.
l Lifting and tilting systems (including hydraulics) are working, are leak free
and hydraulic fluids levels are correct.
l Audible warning
l Lights
l Mirrors
l Any defects should be reported to the supervisor for immediate rectification
Forklift Operations
l Forklifts shall not be driven up to anyone standing in front of a fixed object.
l No one shall be allowed to stand or pass under the elevated portion of a forklift.
l No one, other than the operator, shall be permitted to ride on forklifts.
l When a forklift is left unattended, forks shall be fully lowered, controls neutralized,
power shutoff, and brakes set.
l Operators shall be aware of overhead installations such as electrical lines, pipe
racks, etc. and shall maintain sufficient headroom when necessary to drive under
those installations.
Loading
l Only stable or safely arranged loads shall be handled. Extreme caution should be
exercised when handling off-center loads which cannot be balanced.
l Only loads within the rated capacity of the truck shall be handled.
l Forks should be placed under the load as far as possible.
l The mast shall be carefully tilted backward to stabilize the load.
Traveling
l All traffic regulations shall be observed, including speed limits and right of ways.
l The driver shall maintain a clear line of vision in the direction of travel.
l If the height of the load obstructs forward vision, the forklift must be driven in
reverse.
l When it is necessary, a spotter must be present to ensure that operating equipment
or overhead structures are not accidentally struck.
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 Road Safety

l Fatalities and accidents on the road occur because someone somewhere is not
paying attention to road safety rules.
l There are a number of factors that come into interplay while traveling on the road.
l There are road safety rules for drivers to follow as well as the pedestrians and
other vehicles.
Road safety rules
l Keep to the left while driving and allow vehicles from the opposite direction to
pass.
l Most head-on accidents happen as we fail to keep to the left and stay in the
middle of the road. This is one of the most important road safety rules for drivers.
l Always slow done on bends and turn.
l Be all the more cautious when negotiating bends and sharp turns.
l Move cautiously and slowly during congestion on roads especially at the round-
about and road junctions.
l Remain within the speed limit. This is common sense and a common one among
road safety rules for drivers.
l Keep in mind that the speed limit is related to the traffic condition of the area. If
come within schools and hospitals, just slow down.
l Maintain the right distance. Often it is seen that collisions occur because adequate
distance from the vehicle in front is not maintained. These are important road
safety rules for drivers.
l Understand and follow the road signs. These road safety rules are a must for all to
follow, whether walking on the road or in their vehicles. It can be dangerous for
anyone if he have poor understanding of the road signs.
l Never overtake the vehicle in front in case it is turn
Guidelines for Road safety for four wheeler drivers
l Make sure you know how to drive well & are confident on the roads
l Learn driving from a good reputed school
l Have a clear view when driving
l Check your mirrors before changing lanes
l Try to keep away from the blind spots
l Always wear seat belts
l Keep at a safe distance from other vehicles on the road
l Follow the road signs, traffic lights and speed limits all the time.
l Maintain a safe distance from the bigger vehicles on the road like Trucks and
138 keep out of their blind spots.
l Never ever drive when drunk or you are inviting trouble
 l Look for any pedestrians at the crossings.
l Wait for all the pedestrians to cross
l Be patient, particularly with senior pedestrians
l Be more careful when children and pets are crossing
l Be even more alert and slow down near schools or residential areas
l Avoid any distractions
l Avoid looking at maps or directions
l Avoid looking at navigation system
l Avoid listening to too loud music
l Avoid having an unleashed pet

Guidelines for Road Safety for Two wheeler Riders

l Wear Helmets. Those on two wheelers should never go on the road without a
helmet.
l Make sure the helmet is of superior quality and strapped properly.
l Not to use two wheeler for any material shifting.
l Overtake with care.
l Do not tailgate.
l Maintain a safe distance from the bigger vehicles on the road like Trucks and
keep out of their blind spots.
l Do not use two wheeler for long drive, take break during the drive.

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 OFFICE SAFETY

Following safe work procedures in the office can prevent many accidents.
l Running in offices is not permitted.
l Accidents can result when persons stand in front of doors, so stand away from the
path of the door swing.
l Prevent fall and trip hazards, by keeping stairways, isles and walk areas clear of
boxes, loose materials, wires and other small objects.
l Immediately clean up spilled liquids.
l Do not attempt to carry stacks of materials which are high enough to obstruct
vision.
l Always use handrails when using stairways.
l Proper attention should be given to the act of ascending or descending stairs.
l Falls on stairs occur when persons are distracted through conversation or by turning
to another person while descending.
l Don't lean from chair to pick up objects on the floor.
l Don't propel a chair across the floor while seated.
l Be careful sitting down. Sit in the center of a chair and not on the edge. Watch out
for chairs on casters which can be inadvertently pushed from under you when you
attempt to sit down. Place your hand behind you to make sure your chair is in
place before you settle into it.
l Don't stand on a chair, stools, or other unstable surface to reach for an object. Use
a ladder.
l Don't sit on the edges of desks, tables, boxes, or low filing cabinets.
l Place wastebaskets, briefcases, umbrella stands, and similar objects where they
will not present a tripping hazard.
l To prevent slips and falls select shoes for comfort and safety that are compatible
with your work environment.
l Dispose of broken glass properly to prevent injury to others during waste handling.
Bag and wrap broken glass with heavy paper to prevent penetration by sharp
edges and identify contents.
l Sharps such as razor blades shall be disposed of in an impermeable closed
container. Medical waste sharps require immediate deposit in biohazard sharps
containers and hazardous materials control for disposal.
l Use with caution, razor blades, knives, scissors, and other objects with sharp
edges or points. Keep razor blades in protective containers. Never keep loose
razor blades in desk drawers.

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 l Never fasten envelopes with pins or staples. Exercise care to avoid paper cuts.
l Fasten loose papers together with paper clips or staples, never with pins. Exercise
care when loading or using staple machines. Use a proper staple remover for
removing staples. Properly dispose of broken staple remover.
l Keep fingers away from the sharp edge of paper cutters. Never leave a cutting
knife in a raised position. All guillotine type paper cutters shall have a finger guard;
other types of paper cutters shall have proper finger protection.
l Do not indulge in any form of “horseplay”, such as propelling paper clips, rubber
bands, etc. “Horseplay” is strictly prohibited.
l Wear shoes at all times.
l Properly store office supplies.

Filing Cabinets are a major cause of accidents and should be used with care.
l When caution is ignored, filing cabinets can pinch, cut, crush, or trip a user. Always
be alert for a top heavy filing cabinet. It might tip over if a drawer is opened. Heavy
cabinets shall be secured to prevent this.
l Exercise care in opening and closing file drawers. Open one file drawer at a time
and close it with the handle, making sure your fingers are clear. Never close a
drawer with your knee, elbow or any other part of your body other than your hand.
Close each drawer immediately after use, even if you plan to reopen it in a
short time.
l Never climb on open file drawers.
l Properly store small non-slip stools (used to access upper file cabinets) out of
passageways.
l Wear finger guards to avoid paper cuts.

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 ERGONOMICS

Ergonomics is the science of fitting the job to the worker. When there is a mismatch between
the physical requirements of the job and the physical capability of the worker, musculoskeletal
disorders (MSDs) can result. Musculoskeletal disorders (MSDs) are a category of injuries
that affect the body's muscles, bones, ligaments, tendons, and nerves.
Where feasible, the following MSD risk factors should be avoided:
l repetition and inadequate work/rest scheduling,
l forceful exertions,
l awkward and extreme positions of the body and
l sustained or static positioning of the body
Computer Workstations
Here are some suggestions for setting up your workstation properly:
l Sit with your lower back against the chair, your upper legs parallel to the floor and
your feet flat on the floor or on a footrest. Move, cross and uncross your legs
frequently.
l Adjust your table and chair so that your elbows are bent at right angles and your
forearms are approximately parallel to the floor.
l Keep your wrists neutral (straight) by using a wrist rest that is the same height as
the keyboard.
l Place your mouse (or other pointing device) on a surface close to and at the same
height as your keyboard.
l Position your monitor directly in front of you, approximately an arm's length away,
with the top of the screen at or slightly below eye level. Tip the monitor back at an
angle similar to that used when reading a book.
l Use a document holder to position work at eye level and close to the screen.
l Adjust your lighting and monitor to prevent glare or use an antiglare filter.
l When performing tasks involving repetitive motions or awkward positions, take
periodic stretching breaks or alternate with other tasks.
l If a repetitive job is awkward, try to find a better way to accomplish it.
l Keep your wrists in a neutral position as much as possible, not bent or twisted.

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 HOME SAFETY

General Safety at Home

l Inside the home, lighting needs to be bright.
l Light switches should be easy-to-reach and near doorways, at both ends of the
hall and at the top and bottom of the stairs.
l Keep hallways well lit at night.
l Floors should be kept clean of any spills & free of clutter.
l Glazed ceramic tiles are particularly dangerous, especially when wet.
l Tape or tack down the edges of floor coverings if they are beginning to curl.
l Arrange the furniture so that you can move freely about your house.
l Keep walkways clear of hazards such as low furniture, loose rugs, electrical cords
and toys.
l Keep curtains well away from cooking stoves, radiators and open fires. An ignition
source could easily ignite the grease and dust collected by the curtains.
l Keep flammable like kerosene, insecticides, medicines away from reach of children.
Electrical Safety at Home
l Provide an Earth leakage detector unit in Electrical circuit. This will prevent the
possibility of receiving Electric shocks.
l Purchase only standard Electrical appliances only.
l Always use 3-pin plugs in the electrical appliances and connect them to 3-pin
sockets only.
l Using electrical appliances incorrectly could cause severe electrical shock, and
even death.
l Never place Heaters too close to furniture or flammable material such as clothing.
l Frayed insulation on electrical cord, damaged or deteriorating power points, plugs
and appliances should be repaired or replaced.
l Use a power board rather than double adaptors, or have multiple power points
installed. Avoid using extension cords
l Pull out plugs by gripping the plug, not the cord.
l Electrical cords and phone cables are best run beside the walls. This allows work
and walk areas to be kept clear.
l Never pass electrical cord under the carpets.
l Try to have power points placed where they are easy to reach.
l Always call qualified electrical technician for any repair.
l Always treat an electrical circuit as LIVE unless found DEAD by testing.
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 l Don't clean electric switches, boards etc. with WET cloth.
Safety in Kitchen
l Put items for everyday use where they can be easily reached - waist level is best.
l Keep food items separate from cleaning agents like soaps, detergents, floor
cleaning agents, insecticides.
l If you have a table and chairs, try to choose one with four sturdy legs rather than
3-legged stools or pedestal tables.
l Keep electrical appliances in kitchen away from the sink.
l Make sure the floor surface in kitchen is non-slip and always clean spills as quickly
as possible.
l If you have floor mats, make sure they have a non-slip backing.
l Keep containers of kerosene properly closed, away from heat & source of ignition
in well ventilated place. Not at rack above gas stove.
l Ensure good ventilation in kitchen to avoid eye glasses fogging and reduced vision.
l Avoid loose & long sleeves cloths while cooking in kitchen. Long sleeves are more
likely to catch fire than are short sleeves. Always use cotton clothes instead of
synthetic clothes while cooking.
l Shut off the gas supply for cylinder regulator after use in night & before going
outside the home.
l Replace damaged gas hose immediately. Use only approved gas hose.
l Always check for any leak during delivery of gas cylinder.
Burning Pans
Cooking fat will ignite if the temperature is too high. In such cases, do the following:
l Turn off the source of the heat.
l Don't attempt to move a burning pan.
l Smother the fire with the lid or fire blanket.
l Remember that it is dangerous to pour water on a burning frying pan.
l Call the fire brigade if required.
Safety in Bathrooms
l Avoid slippery surfaces on the floor and don't have mats in the bathroom.
l If you have a slip-resistant rubber mat in the bath or shower, make sure that there
is good suction between the mat and the surface it rests on. Take it up and clean
off mould frequently to keep it slip resistant.
l Consider having grab-rails installed in the bath, shower and near the toilet. They
need to be installed properly to take the weight of a person.
l Avoid using electrical appliances in the bathroom, e.g. hair dryers.

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 l Install hinges on bathroom doors which allow the door to be lifted out in an
emergency.
l Turn the thermostat of your water heater down to around 500C.
Safety during using a ladder
l Never stand on the top rung of a step ladder. Work should be limited to the second
highest or lower rungs.
l When on a ladder/step ladder, work only on parts that are within easy reach. Don't
lean over.
In case of fire at home
In the case of a fire in the house, there are simple rules which the whole household
should know about:
l Get all occupants together and plan how everyone can get outside safely.
l Make sure there are windows or other exit points to get outside safely. If window
locks are fitted make sure everyone knows how to unlock and open the window.
l Select a spot outside your home for an assembly point.
If A Fire Starts In Your House
l It is important to know how, in an emergency, to disconnect both power and gas
by means of the main switch and shut off valve. This of course is only to be done
if safe to do so.
l Remember that smoke is the biggest killer in fires, cover your nose and mouth
with a cloth.
l Smoke rises. Get down low and go to the nearest exit whether it be a window or a
door.
l Yell and bang on walls to let your family know about the danger.
l Use the back of your hand on closed doors. If hot, do not open as the fire is on the
other side. Find another way out or wait at the window for the fire brigade.
Don't Hide!
l Once outside; go to your assembly place.
l Don't walk away from a fire scene without first informing the people in attendance
of where you are going.
l Ring for the fire brigade from a neighbor's house.
First Aid for Burns
l Remove the heat source.
l Put out flames or remove clothing, wet with cold water.
l Apply a large amount of water, by holding the injured part under a running tap or
immersing in a bucket of cold water, or splashing the area with cold water. Continue
for 30 minutes. Do not use iced water.
l Don't apply any ointment, cream or lotions.
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Fire extinguishers
l To protect yourself from the dangers of a fire you can purchase an all-purpose fire
extinguisher and fire blanket.
l Install these in a convenient and accessible place not near the stove.
l Make sure that you will be able to lift and trigger the fire extinguisher.
Burning Clothes
l If someone's clothes catch on fire, lower them to the ground and roll them.
l Treat burns with cool water. Seek immediate medical attention for burns.
Fires in Electrical Appliances
When attempting to extinguish a fire involving an electrical appliance or a fire near electrical
wiring never use water. Water may result in short circuits and fires in new areas. Water is
also a conductor of electricity. If you touch an appliance in contact with water, there is the
danger of electrocution. If a small electrical appliance catches on fire, follow these procedures:
l Switch off the appliance.
l Pull out the plug.
l Use a dry chemical powder or CO2 fire extinguisher.
l Call fire brigade.
Smoking
If you do smoke, please follow the safety rules below.
l Use only deep, wide ashtrays with grooves for cigarettes.
l Never smoke in bed and never smoke if you are drowsy.
l Never leave lit cigarettes in ashtrays.
l Wet ashes or cigarette butts in water before throwing them into a trash can.
l Check ashtrays and furniture before leaving the house or going to bed.
Precautions during flying kites
Flying a kite is so much fun you might be tempted to risk it when it is not safe. Don't! The
danger is often very great to you and other people.
l Never fly kites near power lines. This is the number one danger to which kite-
flyers are exposed. Do not fly the kite close to the lines or poles even though you
are far away. When the string is dry, it should not transmit electricity, but do not
risk it anyway. If it becomes tangled in the power lines, you will lose the kite. Never
try to recover it. Kites are cheap. You are not.
l Never fly kites in stormy weather. Even big, white, puffy clouds can have lightning,
and the kite may attract it. Especially if the string is wet, the kite becomes very
dangerous because the wet string will transmit electricity.
l Never use anything but cotton string to fly a kite. Any kind of wire or string with
metallic content will transmit electricity. You don't want to be a receptor of lightning.
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 l Keep your kite far from roads and highways. Even a small kite diving at a car may
startle a driver and cause an accident.
l Don't let your kite fly above people on the ground. They can hit people & injured
them with string. There are cases, when people's throat cut by strings.
l If you have large kite with a lot of lift or a strong wind, wear gloves. The string can
cut your fingers.
l Don't fly kites at open terrace, not protected by wall. There is always danger of fall
from open terrace.
l Do not take risk in catching kites. Do not cross terrace borders/galleries border to
collect kites.
l Do not try to collect kite from electric poles
l Keep water bottle along with, when flying kites in afternoon.
l Don't fly kites by standing in narrow spaces or near the terrace borders
Tips for Bikers/two wheel riders during kite season.
l If you are driving through road during season of kite flying, make sure you wear
helmet, scarf, muffler or at least neck protector.
l Go slow. Don't drive fast. This can give you a miraculous chance to stop your
vehicle even an inch away in case a kite string comes to your way (which could cut
the neck), also going slow will give you chance to stop an inch away from someone
who is blindly rushing on road to catch the kite.
Precautions during using fire crackers during Diwali
The Do's:
l Before bursting fire crackers, look for an open space and ensure there are no
combustible and inflammatory things around. If so remove them at once.
l Always buy fireworks from licensed and reliable sellers.
l Keep small children away from the bursting area.
l Use a sparkler, agarbatti (incense stick) or a long fire wood to light a cracker as
they keep you at a safe distance and do not possess a naked flame.
l Read the label on the crackers and follow the instructions carefully.
l While igniting aerial fire works like rockets ensure that they are not facing any
opening like an open window, door or an open building which may cause fire
accidents.
l Keep fireworks stock away while lighting a particular firework.
l Wear footwear while lighting fireworks.
l Keep a bucket full of water handy.
l Be prepared for emergency.
l Organize a community display of fireworks rather than individuals handling crackers.

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 l Keep first aid and buckets of water handy. In the event of fire, extinguish flame by
pouring water from the buckets. Every major fire is small when it starts.
l Light only one firework at a time, by one person. Others should watch from a safe
distance.
l In case of burns, pour large quantity of water on the affected area.
l In case of major burns, after extinguishing the fire, remove all smoldering clothes.
Wrap the victim in a clean bed sheet. The patient should be taken to a burns
specialist or a major hospital. Don't panic.
l In case of eye burns, wash the eye with tap water for 10 minutes and take the
victim to a hospital
The Don'ts:
l Do not wear nylon clothes. Prefer cottons while bursting crackers.
l Strictly avoid using matches and lighters for bursting crackers as they have open
flames that can be dangerous.
l Never ignite aerial fireworks (like rockets) if there is any overhead obstruction
present like trees and wires.
l Never ever leave a lit match, agarbatti (incense stick) or sparkler near unused
crackers.
l Never experiment with crackers or make your own fireworks.
l Avoid bursting fire works on roads.
l Never ever light a cracker in your hand. See to it that you put it down and ignite it.
l Don't keep your face close to the cracker while trying to light it.
l Do not throw fireworks at people.
l Never give any firework item to small children.
l Never try to burst crackers indoors or from inside a vehicle.
l Do not have fireworks in your pocket while igniting another.
l Do not tend to burst crackers when someone else is trying to ignite one.
l When crackers take time or do not ignite immediately, do not indulge in trying to
burst them.
l Rush to a safe place immediately. Throw some water to diffuse them.
l Never try to light used fireworks.
l Do not ignite fireworks in any container.
l Do not approach immediately the misfired fireworks.
l Do not tamper with misfired fireworks.
l Do not wear loose, hanging clothes. Secure all clothes properly.
l Do not apply any cream or ointment or oil on burnt area

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Holi Safety Tips
Here are a few tips and suggestion to make holi safe and joyous.
l Play safe. Don't get to boisterous and do not let others to be rude on you.
l The best option would be to play with natural home made colours. Your skin and
hair will feel tampered with the use of skin friendly natural products.
l If natural colours are not possible, then ensure a better quality of colours. Buy
colours from a reputed shop or vendor.
l Use more of red or pink colours which looks good and can easily taken off. Gaudy
purple, green, yellow, orange have more harmful chemicals in them and should
be avoided.
l Make sure that your face is well creamed before and after the play.
l Apply thick coating of paint on your nails- both in fingers and toes so that they
remain protected.
l Oil your hair well, so that colour doesn't stick on your hair and can be washed off
easily later.
l Cover your hair. Make use of hat or caps to protect your hair from being coloured
with hard-to-rinse dyes.
l Make sure that powder or any other product does not get inside your eyes. Eyes
are extremely vulnerable on Holi because of their strategic place in body and also
because of the use of harmful chemicals in colors these days. Please ensure that
your eyes remain protected at all times. Use a sunglass to protect your eyes from
a misfire of colour filled darts or water jets.
l Use dental caps to save your teeth from any unwanted stains.
l Put on your worst clothes so that you won't have to take on the hassles of an
immediate washing.
l Rags like tattered denims and bright shades like black, blue, green, purple are
highly recommended.
l Try to save yourself off from all possible attacks on the face. In case your such
attempts fail, keep your eyes and lips tightly shut if you are attacked on your face.
l If possible avoid going outside your home, atleast for the peak hours of celebration.
The premises of your home ensure that you are safe from pouncing hooligans,
even friends who can be a little rough on the day.
l When traveling keep the car windows thoroughly shut, even if you don't have an
AC car. Do not bump into the frenzied group of mob if you take to streets. Better
you cross the road to the sidewalk across. Or, simply stay at a safe distance.
l Do not use permanent dyes. If someone has applied it on you, do not rub the face
with soap immediately in order to get rid off it, especially when it is wet. Instead,
use good quality cleansing milk for removal. It's better than using soap, which will
dry up your skin.

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 l Rotten eggs when thrown on your head, flying missiles from locality buildings…are
still not too bad, will be smelly yet is a good conditioner for your hair. But tar, shit,
Mobil, stones and all the rubbish that you can be hit with is not. Avoid being a prey
to hooligans.
l Remember you also have police on your side and if any untoward revelers
misbehave, you can make your complaint. Mark out the locality, building and if
possible the person.
l Take a bath much later after the entire Holi celebration is over. Taking frequent
baths, washing the face again and again, will ruin your skin. You will also lose hair,
for too much soap/shampoo has a drying effect.
l If you are prone to skin allergies, avoid playing with gulal altogether. Going to a
dermatologist (skin specialist) serves no purpose, after the damage is done.
l Avoid running or jumping on wet floors, so that you don't slip and injure yourself.
Bones are especially vulnerable on this day.
l Avoid over indulgence in bhang, drinks or food... so that you don't repent later.
l Do not drive if you are high on alcohol or bhang.
l Keep handy pain killers, anti-oxidants, anti-allergic tablets if all the above tips
have been disregarded

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 LIST OF NOTIFIABLE DISEASES
Factories Act, 1948, Schedule III, [Sections 89 & 90]

LIST OF NOTIFIABLE DISEASES

1. Lead poisoning including poisoning by any preparation or compound of lead or
their sequelae.
2. Lead-tetra-ethyl poisoning.
3. Phosphorus poisoning or its sequelae.
4. Mercury poisoning or its sequelae.
5. Manganese poisoning or its sequelae.
6. Arsenic poisoning or its sequelae.
7. Poisoning by nitrous fumes.
8. Carbon bisulphide poisoning.
9. Benzene poisoning, including poisoning by any of its homologues, their nitro or
amide derivatives or its sequelae.
10. Chrome ulceration or its sequelae.
11. Anthrax.
12. Silicosis.
13. Poisoning by halogens or halogen derivatives of the hydrocarbons of the aliphatic
series.
14. Pathological manifestations due to-
(a) radium or other radioactive substances;
(b) X-rays.
15. Primary epitheliomatous cancer of the skin.
16. Toxic anaemia.
17. Toxic jaundice due to poisonous substances.
136 [18. Oil acne or dermatitis due to mineral oils and compounds containing mineral oil
base.
19. Byssionosis.
20. Asbestosis.
21. Occupational or contact dermatitis caused by direct contact with chemicals and
paints. These are of two types, that is, primary irritants and allergic sensitizers.
22. Noise induced hearing loss (exposures to high noise levels).]
137 [23. Beryllium poisoning.
24. Carbon monoxide.
25. Coal miner's pneumoconiosis.
26. Phosgene poisoning.
27. Occupational cancer.
28. Isocyanates poisoning.
29. Toxic nephritis.]
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 PROCESS SAFETY MANAGEMENT

The Proactive and Systematic identification, evaluation and mitigation or prevention of

Chemical releases that occur as a result of failure in Process, Procedures or Equipment is
called Process Safety Management.
Normal Causes / contributing causes of Process Incidents:
l Non Routine Operation
l Operation not covered by Procedure
l Hazards not clearly understood by Plant operating Personnel
l Equipments are changed - No PHA done
l Process Operated at wrong conditions
l Process Technology deficient
l Process Hazard review - inadequate
l Operator - unfamiliar with the task
Process Safety Management System consists of 14 Elements:
1. Technology
a. Process Technology or Process Safety Information (PT or PSI)
b. Operating Procedures and Safe Work Practices
c. Management of Change - Technology
d. Process Hazard Analysis (PHA)
2. Facility
a. Quality Assurance (QA)
b. Pre-Startup Safety Review (PSSR)
c. Mechanical Integrity (MI)
d. Management of Subtle Change
3. Personnel
a. Training & Performance
b. Contractor Safety
c. Incident Investigation & reporting
d. Management of Change - Personnel
e. Emergency Planning & Response
f. Auditing

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 1. Process Technology (PT/ PSI)

Process Technology provides a description of the process or operation. It provides the

foundation for identifying and understanding of the hazards involved.
There are three parts to the Process Technology:
1. Hazards of Materials
2. Process Design Basis
3. Equipment Design Basis
1. Hazards of Materials
All physical & chemical property data from a hazard point of view, to be developed,
documented & maintained current for each hazardous substance.
l Physical Data: Boiling Point, Freezing Point, Vapor Pressure & Flash Point etc.
l Corrosivity Data.
l Thermal & Chemical Stability Data.
l Reactivity Data.
l Toxicity Data.
l Permissible Explosive Limits.
l Hazardous effect that could foreseeably occur from inadvertent Mixing.
2. Process Design Basis
The Process Design basis consists of following:
l Block Flow diagram.
l Process Chemistry.
l Maximum Permissible Inventory of Hazardous Substances.
l Process Steps to include SOC Maximum, Minimum & Normal range for
Temperature & Pressure and Consequence of deviation.
3. Equipment Design Basis
Must be documented and communicated to all working in the plant:
l Process Flow Diagram including Material & Energy balances
l Basis of Equipment design.
l Material of Construction.
l Relief Systems - Design basis & Calculations.
l Protective Safety Systems.
l All Electrical data.
l Ventilation data.
l Design Codes, vendor Manuals.
l QA inspection reports of all Engg inputs.

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 2. Operating Procedures & Safe Work Practices

Operating Procedure:
l Provides a clear understanding of the detailed operating parameters & limits for
safe operation for those who operate the process.
l Explains clearly the Safety, Health and Environmental consequences of operation
outside process limits
l Describes steps to be taken to correct and / or avoid deviation
l Be consistent with PT(Process Technology)
l Address Process steps (Start up, Normal Operations, Shutdown, Emergency
Operations etc.)
l Contain a comprehensive SHE control section that addresses hazards presented
from Process Chemicals, Controls & Measures for containment.
l List of Standard Operating Conditions (SOC) for each process steps including
(Max, Min & Preferred / Normal and consequences etc.
l Identify RM & substances critical to Safety of process including Quality Specification
& Controls.
l Specify Pre-determined inventory limits per PSI
l Describe Safety Systems & their functions ([Link], Scrubbers etc).
l Describe Instrument Controls including Alarms & Interlocks.
l Readily accessible to personnel who work in or maintain a process
l Should be approved prior to implementation of any change in Chemicals,
Technology and Facilities.
Safe work Practices:
l Provides a planning system & Procedure and /or permits involving checks &
Authorization prior to performing non-routine work in process area.
l Safe Work Practices to be developed to ensure the safe conduct of operating &
Maintenance activities during non-routine work.
l Apply to site and contractor employees.
l SWP to include a work permit / authorization provision and would include the
following:
l Opening of Process Equipment & Piping.
l Lock out/Tag out of Hazardous Energy Sources.
l Control of ignition sources (Hot work Permit) except in welding shop authorized
by the Process Owner.
l Entry into Confined Space.

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 3. Management of Change-Technology

Changes to documented PSI (Process Safety Information / Process Technology) i.e. Hazards
of Material, Equipment design basis & Process design basis potentially invalidates prior
Hazard assessments and hence:
l All changes to the documented PSI subjected to the same rigorous review as that
of an New process.
Establish & Implement written procedures to manage changes to PSI which should
include:
l Purpose of Change.
l Technical Basis for Change.
l SHE impact which would include the following:
l Whether & New Process Hazard analysis required.
l If Yes -completed & approved review attached to MOC.
l Detailed description of change in a way that clearly illustrates & documents how
PSI is being modified.
l Modification to Operating Procedures (To be completed prior to implementing
change)
l Training & communication requirement for personnel.
l Limits for the change (Time period & Qty of material)
l Approval & authorization requirements.

What we do in Change Management - PHA

l Objective of this system is to identify, evaluate, understand, eliminate & control any
hazard which is brought into the system due to changes done to Technology, Facility or
Personnel.
l In UPL, we have 3 types of Changes we do:
l Changes to Technology (Process Design Basis or Equipment Design basis or
Hazards of the Material)
l Changes to Facility (All Changes which are not Technological Changes)
l Changes to Personnel ( Movement of People)
l All Changes to Technology or Facility or Personnel routed through Change Management
Process.
l For all Changes to Technology or Facility - PHA by xWhat ifx methodology is Mandatory.
It is mandatory for all stakeholders - Process, Mechanical, Electrical, Instrumentation &
Safety to participate and contribute in the PHA and absence of any of the above member
will make the PHA ineffective and we would have missed any of the critical hazards
which can lead to an incident post startup of the changed system.

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 l If the Risk Factor is less than 3 as identified in PHA, it will be a Minor change.
l For Changes to Personnel - Level 2 Training & Validation Mandatory before a
person can be given independent charge (If the Change is within the Unit)
l For Changes to Personnel - Level 0, 1 & 2 Training & Validation Mandatory before
a person can be given independent charge (If the Change is between units)
l Execution of the Change cannot be started unless the Change Management is
Authorized by the Unit Head.
l The Changed System cannot be started unless all the recommendations of PHA
is complied with.
l For Major Changes involving Capex, detailed PSSR needs to be done and all Cat
A recommendations to be complied with before startup

4. Process Hazard Analysis (PHA)

PHA is used to identify evaluate & Control hazards associated with hazardous process
& facilities in a way that the Hazards are addressed proactively and all Process related
incidents are prevented
l Utilizes an Organized, Methodical Approach.
l Seeks and achieves multi-disciplined consensus.
l Documents results for future use in follow-up and training of personnel so that
injuries and Process related incidents are prevented.
Consist of 2 parts:
l Consequence analysis (CA).
l Process hazards review (PHR).
Consequence analysis (CA).
l An estimate of a range of potential release quantities usually expressed as release
rates that might occur as a result of failure of Engineering or Administrative control.
l An Estimate of the downwind effects (Concentration vs. distance) for Toxic &
Flammables, Heat effects for ignition of flammable clouds & over pressure grids
for explosive substances.
l An estimate of the impact of surrounding population & the Environment (On site
& Off site)
l STAGE-1: Process Hazard review at Basic Engg Stage (Conceptual Safety)
l STAGE- 2: Process Hazard review before the CAPEX approval
l STAGE- 3: Detailed Process Hazard Review after CAPEX approval on the detailed
design.
l Pre-Start-up Safety Review -Related process Safety Management to ensure final
check on all PHR recommendations.

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 What we do in PHA

1) Objective of PHA system is to provide guidelines so that all process related hazards
of any upcoming Project or Major retrofitting Projects are proactively identified, evaluated,
understood and controlled to prevent all process related incidents leading to injury,
property damage & toxic releases.
2) 3 Stage PHA is done for all New Projects of a New Molecule
l Stage I - is the Conceptual Safety at Basic Engg Stage (BFD Stage)
l Stage II - is during design stage to ensure that all the Stage I recommendations
have been included as a part of design and any unidentified Hazards are addressed
(PFD Stage)
l Stage III - After design is completed and to address any left over Hazards in the
Process is addressed (P&ID Stage).
3) For existing Molecule which we are already producing, we do straightaway Stage
III PHA
4) Methodologies / Techniques which are used by UPL are 1),2) and 3) from below:
1) What if (By Brain Storming) - Used mainly in Stage I
2) What if (By guidewords) - Used Mainly in Stage II
3) HAZOP (Hazard & Operability Study) - Used mainly in Stage III
4) Check list
5) Combination of what-if & Check list
6) FMEA (Failure Mode Effect Analysis)
7) Fault Tree Analysis.
5) Process hazard Analysis is a comprehensive analysis of process hazard & consists
of six elements:
l PHR - Process Hazard Review
l CA - Consequence Analysis
l FS - Facility sitting
l SIS - Safety Instrumented System
l HF - Human Factor
l ISP - Inherently Safer Process
6) Following are the situations in which we do a PHA proactively.
l Any Experimentation in R & D for a New Product.
l Addition of a new product in the portfolio of manufacturing in the Unit.
l When there are significant revisions or additions of process.
l As a part of Change Management (Technology & Facility)

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 l A New Facilities involving project level investment.
l Smaller changes and project authorized within the site Change Management
processes when a hazard evaluation is deemed applicable.
l Mothballing or abandoning a process facility in place by setting and maintaining it
in a safe condition until full dismantling is completed.
l Change of Route of chemical Manufacturing.
l Restarting of a mothballed process facility if restarting after the scheduled
revalidation date of the previous cyclical review.
l Dismantling a Process Facility.
l Change in operating Conditions.
l Change in a Safety device setting or its calculation basis.
l Change in a Safety alarm or Interlock.
l Change introducing New Chemicals or Intermediates in the Process.

7) In UPL, we choose from the below Methodologies of PHA:

What IF / FMEA HAZOP FAULT

CHECKLIST TREE
Experimental X o
Basic Data X (What if -
(Project - Both Brainstor
Green Field & ming)
Brown Field)
Pre- X (What if -
Authorization Guidewords) o o o
(Project)
Design Stage X o
Existing Facilities
(Critical Processes) X o X o
Existing Facilities
(Non Critical
Processes) X o o o
Change Management X o o o
Facility Shutdown X o

X - Minimum
o - Optional

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8) Frequency of PHA :
i. Baseline PHA -
1. We do baseline PHA for all New Projects and Expansions before setting up
the New plant.
ii. Cyclic PHA-
1. All the units of UPL are high hazard processes and in view of the same, a
cyclic PHA must be done once in 3 years from the date of the sign off of the
baseline PHA. Consideration is being given to reduce the review frequency
to less than 3 years for process that experience many process safety incidents,
have extreme hazards, or are subject to frequent significant changes due to
business dynamics.
2. If there is any process safety incident which has happened in any plant,
PHA of whole plant is carried out within same financial year or utmost the
next financial year.
3. If there is Change Management (Technology type) more than 5 numbers per
year in a particular plant then Cyclic PHA of that plant is carried out within
the same financial year or utmost the next financial year
4. PHA of following critical processes to be carried out every year:
a) Isomerization
b) Perkow reaction
c) Oxidation
d) Nitration
e) High Pressure Reaction > 5kg / cm2g
f) Chlorine storage
g) EO storage
g) PCl3 storage
h) Acrolein Storage
9) Following is the PHA Team Composition for doing a PHA:
i. Process Lead
ii. Project Lead
iii. Mechanical Lead
iv. Electrical Lead
v. Instrumentation Lead
vi. PHA Leader
vii. External PHA Expert (As and when needed)

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 10) Whatever recommendations arise out the PHA, they are categorized as Cat A,
Cat B and Cat C.
11) Unless all the Cat A recommendations are complied with, startup cannot be done.
Also UH signs off a clearance that it is safe to startup the plant after complying to
all Cat A Recommendations
12) Cat B recommendations needs to complied within 15 days from the Startup
13) Cat C recommendations needs to be complied within 30 days from the startup

5. Quality Assurance (QA)

Bridges the gap between design specifications and the initial installation.
Focus on to ensure that the Process Equipment is
l Fabricated in accordance with Design Specification,
l Delivered to the proper location,
l Assembled and installed properly.
l Design basis & criteria documented & communicated to operation & Maintenance
personnel as part of the Process Safety Information.
QA program to include:
l Written QC procedures for fabrication of critical services to ensure that the
equipment are fabricated and delivered meet design specs.
l Appropriate checks & inspections to ensure that critical equipment is installed
properly & consistent with design specs and as per vender recommendations.
Equipment critical to process safety must include but not limited to
l Pressure Vessel & Storage Tanks
l Piping systems (including components like Valve s, relief Systems and vent Systems
and Devices
l Emergency shutdown system.
l Controls (including monitoring devices & sensors), Alarms & interlocks.
l Fire protection system.
l Interlocks

6. Pre-Start up Safety Review (PSSR)

Provides a final checkpoint for new and modified equipment.
A final checkpoint that all appropriate elements of PSM addressed satisfactorily.
Purpose is to confirm that prior to introduction of hazardous substance to a facility, the
following elements are in place.

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l Construction & equipment's are in accordance with design specs.
l All PSI parts appropriately documented & communicated to Process owner so
that such information is readily available to facility personnel.
l PHA recommendations addressed & action necessary for start-up completed.
l MOC documentation completed.
l Safety, operating, maintenance & emergency procedure in place, adequate ,
Authorized & consistent with PSI , incorporated all PHA Recommendations
l Training of operating and maintenance personnel completed.
l MI systems established & are in place.
l Basic safety, Health & environment items checked one last time during a physical
inspection of the facility - guided by a prepared checklist.
l Facility is safe to start up.
l To be conducted by multi-disciplinary teams (Mfg., Tech., Mech., Elec. & Safety).
l PSSR documented, Signed off by review team and authorized by Process Owner.
l Conclusion that the facility is safe for startup.
l A system established & controlled by Unit Head to ensure compliance of
recommendation prior to introduction of any hazardous Material.

What we do in PSSR System in UPL

l PSSR is Pre-Startup Safety review by a Team
l PSSR is the final check of the mechanically completed Facility which we do before
startup of a New Facility.
l PSSR should not be done if the facility is not completed mechanically completed
in all respect.
l We have a detailed checklist for doing PSSR in UPL.
l The Checklist covers all aspects of a Chemical Industry as below:
l General Safety
l Machinery Safety
l Ergonomics
l Occupational Health
l PSM Elements - all 14 Elements
l Interlocks and Alarms
l Environment
l Emergency Preparedness
l Electrical Safety

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 l Fire Protection
l Statutory Clearances
l Materials
l Manufacturing Management Safety
l Quality Control
l Manpower
l Infrastructure
l Housekeeping & Aesthetics
l PSSR to be done by a team consisting of following members:
l Process
l Mechanical
l Electrical
l Projects
l Instrumentation
l Safety
l Unless Cat A recommendations are complied and the Unit Head gives clearance
in the standard PSSR format, the new facility cannot be charged with Chemicals.
l Cat B recommendations to be complied within 15 days
l Cat C recommendations to be complied within 30 days.
l All legal compliance related recommendations is categorized as Cat A

7. Mechanical Integrity (MI)

l This covers the life of the facility from the initial installation through dismantlement.
l Focuses on ensuring that system integrity to contain hazardous substance is
maintained throughout the life of the facility.
l Maintenance procedures are established & implemented to ensure MI.
l Training and performance of Maintenance Personnel.
l Maintenance personnel are trained per PSM requirement.
l Quality control procedures established to ensure maintenance Materials, spare
parts & equip. design specs are met.
l Equipment tests and inspections including predictive and preventative
maintenance.
l Predictive & preventive maintenance programme established for process safety
critical equipment consisting of inspection & tests to detect impending or minor
failure & procedures to mitigate their potential before they can develop in to more
serious failure.

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l Reliability Engg. Analysis - On going Reliability Engg Analysis for all process safety
critical equipment's. (Reliability Engg is the process of evaluating how long a system
and its individual component can be operated safely before they are taken for
Maintenance or replacement.

8. Management of “Subtle” Changes

Subtle Changes are those changes done in the field which does not lead to any change
in any of the Engg Drawings.
l Subtle changes in the field can lead to & have led to catastrophic events.
l All changes (However small -not replacement of kind) receive appropriate review
and approval.
l PSM requirements for all such modification established /documented &authorized.
l Site to establish & implement written procedure to manage subtle change to facility.
l Communication to ensure understanding of ;
l What constitutes a change?
l Difference between a technology change & subtle change.
l System in place to manage each type of change

9. Training & Performance

l Properly performing personnel are not only a key critical but an absolute
requirement to ensure safe Operation.
l All other elements of PSM can be in place, but w/o personnel who are dedicated
to consistently following documented policy and procedures, the chances of unsafe
operation operations high.
l Knowledgeable, well trained employees alone do not ensure safe operations that
are free from human error.
l Essential that employees are physically able, mentally alert and capable of using
good judgment to properly follow prescribed practices.
l Develop document & Implement Training Policies which includes
l Initial Training - Trained & qualified before working in newly assigned process.
l Training emphasis on specific safety & Health hazards, Emergency procedure,
SOP, SWP applicable to job task.
l Refresh Training & Re-qualification at appropriate interval.
l Qualification of the Trainer
l Basic skills
l Job tasks
l Emergency response & control

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 What we do in Training & Performance System
l A well informed employee always takes a well informed decision which makes a
chemical operation safe devoid of any mistakes by our operating personnel.
l The purpose and objective of this system is provide inputs in the form knowledge
through various trainings to achieve the above objective
l Training is provided in following situations in UPL
l When an Employee joins UPL,
l Level 0 & 1 Training is given by Safety & HR
l Level 2 training is given by the HOD of the Department in which he
joins.
l Level 2 training topics are defined in the Training & Performance
procedure. The topics are different for different Functions
l Monthly Theme based Safety Training
l Every month we have One Safety Training which is given to all members
of Manufacturing in the Unit (Except HR, Finance & Purchase)
l Safety Lead / Safety Manager of the unit gives this training to all PSR's
and HODs
l PSR's in turn after they are trained in above give the same training to
their team.
l The training material could be a Video Film or Presentation.
l Training effectiveness is calculated of the above training thru a small
test of 10 questions to all the staff.
l Training Effectiveness of the Plant = {Number of Members Attended /
Total number of members in the Team X Addition of Actual Score of the
attended Members / Total Marks for all Attended members}
l The overall Training effectiveness of the Unit is calculated by
= {Number of Trainings Actually Conducted / Number of Trainings
Planned X Number of Members Attended / Total number of
members in the Team X Addition of Actual Score of the attended
Members / Total Marks for all Attended members}.
l When an Employee is transferred either within the Unit or from another
Unit or from one Function to another Function
l Level 0, 1 & 2 Training is provided to all Employees transferred
from one unit to another unit.
l Level 2 training is provided to all Employees who are transferred
from one Plant to another Plant
l Level 2 training is provided to all employees whose function is
changed within the Unit.

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 l In case an employee is transferred from One Unit to another Unit
and his function also changes, he is given Level 0,1 & 2 training.
l When an employee return after a long leave (Leave of 10 &> days)
l Debriefing training by the HOD to make him aware of the changes
happened in the plant during his absence so that he does not take
wrong decision leading to a Safety Problem.
l When an employee is sent for outside Safety Training
l Within 15 days of his external training, he needs to prepare a training
presentation and conduct a 2 hours training to all his peers and HOD's

10. Contractor Safety

l All Tasks must be completed safely& performed as per procedures and / or safe
work practices, consistent with PSM- whether by site employees or by contract
employees.
l Applicable to both operating & Maintenance Contractors & to contractor exposed
to process hazards.
l Contactor's safety performance evaluation to be part of contractor selection.
l Establish clear lines of communication between site contract administrator&
contactor.
l Inform contactor of known hazards related to his work.
l Inform safety rules & procedures of site including SWP for control of Hazards.
l Explain any applicable provision of emergency response.
l Maintain a contract employee injury & illness log & review periodically.
l Periodically evaluate contactor performance in fulfilling responsibilities as below;
l Ensure each contract employee has necessary job skill Training & qualified
to perform contracted work safely.
l Ensure each contract employee receives & understands training on safety
rules, & SWP.
l Document that each contract employee has received & understood the require
training.
l Ensure that each contract employee follows site safety rule & SWP.
l Establish program to ensure that each contract employee is fit for duty w/o
external influence.

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 What we do in Contractor Safety Management System - CSM

The Objective of CSM is to make Contractor Safety becomes an integral part of overall
Safety Management System of site and to ensure that all Activities performed by contract
employees are conducted in a safe manner without any incidents of Safety
l Each site has assigned SCA (Site Contract Administrator) who is the lead person to
implement CSM in the site.
l SCA has assigned FCA's for each contract who play the role of Field Contract
Administrators to manage Safety of Contractors working for them.
l Normally FCA's are assigned based on the trade of work like Mechanical / Electrical /
Instrumentation / Painting / Insulation etc.
l If the Unit is large, an FCA's can be assigned for managing more than one contractors
of the same trade and in view of the same, their could be more than one FCA for each
trade due to large number of Contractors. However an Electrical Member of UPL will
take care as FCA of Electrical Contractor only. Same is the philosophy for other Functions
like Mechanical, Instrumentation. Painting Contractor, Insulation Contractors will be
part of the Mechanical Trade.
l Three Categories of Contractors work in UPL
l Cat A - Assist Production Team in Production
l Cat B - Assist Engineering Team in Maintenance
l Cat A - Service Contractor - Like Security / Canteen / Horticulture
l All Contractors of a Project is Cat B
l CSM for Cat B has been implemented in all UPL Units
l CSM A has been implemented only in Unit 0 & 5
l Assignment of CSS :
l Every Cat B Contractor who has strength of 11 and upto 50 will have a CSS
(Contractor Safety Supervisor)
l In case the strength is > 50 and Upto 100, the contractor will assign 2 CSS.
l In case the strength is > 100, the contractor will assign 3 CSS
l All the CSS will be Safety Qualified personnel
l Major responsibilities of CSS:
l Undergo regular Weekly Safety Training given by UPL Safety
l Conduct Daily Tool Box Talk for his team
l Capture Near Miss thru his team.
l Ensure all his tools and equipment's are inspected thru UPL and Status of inspection
displayed thru a Sticker on each and every equipment.
l Get all Unsafe Conditions and Unsafe Act of his area of work corrected.
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 l Provide required PPE's to his team members
l Ensure all members of his team are complying to PPE's at all times
l Nominate any of his members who is following Safety religiously for UPL award.
l Conduct regular walk thru Safety Audit of his work place
l Report any Near Miss / Incident immediately to CS or FCA
l Below activities are done as a part of CSM
l Contractor Safety Screening for new contractors to understand Safety Competency
of the Contractors.
l SHE requirement from Contractors - accepted and duly signed by the Contractor
Owners as declaration.
l All Contract employees to have a Photo ID
l All Contract employees have to undergo SHE Orientation by Safety which is valid
for 3 Months
l All Contract employee to submit Medical Fitness Certificate after medical
examination duly done by UPL Authorized Hospital / Doctor
l All Contract Employees to undergo routine medical examination by FMO every 6
months
l Stamping of the SHE Orientation is done at the back of the ID
l All Contractors to conduct Daily Tool Box Talk for all his Employees
l All Tools & Equipment of Contractors to be inspected by UPL and Sticker displaying
the status of inspection and next due date of Inspection. Inspection is valid for 3
Months only.
l All Lifting Tools and Equipment will have TPI (Third Party Inspection) every 6
Months.
l All Fork Truck Pilots to be Godrej Trained or Equivalent and carrying the Training
Card in person.
l All Fork Truck to perform Operations and Maintenance Checks as per the Standard
Checklist given by UPL.
l All Contractor employee who has to work at height has to undergo Vertigo test
and medical check up by FMO to ensure fitness to work at height.
l Red Cards are issued to contractors by SCA, FCA and SM for violating any of the
Safety Standards of the site
l FCA's to conduct Weekly Safety Performance review of their contractors and
circulate MOM to SCA, UH and SH.
l FCA's and SM to conduct Contractor Field Audit as per the Standard Checklist
once in a week
l SCA to conduct Contractor Field Audit once a Month

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 l SCA conducts Monthly Safety Performance Assessment and gives Score against
total of 140
l FCA's nominate Contractor employees for good Safety Performance.
l Evaluation of the nominees are done by SM and FCA together to not to have a
bias.
l Contractors scoring 40 to 45 in evaluation gets an award of Rs 500 and those
scoring from 46 to 50 are given an award of Rs 750.
l SCA approves awarding

11. Incident Investigation

l Serious incidents and serious potential incidents recur unless key factors are
identified and corrected.
l Thorough and persistent investigation of all serious and Serious Potential Incidents
coupled with action directed to prevention of recurrence continually improve safety.
l Process related accidents to be reported.
l Incident investigation to be initiated &detailed report circulated within 4 days.
Report to include:
l Date & Time of incident.
l Date & Time of investigation.
l Detailed description of incident.
l Details / learning's - factual information arising from the investigation including
chronology as appropriate & pertinent fact.
l Key factors - (Human factor, rules & procedure , machine, material )
l System elements that need to be strengthened
Recommendations must include:
l Responsibilities.
l Time line.
l Investigating member names.
l Approval by Unit head.
l Follow-up system to be established to ensure prompt resolution of recommendation.
l All recommendations, resolution and corrective actions to be documented and
maintained along with incident report file.
l Incident investigation tracking mechanism.
l Incident Investigation close out report

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Analysis of incident, trends & focus shall be on
l Prompt detection of significant change.
l Prevention of recurring incidents.

What we do in Incident Investigation & Reporting

l Whenever an Incident happens, FIR needs to be sent to top Management within
4 hours
l Detailed investigation to be done & investigation report to be circulated within 4
days to the top management
l Incident classification:
l LTI - Loss Time Injury
l RWC - Restricted Workday Case
l MTC - Medical Treatment Case
l LTI + RWC + MTC = Recordable Injuries
l DO
l Minor DO or DO
l MPSI (Major Process Safety Incident - Major Fire or Major Toxic Release
or Explosion)
l FAC - First Aid Case
l Investigating Team - Plant HOD + Mech + Electrical + Instrumentation + Safety
in case of all Incidents except in case of LTI and DO where UH and SH will also be
part of the Investigating Team.
l Fish Bone analysis to be mandatorily used for the investigation.
l CAPA and the timeline needs to be identified and agreed with the FPR.
l CAPA of the investigation to be implemented within the timelines in report
l Safety to verify the CAPA at site and to reopen in case the CAPA is not implemented
completely or the CAPA is not effective
l Safety Manager to circulate the Investigation report to other Unit Safety Managers
for sharing and identifying lateral deployment opportunities
l Other Unit Safety Manager to immediately share the investigation report with all
HOD's and PSR's of the Unit in the PSR meeting.
l Other Unit Safety Manager to study the Investigation report and identify Lateral
Deployment opportunities to prevent that type of incident in his Unit.

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 12. Management of Change - Personnel
l Unit to develop & Implement criteria & procedure /guidelines regarding MOC -P
to ensure minimum levels of skills/knowledge are maintained to manage process
safety.
l Provide training to line Manager & Tech. personnel newly assigned to chemical
process involving hazardous material & such training to address.
l Basic Process Safety Management.
l Technology & PSM specific to the operations.
l Line supervisor newly assigned to chemical process must develop & demonstrate
degree of proficiency within 03 months.
l Methodology can take a format of a review of Hazards of Operations, including
lines of defense to a groups of managers and (or peers familiar with operation.)
l People are the essential ingredient that is interwoven through all of the elements
of PSM, it is important to maintain the minimum level of
l Specific direct process experience, and
l Knowledge and skill in managing Process Safety.
l Loss of minimum levels of experience and knowledge through personnel
movements, and organizational changes (like changes to technology or facilities)
potentially invalidate prior hazard assessments which are based upon
knowledgeable people being present and in charge.
Minimum levels of experience and knowledge is always maintained

13. Emergency Planning & Response

l In depth planning for potential emergencies is essential for ensuring aneffective
response by site personnel working in close conjunction with supporting response
organization.
l The important products of these effects are
l Mitigation of impact on Personnel, Environment & Facilities
l Prompt control of emergency situation.
l Site to conduct & utilize CA as input to the ERP efforts.
l Written emergency action plan to provide for mitigation of the potential effects
arising out of the CA.
l Plan shall address a range of release quantities.
l Plan to be developed in conjunction with local Community ERP.
l Plan to address following areas.
l Activation of Emergency Action Plan including notification of & Co-Ordination
of efforts with appropriate emergency response organization.

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 l Notification of affected personnel, appropriate regulatory agencies.
l Escape & evacuation routes & plans.
l Personnel accounting.
l Rescue operation including medical assistance.
l Designation of primary & secondary control center.
l A written emergency action plan to terminate any release of hazardous material &
to bring under control any resulting fire and / or explosions.
l Plan to address:
l Emergency shutdown procedures including isolation, venting or purging as
appropriate.
l Activation of Emergency system such as water sprays or deluge system.
l Acceptable repair procedure
l Activation of spill clean-up procedure.
l Barricading
l Activation of local response management system.
l Training site personnel in prompt & efficient Implementation of ERP & control and
to include following:
l Mock drill at appropriate frequency(Unplanned & planned)
l Involvement of local response management in drill at frequency.

What we do in Emergency Preparedness System in UPL

l Each Unit has On Site Emergency Response Plan
l Various credible Loss scenarios have been identified in the Emergency Response
Plan.
l Plant Level Mock Drills are conducted every month
l Table top exercise is also conducted regularly
l Unit Level Mock Drills are conducted every Quarter
l We have very Objective mechanism / Process for rating the Unit Level Mock drills
and each Unit Level Mock Drill is rated by a Second Party Observer from other Unit.
l Mock Drill rating is considered as one of the Parameters for Unit Assessment as
Emergency Preparedness of the Unit.
l Each Unit has > 45 ERT Members who are continuously trained on emergency
Preparedness thru an external expert agency (Loss Control Services) on mitigation,
rescue and salvage.
l Each Plant of all Units has at least 4 to 5 ERT members in the team to ensure
complete coverage
l Every year we conduct ERT Competition to create a motivating environment to
motivate the ERT members and also to check the agility of the ERT teams. The
judges are Third Party Judges to eliminate biases in judgment
l ERT members have a special Helmet color (Green) to easily identify them.

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 14. Auditing
l The Only way one can know and understand - How one is really doing is by
observing (in the field) and comparing with the established standards.
l Positive feedback on significant strengths.
l Corrective feedback on areas needing improvement.
l Develop & implement procedure for Auditing process facilities with site PSM
guidelines.
l Procedure to address :
l Internal Auditing (First Party): Auditing by operating organization.
l External auditing (Second Party): Second Party Auditors.
l Audits to be conducted using prepared check lists for each of elements of
PSM.
l Facilities to be audited once in 3 months for all elements.
l Result to be documented & reported to site safety & health committee.
l Non Compliance to be promptly addressed & corrected as per the time line.
l Third Party auditing: Auditing done by an external Consultant / Agency external
to UPL.

What we do in Second Party Safety Audit System in UPL

l Audit is reality check of the actual Safety Performance against set standards /
Systems of Safety.
l UPL has 3 Second Party Safety Auditors located at Unit 0, 2 & 5.
l Second Party is done not only to identify gaps in the Safety Systems, but also to
work closely with the HOD's to bridge the gap and take compliance level to a
higher level.
l One Auditor does Audit of Unit 3 & 5, One does for Unit 1,2 & 4 and One does for
Unit 0 & 10.
l Process of Second Party Safety Audit commenced in Qtr 2 of FY 2015-16 in Unit
1,2,3 & 5 and in Qtr 4 in UNIT 0 & 10
l There are 14 Safety Systems with a very defined and detailed Protocol for each of
the Safety Systems which are as follows:
1. Facility Safety
2. PSR System
3. Incident Investigation and Reporting
4. CSM A
5. CSM B

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 6. Electrical Safety
7. Change Management - PHA
8. PHA
9. PSSR
10. Construction Safety
11. Training & Performance System
12. BBS
13. Work Permit System
14. Emergency Preparedness
l Audits are done Quarterly
l The second Party Audits are scoring audits

What is Operational Discipline?

Deeply rooted dedication & Commitment by each member of the organization to carry out
each task the right way each time.
Key indicators of Operational Discipline:
1. Leadership - Leading by Example
2. Sufficient resources & support safety programme
3. High degree of employee involvement
4. Open & Active lines of Communication
5. Strong sense of team work
6. Common shared values
7. Current up to date documentation (SOP, Records, P&ID etc.)
8. Practice consistent with procedure
9. No shortcuts (Examples of job being stopped whenever there is a safety problem)
10. Housekeeping of highest order
11. Pride in work & the organization.

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 PSR SYSTEM

What we do in PSR System

l Safety of a Site cannot be managed by few people in the Organization.
l Concept of PSR was initiated to have extended arms for managing Safety of
Units.
l Each Plant / Area / Section of the Unit has nominated PSR (Plant Safety
Representatives) to lead Safety in individual Plants / Areas / Section of the Unit.
l The responsibilities of PSR of each Plant / Area is well defined to cover fundamental
aspect of Safety of each Plant / Section and hence coverage of the whole unit.
l The Process of PSR is facilitated by Safety Function
l Some of the Key responsibilities of PSR (All Functions put together) are as below:
l Provide Monthly Safety Training (Theme based Safety Training) to all
members in his team
l Ensure that no new joinee is given independent charge of work without having
undergone level 2 training
l Take One Safety Initiative per week to continually improve safety in his Plant
/ Area.
l Ensure that all rotating parts of all machines in his Plant is properly guarded
to prevent injury.
l Ensure that no changes to Technology or Facility or Personnel is done without
a formal Change Management - PHA process.
l Capture Safety Abnormalities (Near Miss, Unsafe Condition, Unsafe Act)
through his team
l Proper Analysis of all Near Misses of his Plant
l All Safety Interlocks of the Plant are tested as per the defined frequency
l Safety Shower & Eye Wash are tested and ensure that it works all the time
l Fire Extinguishers are in Good Working Condition
l Fire Hydrants are working and access always kept free
l Safety Valves, Rupture Disc's & Orifice in his Plant is tested as per the defined
frequency. The Status board duly kept updated all the time.
l Ensure that there are No leakages / Spillages in the plant and get it attended
in case it happens.
l Do 2 no's Behaviour based Safety Observations every month to improve
Safety behavior of the members (UPL + Contractors) working in his Plant.
l Ensure 100% PPE compliance in his Plant / Area.

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 l Take actions which have been decided in the PSR meetings
l Ensure proper documentation of Change Management - PHA of his Plant
l All Chemicals in the Lab are properly labelled and identified
l No damaged Glassware is used in the Lab and they are disposed off Safely
l Compressed Gas Cylinders in the Lab are stored as per the Standards.
l Daily Tool Box Talk is conducted by his contractors.
l Ensure that all Tools / Equipments of his Contractors are duly inspected and
inspection status sticker displayed properly with Validity of 3 Months.
l Red Cards are issued to his contractors for any Safety Violation
l Weekly Safety Performance of his Contractors is done & gaps are identified
and corrective actions are taken to bridge the Safety gaps.
l Ensure PPE Compliance by all Contractor employees of his contract
l Conduct the Contractor Field Audit as per CSM
l Ensure provision of Rubber Mats for all Electrical Panels
l All Electrical Panel doors are closed and locked.
l Ensure Inspection of all Material Handling equipments like Fork Truck / Hand
Pallet trucks / Stackers.
l No Spillage of chemicals in the store
l PHA done for all New Experiments in the Max Pro / R&D Labs
l MSDS of all Chemicals being handled available in the QA / Max Pro / R&D
Labs.
l All the above responsibilities are part of the PSR effectiveness.
l Weekly PSR meeting takes place to review PSR activities and actions identified
to improve
l PSR effectiveness is calculated every month for all PSR's of all Plants / Areas in
all Units.
l There is a 3 step process for finalizing the PSR effectiveness
l Step One - Self Assessment by PSR
l Step Two - Rating by HOD and Safety Lead together on above
l Step Three - Final rating of the PSR by UH
l The Average PSR effectiveness of all PSR's is reported in the MIS

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 Behaviour based Safety Management System

A BBS approach is one which:

l 96% of the injury happens due to At-Risk behavior of the people
l Is based on solid principles about engaging, motivating, assisting, reinforcing,
and sustaining safe behaviors.
l Takes a systematic approach, examining the motivation underlying behaviors, in
order to increase safe behavior.
l Is an ongoing effort; not 'once-off' provisions, but a new way of working that the
safety leader must continually promote for sustainable, positive results. Takes
time to achieve; however, results can be observed immediately due to the nature
of measurement involved.
l Emphasizes increasing safe behaviors rather than focusing on length of time without
injury. BBS programme do not depend solely on 'lagging indicators' (after the
fact), and instead shift the focus to 'leading indicators' (preventative).
l Is not a substitute for an already existing comprehensive health and safety
programme; it is a supplementary tool that will enhance the effect of already existing
practices, and will allow for an objective measurement system.
l Aims to understand causes of incidents and near misses and correct them through
the behavior of relevant people. For example, reducing hazards often requires
behavior change of managers and frontline workers, and equipment redesign
involves behavior change of engineers.
l The aim of the behavior-based approach is to reduce the occurrence of at-risk
behavior by modifying such behaviors through observation, feedback, and positive
interventions.
l Behavior-Based Safety refers to the use of applied behavior analysis models to
achieve continuous improvement in safety performance. In-depth research about
what works and what doesn't.
l Behavior is a Function of Consequences
The ABC's of BBS
Despite the fact that we rely heavily on antecedents, it is consequences that have the greatest
influence on behavior.
l Antecedents - According to Thomas Krause, antecedents are preexisting sensory
or intellectual input that trigger behaviors and influence decision-making. A stimulus
or event that occurs before a behavior in time. This stimulus or event may result in
the behavior. Work examples include goals, policies, training, job aids, and guides.
l Behavior - According to E. Scott Geller, behavior refers to acts or actions by
individuals that can be observed by others. In other words, behavior is what a
person does or says, as opposed to what he or she thinks, feels, or believes.

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l Consequence - A stimulus or event that occurs after a behavior in time. This
consequence could increase or decrease behavior in the future, depending on its
reinforcing or punishing properties. Work examples include feedback, recognition,
task completion, goal achievement, rewards. According to Aubrey Daniels, a
consequence is simply what happens to the performer as a result of the behavior.
Definitions related to BBS observation:-
l At Risk : The act of person which is having potential to cause any injury or ill
health or a combination of these
l Safe : Freedom from unacceptable risk of harm
l Risk assessment: process of evaluating the behavior of persons actual act arising
from a at risk behavior done during the working, taking into account the adequacy
of any existing controls, and deciding whether or not the at risk behavior is
acceptable.
l Workplace: any physical location in which work related activities are performed
under the control of the organization
l Control measures: Action initiated by means of elimination; substitution; re-
engineering, administrative measure and usage of Personnel Protective Equipment.
Steps for BBS observation:-
l Following are the steps of doing an effective BBS Observations
l Make Visual Contact
l Introduce yourself in a nice way or initiate discussions to create a rapport.
l Appreciate any safe behaviour you observed.
l Positively reinforce the safe behaviour.
l When you give positive comments, note below
l Comment has to be real.
l Comment is about something important
l Question to explore & learn and NOT to teach.
l Stop the unsafe act / behaviour
l Talk with the employee about the
l The consequence of the unsafe behaviour
l Comment on the unsafe Act to express your concern.
l Focus on the effects not on the unsafe act.
l Question to explore & learn and NOT to teach.
l Arrive together Safe way of doing the work.
l Get the agreement & commitment of doing the work Safely
l Discuss other Safety issues
l Thank the employee

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 What we do in BBS System in UPL

l 96% of the Injuries happens due to At-Risk behavior of the People.

l Behavior has a very important role to play in reducing injuries
l Injury can be reduced by Compliance & Management Systems to certain extent
only
l But behavior change is what brings the injury to a very low level
l All PSR's and HOD's (in many of the Units) have been trained in doing BBS
l PSR's do 8 Observations per Month and HOD's 4 per month.
l Behavior based Safety Observation is a coaching process to correct At Risk
behavior of the people.
l Following are the behaviors which are observed during BB Safety Observations:
l Reactions of People
l PPE Used
l Position of People
l Tools and Equipment usage
l Organization of the Work Place
l Work Procedures
l Following are the steps of doing an effective BBS Observations
l Make Visual Contact
l Introduce yourself in a nice way or initiate discussions to create a rapport.
l Appreciate any safe behaviour you observed.
l Positively reinforce the safe behaviour.
l When you give positive comments, note below
l Comment has to be real.
l Comment is about something important
l Question to explore & learn and NOT to teach.
l Stop the unsafe act / behaviour
l Talk with the employee about the
l The consequence of the unsafe behaviour
l Comment on the unsafe Act to express your concern.
l Focus on the effects not on the unsafe act.
l Question to explore & learn and NOT to teach.
l Arrive together Safe way of doing the work.

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 l Get the agreement & commitment of doing the work Safely
l Discuss other Safety issues
l Thank the employee
l The output of the BBS observation are
l Safety Commitment (Safety Observations Plan Vs Actual done)
l Safety Climate
l Number and % age of At-Risk behavior corrected

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EMERGENCY PREPAREDNESS FOR NATURAL EVENTS

EARTHQUAKE
l An earthquake is a sudden, rapid shaking of the ground caused by the breaking
and shifting of rock beneath the Earth's surface.
l This shaking can cause buildings and bridges to collapse; disrupt gas, electric,
and phone service; and sometimes trigger landslides, avalanches, flash floods,
fires, and huge, destructive ocean waves (tsunamis).
l Buildings with foundations resting on unconsolidated landfill, old waterways, or
other unstable soil are most at risk.
l When an earthquake occurs in a populated area, it may cause deaths and injuries
and extensive property damage.
l Ground movement during an earthquake is seldom the direct cause of death or
injury.
l Most earthquake-related injuries result from collapsing walls, flying glass, and
falling objects as a result of the ground shaking, or people trying to move more
than a few feet during the shaking.
Precautions during Earthquake:
l Find safe places in every room of your home. A safe place could be under a sturdy
table or desk or against an interior wall away from windows and bookcases, or tall
furniture that could fall on you. If there's no table or desk nearby, sit down against
an interior wall. An interior wall is less likely to collapse than a wall on the outside
shell of the building.
l The shorter the distance to move to safety, the less likely you will be injured. Injury
statistics show that people moving as little as 10 feet during an earthquake's shaking
are most likely to be injured.
l Practice drop, cover, and hold-on in each safe place. Drop under a sturdy desk or
table and hold on to one leg of the table or desk. Protect your eyes by keeping
your head down. Practice these actions so that they become an automatic
response.
l Wait in your safe place until the shaking stops, then check to see if you are hurt.
You will be better able to help others if you take care of yourself first, then check
the people around you.
l Move carefully and watch out for things that have fallen or broken, creating hazards.
Be ready for aftershocks.
l If you are in bed, hold on and stay there, protecting your head with a pillow. You
are less likely to be injured staying where you are.
l If you are in a vehicle, pull over to a clear location, stop and stay there with your
seatbelt fastened until the shaking has stopped. Stopping will help reduce your

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 risk, and a hard-topped vehicle will help protect you from flying or falling objects.
Once the shaking has stopped, proceed with caution. Avoid bridges or ramps that
might have been damaged by the quake.
l Be on the lookout for fires. Fire is the most common earthquake-related hazard,
due to broken gas lines, damaged electrical lines or appliances, and previously
contained fires or sparks being released.
l If you must leave a building after the shaking stops, use the stairs, not the elevator.
l Stay away from windows. Windows can shatter with such force that you can be
injured several feet away.
l If you are in a coastal area, move to higher ground. Tsunamis are often created by
earthquakes.
l If you are in a mountainous area or near unstable slopes or cliffs, be alert for
falling rocks and other debris that could be loosened by the earthquake. Landslides
commonly happen after earthquakes
l If you're outside in an earthquake, stay outside. Move away from buildings, trees,
streetlights, and power lines. Crouch down and cover your head.
l Bricks, roofing, and other materials can fall from buildings, injuring persons nearby.
Trees, streetlights, and power lines may also fall, causing damage or injury.
How to Protect Your Property
l Bolt bookcases, china cabinets, and other tall furniture to wall studs. Brace or
anchor high or top-heavy objects. During an earthquake, these items can fall over,
causing damage or injury.
l Secure items that might fall (televisions, books, computers, etc.). Falling items
can cause damage or injury.
l Install strong latches or bolts on cabinets. The contents of cabinets can shift during
the shaking of an earthquake. Latches will prevent cabinets from flying open and
contents from falling out.
l Move large or heavy objects and fragile items (glass or china) to lower shelves.
There will be less damage and less chance of injury if these items are on lower
shelves.
l Store breakable items such as bottled foods, glass and china in low, closed cabinets
with latches. Latches will help keep contents of cabinets inside.
l Store weed killers, pesticides, and flammable products securely in closed cabinets
with latches, on bottom shelves. Chemical products will be less likely to create
hazardous situations from lower, confined locations.
l Hang heavy items, such as pictures and mirrors, away from beds, couches, and
anywhere people sit. Earthquakes can knock things off walls, causing damage or
injury.
l Brace overhead light fixtures. During earthquakes, overhead light fixtures are the
most common items to fall, causing damage or injury.
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 l Strap the water heater to wall studs. The water heater may be your best source of
drinkable water following an earthquake. Protect it from damage and leaks.
l Bolt down any gas appliances. After an earthquake, broken gas lines frequently
create fire hazards.
l Install flexible pipe fittings to avoid gas or water leaks. Flexible fittings will be less
likely to break.
l Repair any deep cracks in ceilings or foundations. Earthquakes can turn cracks
into ruptures and make smaller problems bigger.
What to Do After an Earthquake
l Check yourself for injuries. Often people tend to others without checking their own
injuries. You will be better able to care for others if you are not injured or if you
have received first aid for your injuries.
l Protect yourself from further danger by putting on long pants, a long-sleeved shirt,
sturdy shoes, and work gloves. This will protect your from further injury by broken
objects.
l After you have taken care of yourself, help injured or trapped persons. Don't try to
move seriously injured people unless they are in immediate danger of further
injury.
l Look for and extinguish small fires. Eliminate fire hazards. Putting out small fires
quickly, using available resources, will prevent them from spreading. Fire is the
most common hazard following earthquakes.
l Clean up spilled medicines, bleaches, gasoline, or other flammable liquids
immediately. Avoid the hazard of a chemical emergency.
l Open closet and cabinet doors cautiously. Contents may have shifted during the
shaking of an earthquake and could fall, creating further damage or injury.
l Inspect your home for damage. Get everyone out if your home is unsafe.
Aftershocks following earthquakes can cause further damage to unstable buildings.
If your home has experienced damage, get out before aftershocks happen.
l Help neighbors who may require special assistance. Elderly people and people
with disabilities may require additional assistance. People who care for them or
who have large families may need additional assistance in emergency situations.
l Listen to a portable, battery-operated radio (or television) for updated emergency
information and instructions. Local radio and local officials provide the most
appropriate advice for your particular situation.
l Expect aftershocks. Each time you feel one, drop, cover, and hold on! Aftershocks
frequently occur minutes, days, weeks, and even months following an earthquake.
l Watch out for fallen power lines or broken gas lines, and stay out of damaged
areas. Hazards caused by earthquakes are often difficult to see, and you could be
easily injured.

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 l Stay out of damaged buildings. If you are away from home, return only when
authorities say it is safe. Damaged buildings may be destroyed by aftershocks
following the main quake.
l Use battery-powered lanterns or flashlights to inspect your home. Kerosene
lanterns, torches, candles, and matches may tip over or ignite flammables inside.
l Take pictures of the damage, both to the house and its contents, for insurance
claims.
l Avoid smoking inside buildings. Smoking in confined areas can cause fires.
l When entering buildings, use extreme caution. Building damage may have occurred
where you least expect it. Carefully watch every step you take.
l Examine walls, floor, doors, staircases, and windows to make sure that the building
is not in danger of collapsing.
l Check for gas leaks. If you smell gas or hear a blowing or hissing noise, open a
window and quickly leave the building. Turn off the gas, using the outside main
valve if you [Link] you turn off the gas for any reason, it must be turned back on by
a professional.
l Look for electrical system damage. If you see sparks or broken or frayed wires, or
if you smell burning insulation, turn off the electricity at the main fuse box or circuit
breaker.
l Check for sewage and water line damage. If you suspect sewage lines are
damaged, avoid using the toilets and call a plumber.
l If water pipes are damaged, contact the water company and avoid using water
from the tap. You can obtain safe water from undamaged water heaters.
l Watch for loose plaster, drywall, and ceilings that could fall.
l Use the telephone only to report life-threatening emergencies. Telephone lines
are frequently overwhelmed in disaster situations. They need to be clear for
emergency calls to get through.
l Watch animals closely. Leash dogs and place them in a fenced yard. The behavior
of pets may change dramatically after an earthquake. Normally quiet and friendly
cats and dogs may become aggressive or defensive.
FLOODS
Responding Appropriately During a Flood
l Listen to area radio and television stations for possible flood warnings and reports
of flooding in progress or other critical information.
l Be prepared to evacuate at a moment's notice.
l When a flood or flash flood warning is issued for your area, head for higher ground
and stay there.
l Stay away from floodwaters. If you come upon a flowing stream where water is
above your ankles, stop, turn around and go another way. Six inches of swiftly
moving water can sweep you off of your feet.
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 l If you come upon a flooded road while driving, turn around and go another way. If
you are caught on a flooded road and waters are rising rapidly around you, get out
of the car quickly and move to higher ground. Most cars can be swept away by
less than two feet of moving water.
l Keep children out of the water. They are curious and often lack judgment about
running water or contaminated water.
l Be especially cautious at night when it is harder to recognize flood danger.
l Because standard homeowner's insurance doesn't cover flooding, it's important
to have protection from the floods associated with hurricanes, tropical storms,
heavy rains and other conditions.
Basic Steps to Prepare for the Floods
l Learn about your community's emergency plans, warning signals, evacuation
routes, and locations of emergency shelters.
l Post emergency phone numbers at every phone.
l Inform local authorities about any special needs, i.e., elderly or bedridden people,
or anyone with a disability.
l Identify potential home hazards and know how to secure or protect them before
the flood strikes. Be prepared to turn off electrical power when there is standing
water, fallen power lines, or before you evacuation. Turn off gas and water supplies
before you evacuate.
l Have a fire extinguisher and make sure your family knows where it is and how to
use it.
l For drains, toilets, and other sewer connections, install backflow valves or plugs
to prevent floodwaters from entering.
If you are under a flood watch or warning:
l Gather the emergency supplies you previously stocked in your home and stay
tuned to local radio or television station for updates.
l Turn off all utilities at the main power switch and close the main gas valve if
evacuation appears necessary.
l Fill bathtubs, sinks and plastic soda bottles with clean water. Sanitize the sinks
and tubs first by using bleach. Rinse and fill with clean water.
Emergency Supplies You Will Need
You should stock your home with supplies that may be needed during the emergency
period. At a minimum, these supplies should include:
l Several clean containers for water, large enough for a 3-5 day supply of water.
l A 3 to 5 days supply of non-perishable food.
l A first aid kit and manual and prescription medicines and special medical needs.
l A battery-powered radio, flashlights, and extra batteries.

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l Sleeping bags or extra blankets.
l Water-purifying supplies, such as chlorine or iodine tablets or unscented, ordinary
household chlorine bleach.
l Baby food and/or prepared formula, diapers, and other baby supplies.
l Disposable cleaning cloths, such as xbaby wipesx for the whole family to use in
case bathing facilities are not available.
l Personal hygiene supplies, such as soap, toothpaste, sanitary napkins, etc.
l Rubber boots, sturdy shoes, and waterproof gloves.
l Insect repellent containing cream/ lotion, screens, or long-sleeved and long-legged
clothing for protection from mosquitoes which may gather in pooled water remaining
after the flood.

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 Major Chemical Processes & their definition

No Process name Definition [Link] UPL

1 Perkow reaction The Perkow reaction is an organic reaction in which GF, MCP
a trialkyl phosphite ester reacts with a halo ketone
to form a dialkyl vinyl phosphate and an alkyl halide.
2 Oxidation Oxidation is the loss of electrons or an increase in POCl3,
oxidation state by a molecule, atom, or ion phorate
3 Isomerization Isomerization is the process by which one molecule Acephate
is transformed into another molecule which has exactly
the same atoms, but the atoms have a different
arrangement e.g. A-B-C ? B-A-C (these related molecules
are known as isomers).
4 Nitrification the chemical process in which a nitro group is Pendimethelene
added to an organic compound (or substituted for
another group in an organic compound)
5 Hydrogenation a chemical process that adds hydrogen atoms Pendimethelene
to an unsaturated oil
6 Chlorination the addition or substitution of chlorine in PCl3, PCl5
chemical compounds
7 Acylation the process of introducing an acyl group
into a compound
8 Cracking the process whereby heavy molecules of naphtha
or petroleum are broken down into hydrocarbons
of lower molecular weight (especially in the
oil-refining process)
9 Deamination removal of the amino radical from an amino acid
or other amino compound
10 Decarboxylation the process of removing a carboxyl group from
a chemical compound (usually replacing it with hydrogen)
11 Iodination the substitution or addition of iodine atoms
in organic compounds
12 Polymerization a chemical process that combines several
monomers to form a polymer or polymeric compound
13 Synthesis the process of producing a chemical compound
(usually by the union of simpler chemical compounds)
14 Pyro chemical processes for chemical reactions
process at high temperatures
15 Friedel-Crafts Synthesis of alkylated products via the reaction
Alkylation of arenes with alkyl halides or alkenes.
16 Grignard Reaction The Grignard Reaction is the addition of an GF
organomagnesium halide (Grignard reagent) to a
ketone or aldehyde, to form a tertiary or secondary alcohol,
respectively. The reaction with formaldehyde leads to a
primary alcohol.

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 PPE's & Their Standards

No Type of PPE Applicable Standard/ Specifications Usage/ protection

1 Safety Helmets IS 2925: 1984 (Re affirmed in 2000) (Specification Provide impact and
for industrial safety helmets). Also complying ANSI/ penetration protection in
ISEA Z89.1-2009 Type 1, Class C, G and E. the event of a top or
lateral blow to the head
2 Face shield with visor Industrial Safety Face-shields: Provide protection from
Part 1 with Plastic Visor; reaffirmed (1991), flying objects, impact,
IS:8521-1977. Also complying ANSI Z87+ and CSA chemical splash,
Z94.3 safety standards
3 Welding face shield Equipment of Eye and Face Protection during Provide protection from
Welding (First revision); Reaffirmed (1991), arc welding hazards
IS: 1179-1967. Also complying ANSI Z87.1, & CSA
4 Arc shield Electrical Safety Requirements for Employee Provide protection from
Workplaces (NFPA 70E).-2004; ANSI Z87.1 the hazards of arc flash.
5 Chemical splash IS 5983: 1980 (Re affirmed 1997) (Eye Protectors). Eye protection from
goggles Meets ANSI Z87.1-2010 (High Impact) and CSA impacts and chemical
Z94.3 standards splashes
6 Safety glasses Safety Glass (Second revision), IS:2553-1971. Eye protection from
Meets ANSI Z87.1-2003 High Impact requirements impacts, flying objects
and provide 99% UV protection
7 Ear plug Guide for Selection of Industrial Equipment for Eye, For protection against
Face and Ear Protection; reaffirmed (1991), high noise
IS:8520-1977, Ear Protectors; reaffirmed (1989),
IS:9167-1979
8 Ear muff
9 Dust/ particulates Filter Type Particulate Matter Respirators; reaf- Provide protection against
mask firmed (1996), IS: 9473- 1980, ANSI Z88.2 (1992), solid particulates
NIOSH standards for N95 protection.
10 Nuisance Odor mask IS 15323:2003 Reaffirmed 2009, Provide comfortable
NIOSH standards protection against certain
oil and non-oil based
particles including those
present with nuisance
levels of organic vapors,
such as solvents,
degreasers, and resins.
11 Half face mask with Respirators, Chemical Cartridge; reaffirmed (1991), Provide comfortable
cardtridge/conster IS: 8522-1977, Respirators, Canister Type (Gas protection against nui-
Masks), (First revision 1998); reaffirmed (1991), IS: sance levels of organic/
8523-1977, IS 14746 : 1999 Respiratory protective inorganic vapors, gases
devices : Half masks and quarter masks, ,NIOSH
standards
12 Full face mask with Respiratory Protective Devices - Full Face Masks,
cardtridge/conster IS: 14166-1994 Respirators, Chemical Cartridge;
reaffirmed (1991), IS: 8522-1977, Respirators,
Canister Type (Gas Masks), (First revision 1998);
reaffirmed (1991), IS: 8523-1977, NIOSH standards

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No Type of PPE Applicable Standard/ Specifications Usage/ protection
13 SCBA set Part 1 - Closed Circuit Breathing Apparatus (Com- For protection in O2
pressed Oxygen Cylinder), IS: 10245-1996 Part 2 - deficient & toxic
Open Circuit Breathing Apparatus (First revision), gas area
IS: 10245- 1994 Part 3 - Fresh Air Hoses and
Compressed Air line Breathing Apparatus;
reaffirmed (1992), IS: 10245-1982
14 Escape breathing Part 4 - Escape Breathing Apparatus (Short Dura- For escape from O2
appratus tion Self-contained Type); reaffirmed (1991), IS: deficient & toxic
10245-1982 gas area
15 Apron or cotton bolier IS 8519: 1977 (Guide for selection of industrial For normal
suit safety equipment for body protection) activities use
16 Leather apron Protective Leather Clothing; reaffirmed (1990), For protection against
IS:6153-1990 heat and abrasion during
welding, handling moder-
ately hot materials or
materials with sharp and
rough edges.
17 Full body suit- Acid/ Aprons, Rubberized, Acid and Alkalis Resistant For protection during acid/
alkali protection (First revision); reaffirmed (1991), IS:4501-1981 alkali handling.
18 Full body chemical Guide for Selection of Industrial Safety Equipment For protection during
protection suit for Body Protection; reaffirmed (1991), IS:8519-1977 chemical handling
19 Full body arc flash Conductive Clothing for Live Working at a Nominal Provide protection from
protection suit Voltage up to 800 kV AC, IS:13771-1993, Electrical the hazards of arc flash.
Safety Requirements for Employee Workplaces
(NFPA 70E)., ASTM F1506, Standard Performance
Specification for Flame-Resistant and Arc-Rated
Textile Materials for Wearing Apparel for use by
Electrical Workers Exposed to Momentary Electric
Arc and Related Thermal Hazards
20 Water Resistant Part 1 - PVC Coated Fabrics (First revision); For protection from water
Clothing reaffirmed (1994), IS:3322- 1987 sprays
Part 2 - Polyurethane and Silicon Coated Fabrics,
IS: 3322-1965
21 PVC Gloves Guide for Selection of Industrial Safety Equipment For protection during
for Protection of Arms and Hands; reaffirmed handling of acid/ alkalis
(1991), IS:8807-1978
21 Cotton gloves Part 1, Leather and Cotton Gloves; reaffirmed For protection during
(1991), IS:6994-1973 mechanical jobs like
rigging, pipe/ sheets
shifting etc.
22 Natural rubber gloves Guide for Selection of Industrial Safety Equipment For protection during
for Protection of Arms and Hands; reaffirmed handling of acid/ alkalis
(1991), IS:8807-1978
23 Electrical rubber gloves IS 4770: 1991 (Rubber Gloves - electrical purposes For protection from
- specification) electrical shock
24 Leather gloves Part 1, Leather and Cotton Gloves; reaffirmed For protection during
(1991), IS:6994-1973 welding
25 Nitrile gloves Guide for Selection of Industrial Safety Equipment For protection during
for Protection of Arms and Hands; reaffirmed handling of chemicals,
(1991), IS:8807-1978 solvents
26 Neoprene gloves

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No Type of PPE Applicable Standard/ Specifications Usage/ protection
27 Leather Grauntlets & Guide for Selection of Industrial Safety Equipment For protection against
mittens for Protection of Arms and Hands; heat and abrasion during
reaffirmed (1991), IS:8807-1978 & IS:2573:1986 welding, handling moder-
ately hot materials or
materials with sharp and
rough edges.
28 PVC dipped Cotton IS 8807: 1978 (Guide for selection of industrial For protection during
gloves safety equipment for protection of arms and acids/ alkalis handling
hands), IS 6994: 1973 Part 1(Specification for
For protection during
safety gloves)
welding
29 Welding hand gloves
30 Safety Shoes IS 15298-2 (2011): Personal Protective Equipment, For foot protection in
Part 2: Safety Footwear industries
31 Rubber Gum boots Industrial and Safety Rubber Knee Boots, IS:5557- For acid/ alkali chemical
1969 handling
32 Fireman's leather boots Fireman's Leather Boots, IS: 4128-1980. To be used by
fire fighters
33 Electrical safety shoes IS 15298-2 (2011): Personal Protective Equipment, To be used by electrical
Part 2: Safety Footwear person
34 Electrical-cum-Chemi- PVC Boots, IS:12254-1988 PVC full gums boots with
cal Gum Boots stockinet lining inside can
be used both for chemical
and electrical purposes
35 Safety Harness Industrial Safety Belts and Harness (Second For protection from fall
revision), IS: 3521-1989 while working at height
36 In line Fall arrestors EN 353- 2: 2002 (Personal protective equipment
against falls from a height)
37 Retractable fall arres- EN 360: 2002 (Personal protective equipment
tors against falls from a height)

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 What is Preliminary LOPA

What we do in Preliminary LOPA & RA in UPL

l Layers of protection analysis (LOPA) is a semi-quantitative methodology that is
used to identify safeguards that meet the independent protection layer (IPL)

l As per LOPA, there are seven Independent Layers of Protection for each Process
which are listed below:
1. BPCS
2. Alarms and Operator Intervention / Actions
3. SIS
4. Safety Relief Devices
5. Dykes
6. Emergency Preparedness
7. Community awareness and Emergency Preparedness
l Identified 10 to 15 Top Hazardous Processes and Storages of each Unit.
l Conducted Preliminary LOP Analysis of all the Identified Top Hazardous Processes
l Identified Independent Layers of Protection in Place and Missing Independent
Layer of Protection for each Hazardous Processes and Storages
l Conducted Risk Assessment of Missing Layer of Protection to evaluate whether
we have risk which is not tolerable or above ALARP. i.e as per UPL risk Matrix
where the Risk Factor is 6 & above.
l Identified Actions to be taken to bring the risk level to tolerable levels or ALARP.
l Classified the recommendations to be implemented immediately or within a defined
time frame
l Identify resource resource requirement to implement the recommendations to bring
the risk levels to below ALARP (As Low as reasonably Practicable)

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 What are Safety Control Points

What we do in Safety Control Points in UPL

l Identified Top 10 to 15 Hazardous Processes of each Unit which could lead to

disastrous Safety Event like Fire or Explosion or Toxic Release.
l Analysis done and Identified Causes which could lead to these safety events
l Identified the current controls we have in place
l Identified One cause which when plugged could prevent a Safety event
l This single parameter has been named as Safety Control Point
l Safety Control Points displayed in all the Plants
l All the members of the Plant trained on Safety Control Points
l Inspection sheet prepared to monitor the Safety Control Points
l Routine inspection of the Safety Control points will be done in the Field by HOD,
PSR and Safety Managers.
l This process will enable continuous monitoring of these Safety Controls and
prevent any untoward Safety event
l A list of Safety Control Points will be displayed at the entrance of the Plants to
train and sensitize all members of the team on Safety Control Points

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 What is MSDS

l A material safety data sheet (MSDS) is an important component of product

stewardship and occupational safety and health.
l It is intended to provide workers and emergency personnel with procedures for
handling or working with that substance in a safe manner, and includes information
such as physical data (melting point, boiling point, flash point, etc.), toxicity, health
effects, first aid, reactivity, storage, disposal, protective equipment, and spill-
handling procedures.
l The MSDS follows a 16 section format which is internationally agreed.
l As per Rule 68 (j) , (2) & (3) of GFR and Schedule - V , and also as per Rule 17
& Schedule - IX of MSIHC rules - 1989 to make MSDS is a duty of occupier, who
is handling hazardous chemicals as per stipulated rules.
l Employers must ensure that each employee has a basic knowledge of how to find
information on an MSDS and how to properly make use of that information.
l MSDS must be readily available for employee review at all times in the work place.
l MSDS cannot be locked in an office or filing cabinet to which employees do not
have access.
l Employers also must ensure the following:
l Complete and accurate MSDS are made available during each work shift to
employees when they are in their work areas.
l Information is provided for each hazardous chemical.
l Provide training on their content.

The 16 headings required are listed below:-

Section 1 - Chemical product and company identification.

l Identification of the substance or preparation and supplier - including
name, address and emergency contact phone number
Section 2 - Hazards identification
l A summary of the most important features including adverse health
effects and symptoms.
Section 3 - Composition/information on ingredients
l Chemical Names
Section 4 - First aid measures
l Separated for the various risks and specific, practical and easily
understood.
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Section 5 - Firefighting measures
l Emphasises any special requirement
Section 6 - Accidental release measures
l It covers Safety, Environmental Protection and cleanup
Section 7 - Handling and storage
l It covers recommendations for best practices, including any special
storage conditions or incompatible materials.
Section 8 - Exposure controls and personal protection
l It covers any specific recommendations such as ventilation systems
and PPE
Section 9 - Physical and chemical properties
l It covers physical, Stability and Solubility properties
Section 10 - Stability and reactivity
l It covers conditions and materials to avoid
Section 11 - Toxicological information
l It covers acute and chronic toxicological effects, routes of exposure
and symptoms
Section 12 - Ecological information
l It covers environmental effects which could include effects on aquatic
organisms etc
Section 13 - Disposal considerations
l It covers advice on specific dangers and legislation
Section 14 - Transport information
l It covers special precautions to be taken while transportation
Section 15 - Regulatory information
l It covers overall classification of the product and any specific legislation
that may be applicable.
Section 16 - Other information
l It covers any additional relevant information eg explanation of
abbreviation”

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Terminology Used In MSDS:
l Synonym: It indicates another name of chemical.
l Formula : Chemical descriptive name and the chemical formula.
l HAZCHEM code : Indicates precautions to be taken when accident occur with the
chemical.
l CAS NO : Chemical Abstract Service Registry Number which identifies the product.
l Boiling point: Temperature at which a liquid changes in to vapour.
l Melting point: temperature at which solid changes to liquid.
l Vapor pressure: Pressure exerted by a saturated vapor at definite temperature
(e.g. 200C).
l Vapor density: indicates ratio of densities of vapor and air (density of air is 1).
l Specific gravity: indicates ratio of densities of given substances w.r.t water (specific
gravity of water is 1).
l Solubility in water: solubility of the product by weight in water.
l Appearance / odor: description of material at normal temperature and pressure
that may useful in identifying the presence of product.
l Evaporation rate: ratio of the rate of vaporization of the product
l Flash point: Lowest temperature at which the chemical will give off enough vapor
to ignite.
l Auto ignition Temperature: Minimum temperature at which substance catch fire
automatically (without source of ignition).
l Hazardous decomposition product: Describes the hazardous materials produced
from a chemical reaction.
l Flammable limits: Range of vapor concentration (percent by volume in air) which
will burn or explode in the presence of spark or flame. LEL is the lower explosive
limit and UEL is the upper explosive limit).
l Hazardous Polymerization: Indicates the tendency of the chemical molecules to
combine in a violent reaction.
l TLV: Maximum concentration believed to be safe for 8 hours working in a day, 48
hours in a week for prolonged period. It is also known as TWA, PEL, MAC.
l STEL: Maximum concentration believed to be safe for 15 minutes, such
concentration should not exceed for times in a day and there is an interval of one
hour between two exposures.
l Odor Threshold: Minimum concentration at which one can feel odor of the
substance.
l IDLH: The concentration is immediately dangerous to life and health for vapor /
gas the above is express in PPM and for dust, fume and mist in mg/m3.

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l ppm = mg/ m3 x 24.45 / mw.
l LD50 : The dose which kills half of the test animals (mg/kg) (oral).
l LC50 : The dose which kills half of the test animals ( ppm or mg/hr) (inhalation or
injection).
l Vapor : The gases form of substances which are normally in the solid or liquid
state and which can be changed to these states either by increasing the pressure
or decreasing the temperature.
l Gas : Formless fluids which tend to occupy the entire space uniformly at ordinary
temperature and pressure.
l Fumes : small, solid particles formed by the condensation of vapors of solid
materials.
l Dust : small solid particles created by the breaking up of larger particles by
processes crushing, grinding, drilling, explosions etc. dust particles already in
existence in a mixture of materials may escape into the air through such operations
as shoveling, conveying, screening, sweeping etc.
l Mist : Small droplets of materials that are ordinarily liquid at normal temperature
and pressure.

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 Hazardous Area Classification

HAC is a method of analyzing and classifying the environment where explosive gas atmo-
spheres may occur to allow the proper selection of electrical apparatus to be installed in that
environment
Hazardous Areas are classified in zones based on the frequency of the appearance and the
duration of an explosive gas atmosphere
Why Zoning is required?
o Leak Potential & Presence of Ignition Sources
o Hazardous properties of hydrocarbons
o Safe selection (& optimization) of Electrical Equipment
Zone 0 -Typical areas
(Continous grade)
o Vapour space above:
- closed process vessels,
- storage tanks
- closed containers,
- areas containing open tanks of volatile, flammable liquid
How to identify Zone 1 areas ?
o Flammable gas or vapour concentration is likely to exist in the air under normal operat-
ing conditions
o Flammable atmospheric concentration is likely to occur frequently because of mainte-
nance, repairs or leakage
o Flammable liquid or vapour piping system (containing valves, meters, or screwed or
flanged fittings) is in an inadequately ventilated area
o The area below the surrounding elevation or grade is such that flammable liquids or
vapour may accumulate therein
Zone 1 -Typical areas
o Imperfectly fitting peripheral seals on floating roof tanks
o Inadequately ventilated pump rooms for flammable gas or for volatile, flammable liq-
uids
o Oily waste water sewer / basins
o Loading / unloading gantries of hazardous products
Typical Zone 2 areas
o The system handling flammable liquid or vapour is in an adequately ventilated area and
is so designed and operated that the explosive or ignitable liquids, Vapours or gases
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 will normally be confined within closed containers or closed systems from which they
can escape only during abnormal conditions such as accidental release of a gasket or
packing
o The flammable vapour can be conducted to the location as through trenches, pipes or
ducts
o Locations adjacent to Zone 1 areas
o Pressurized rooms where flammable gas / vapour can enter in the case of failure of
positive mechanical ventilation
Safe Areas -Typical areas
The following locations are considered safe from the point of view of electrical installation:
o Areas where the piping system is without valves, fittings, flanges or similar appurtenances
o Areas where flammable liquids or vapour are transported only in suitable containers or
vessels
o Areas where permanent ignition sources area present like area where combustion gases
are present, for example flare pits, tips, other open flames 7 hot surfaces
o DG shed room / shed having adequate ventilation
HAC- Comparison
o North America (NFPA / API/ NFPA 70E or NEC)
- Hazardous Areas:
- Division I- Z0 + Z1
- Division II- Z2
- Hazardous Locations
- Class I-Flammable Gases / Vapour
- Class II- Combustible dust
- Class III- Combustible fibres or flyings
- Gas / vapour grouping
- A, B, C, D, E, F & G
o Japan
- Hazardous Areas
- Classes 1, 2 & 3
- Gas / vapour groups
- G1, G2, G3, G4, G5 & G6
Factors to be considered (IS 5572)
o Vapour / Gas Density
o Effect of Air Current
o Identification of leak scenarios
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GENERAL CONSIDERATIONS
o In the absence of walls, enclosures, etc. & air currents, vapour/gas dispersion will de-
pend on density & velocity. Denser gas/vapour will disperse downward and outward,
lighter gases upward & [Link] for a single leak source would be a circle.
o Vapours / gas released(high density releases) at or near ground level, will be found
below ground, thus altering the shape of HA.
EFFECT OF AIR CURRENT
o Winds alter the shapes of hazardous areas
o A mild breeze may extend the HA and a strong wind could dilute the flammable
concentration,making it non-hazardous
o But what are logically to be considered are the most unfavourable conditions
How to classify areas?
o Mark in elevation and plan drawings
o Separate identification (hatching) for various zones
- Zone 0
- Zone 1
- Zone 2
o Frequency of HAC?
SELECTION OF ELECTRICAL EQUIPMENT IN HAZARDOUS AREAS
o How to select equipment for various zones?
o Selection Criteria
- Gas Grouping (based on ignition energy)
- Temperature Classification
- Classified Zones
TEMPERATURE CLASSIFICATION
T Class Max. Surface Temperature(Deg. C)
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85

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GAS GROUP CLASSIFICATION (based on MESG & MIE)
o Gas group I
- Methane
o Gas group II A
- Ammonia, CO, Propane, Butane, Benzene, Acetone, Methanol
o Gas group II B
- Butadiene, Ethylene, Ethylene Oxide, Diethyl Ether
o Gas group II C
- Hydrogen
GAS GROUP & TEMPERATURE CLASSIFICATION-VARIOUS GASES/VAPOURS

Gas Representative Gas Ignition Energy

Group (mj)
I Methane 280
II A Propane 260
IIB Ethylene 95
IIC Hydrogen 18
RECOMMENDED PROTECTION METHODS FOR ZONE O
No electrical equipment should be allowed. When this is not practicable, Ex 'i ' (ia or ib)
apparatus or circuits to be used
o No transformers, motors, lights, switch gear or control gear
RECOMMENDED PROTECTION METHODS FOR ZONE 1
Motors- Ex d, Ex p
Transformers & Capacitors - Ex d
Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d
Switch Gear & Control Gear - Ex d
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i
*Ex o, Ex q type equipment are also allowed for use as per IS 5571
RECOMMENDED PROTECTION METHODS FOR ZONE 2
Motors- Ex d, Ex p, Ex n, Ex e,
Transformers & Capacitors - Ex d, Ex p (auxiliary devices to be located in pressurized room/
hermetically sealed / intrinsically safe)

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Control & Instrument Transformers - Ex i
Lighting Fitting - Ex d, Ex e, Ex n
Switch Gear & Control Gear - Ex d, Ex o, Ex
Communication/ Telephone equipment/Meters - Ex i
Portable Hand Lamps- Ex i
Minimum IP 55 (for UN-insulated parts) and IP 44 (for insulated parts) if Ex e protection is
used for outdoor applications

EXPLOSION-PROTECTION METHODS / EQUIPMENT -Popular types

o Flameproof (EX d)
o Increased Safety (Ex e )
o Non-Sparking (Ex n )
o Pressurization (Ex p )
o Intrinsically Safe (Ex i )

OTHER TYPES OF EXPLOSION PROTECTION- Not so popular types

o Powder filled Ex 'q' type
o Oil immersed Ex 'o' type
o Special Ex 's' type

EX 'd' Type FLAMEPROOF EQUIPMENT

A type of protection in which the parts can ignite an explosive atmosphere are to be placed in
an enclosure, which can withstand the pressure developed during internal explosion of
an explosive mixture, and which prevents the transmission of the explosion to the ex-
plosive atmosphere surrounding the enclosure

INTRINSICALLY SAFE EQUIPMENT & CIRCUITS (Ex 'i' )

A type of protection which a circuit or part of the circuit is intrinsically safe when any spark or
thermal effect produced normally is incapable, under prescribed test conditions, of caus-
ing ignition of prescribed gas or vapour

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INCREASED SAFETY EQUIPMENT (Ex 'e')
A type of protection by which measures are applied so as to prevent with a minor degree of
security, the possibility of excessive temperature and the occurrence of arcs or sparks in the
interior and the external parts of electrical apparatus which does not produce them in normal
service
PRESSURIZATION TYPE (Ex 'p' )
A type of protection by which the entry of surrounding atmosphere into the enclosure of the
electrical apparatus is prevented by maintaining inside the said enclosure, a protective gas
at a higher than that of the surrounding atmosphere
NON-SPARKING TYPE EQUIPMENT (Ex 'n' )
A type of protection applied to electrical apparatus such that , in normal operation it is not
capable of igniting a surrounding atmosphere and a fault capable of causing ignition is not
likely to occur
POWDER FILLED TYPE EQUIPMENT ( Ex 'q')
o Equipment enclosure filled with quartz /sand so that in normal operating condition, any
arc occurring within the enclosure of electrical equipment will not ignite the surrounding
atmosphere
o No ignition shall be caused either by flame or by excessive temperature of the surfaces
of the enclosure
o Enclosure constructional features:
o High mechanical strength
o Ingress protection
o Powder filled
o Insulation of enclosed equipment
OIL IMMERSED TYPE EQUIPMENT (Ex 'o')
o Protection technique in which the equipment or its parts are immersed in oil in such a
way that an explosive atmosphere which, may be above the oil or outside the enclosure
cannot be ignited.
o Oil used shall be mineral oil confirming to relevant standards
o Constructional features:
- Fully enclosed, leak-proof enclosure
- Oil level indicator
o Transformers, Switch gears, Control gears
SPECIAL TYPE EQUIPMENT (Ex 's')
o This is a concept that has been adopted to permit the certification of those types of
equipment which by their nature, do not comply with the constructional or other
requirements specified for equipment with established types of protection but which,
nevertheless, can be shown, wherever necessary, by test to be suitable for use in
hazardous areas in prescribed zones
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o This concept permits flexibility on the part of certifying and assessment authorities in
their approach to applications for certification of equipment the use of which would
otherwise not permitted in hazardous areas on account of non-compliance with the
requirements of standards for established types of protection. This allows flexibility of
approach to innovative ideas and new designs, the development of which otherwise be
obstructed.
o Examples:
- Factory sealed hand lamps, Encapsulation (Ex 'm' type), Gas detection apparatus
o INGRESS PROTECTION (IP)
IP
I- Degree of Protection of persons against contact with or moving parts inside the
enclosure & Protection Of Equipment against Solid ingress
P- Ingress of Liquid
IP Types and Protection Details
FIRST NUMERAL
0 - No protection
1 - Objects greater than 50 mm
2 - Objects greater than 12 mm
3 - Objects greater than 2.5 mm
4 - Objects greater than 1.0 mm
5 - Dust - protected
6 - Dust tight
SECOND NUMERAL
0 - No protection
1 - Vertically dripping
2 - Angular dripping
3 - Sprayed water
4 - Splashed water
5 - Water jets
6 - Heavy seas
7 - Effects of immersion
8 - Indefinite immersion

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 Lab Safety

o Before starting any experiment, training to be imparted to all concerns about the proce-
dures and associated safety information.
o Only authorised experiments to be performed in the laboratory.
o No one to be allowed to work alone in the laboratory.
o The locations and operating procedures for all safety equipment should be known to all
persons. This includes the eyewash station and safety shower.
o Laboratory building should have emergency exit.
o Proper emergency response procedures for accidents or injuries should be known to
all persons in the laboratory.
o Every person should work in a responsible and professional manner at all times. No
pranks. No practical jokes.
o While in the laboratory, must wear approved safety goggles. Hair and easily combus-
tible clothing must be confined at all times.
o Wear clothing and shoes that cover exposed skin and give protection from potential
splashes.
o Do not store food in refrigerators with chemical, biological or radioactive materials.
o Never eat food, drink beverages, chew gum, smoke, apply cosmetics (including lip
balm), or handle contact lenses in the laboratory.
o Liquid chemicals/ reagents bottles to be kept below eye level in rack.
o All containers including waste containers must be properly labeled and appropriate
signs must be posted.
o MSDS of all chemicals should be readily available in the laboratory and chemical safety
training given to all persons.
o Use a chemical fume hood or biosafety cabinet. If objectionable vapors are given off
during an experiment, the experiment must be performed in a hood.
o Observe good housekeeping - keep aisles clear.
o Do not use damaged electrical equipment.
o Do not leave active experiments unattended. Never leave anything that is being heated
or is visibly reacting unattended.
o Practice good personal hygiene. Wash hands after removing gloves, before leaving the
laboratory, and after handling a potentially hazardous material.
o While working in the laboratory, wear personal protective equipment - eye protection,
gloves, and laboratory coat.
o Properly segregate and dispose of all laboratory waste.
o When cutting glass tubing or inserting tubing into stoppers, protect your hands by using
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 a towel. Glass tubing should be lubricated with glycerol or water to aid insertion of the
tubing into stoppers. To remove tubing from stoppers, cut the stoppers.
o When heating or carrying out reactions in a test tube, never point the mouth of the tube
at your neighbor or yourself.
o Never taste or smell a chemical.
o Never pour water into concentrated acid; slowly add the acid to the water with constant
stirring in a pyrex beaker or flask, not in a graduated cylinder.
o Never pipette liquids by mouth; use a suction bulb.
o Flammable solvents should be contained in flasks rather than in open beakers.
o No chemicals should be disposed off in the sink. Chemicals to be disposed of as per
defined procedure.
o Materials such as broken glass to be kept separately with label.
o Always handle broken Glass Ware with Cut resistant gloves
o Never dispose of sodium or potassium metal in the sinks as they react violently with
water.
o Learn the proper procedure for igniting and operating a laboratory burner. Always ex-
tinguish the flame when the burner is not being used. Make sure that all flammable
reagents are well removed before lighting the burner.
o Never place chemicals directly on the balance pan. Always use a proper weighing con-
tainer when using a balance to weigh a chemical. Never pour chemicals directly over
the balance.
o Securely replace lids, caps, and stoppers after removing reagents from containers.
o Always wipe spatulas clean before and after inserting into reagent bottles.
o Never place anything that is not directly required for the experiment on laboratory desks;
other items may interfere with the experiment.
o Clean up any spill immediately.
o Before leaving the laboratory, make sure work area is clean and dry. Ensure that all
gas, water, vacuum, and air valves are completely turned off.

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