MX3089 INDUSTRIAL SAFETY LTPC

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COURSE OBJECTIVES
 To Understand the Introduction and basic Terminologies safety.
 To enable the students to learn about the Important Statutory Regulations and standards.
 To enable students to Conduct and participate the various Safety activities in the Industry.
 To have knowledge about Workplace Exposures and Hazards.
 To assess the various Hazards and consequences through various Risk Assessment
Techniques.
UNIT I SAFETY TERMINOLOGIES
Hazard-Types of Hazard- Risk-Hierarchy of Hazards Control Measures-Lead indicators- lag
Indicators-Flammability- Toxicity Time-weighted Average (TWA) - Threshold LimitValue
(TLV) - Short Term Exposure Limit (STEL)- Immediately dangerous to life or health (IDLH)-
acute and chronic Effects- Routes of Chemical Entry-Personnel Protective Equipment- Health
and Safety Policy-Material Safety Data Sheet MSDS
UNIT II STANDARDS AND REGULATIONS
Indian Factories Act-1948- Health- Safety- Hazardous materials and Welfare- ISO 45001:2018
occupational health and safety (OH&S) - Occupational Safety and Health Audit IS14489:1998-
Hazard Identification and Risk Analysis- code of practice IS 15656:2006
UNIT III SAFETY ACTIVITIES
Toolbox Talk- Role of safety Committee- Responsibilities of Safety Officers and Safety
Representatives- Safety Training and Safety Incentives- Mock Drills- On-site Emergency Action
Plan- Off-site Emergency Action Plan- Safety poster and Display- Human Error Assessment
UNIT IV WORKPLACE HEALTH AND SAFETY
Noise hazard- Particulate matter- musculoskeletal disorder improper sitting poster and lifting
Ergonomics RULE & REBA- Unsafe act & Unsafe Condition- Electrical Hazards- Crane Safety-
Toxic gas Release
UNIT V HAZARD IDENTIFICATION TECHNIQUES
Job Safety Analysis-Preliminary Hazard Analysis-Failure mode and Effects Analysis- Hazard
and 188 Operability- Fault Tree Analysis- Event Tree Analysis Qualitative and Quantitative Risk
Assessment- Checklist Analysis- Root cause analysis- What-If Analysis- and Hazard
Identification and Risk Assessment
TOTAL : 45 PERIODS
COURSE OUTCOMES
Course outcomes on completion of this course the student will be able:
 Understand the basic concept of safety.
 Obtain knowledge of Statutory Regulations and standards.
 Know about the safety Activities of the Working Place.
 Analyze on the impact of Occupational Exposures and their Remedies
 Obtain knowledge of Risk Assessment Techniques.
TEXTBOOKS
1. R.K. Jain and Prof. Sunil S. Rao Industrial Safety, Health and Environment Management
Systems KHANNA PUBLISHER
2. L. M. Deshmukh Industrial Safety Management: Hazard Identification and Risk Control
McGraw-Hill Education
REFERENCES
1. Frank Lees (2012) ‘Lees’ Loss Prevention in Process [Link]-Heinemann
publications, UK, 4th Edition.
2. John Ridley & John Channing (2008)Safety at Work: Routledge, 7th Edition.
3. Dan Petersen (2003) Techniques of Safety Management: A System Approach.
4. Alan Waring.(1996).Safety management system: Chapman &Hall,England
5. Society of Safety Engineers, USA
 Unit - 1
Safety Terminology
Hazard
In safety terminology, a hazard refers to any source of potential harm or danger. There are
several types of hazards, which can be categorized in different ways based on the nature of
the risk they pose. Here are the main types of hazards:
1. Physical Hazards
 Definition: These are environmental factors that can cause harm to a person or property.
 Examples:
o Noise: Exposure to loud sounds, especially in industrial settings.
o Temperature Extremes: Exposure to excessive heat or cold.
o Radiation: Ionizing or non-ionizing radiation from sources like X-rays, UV rays,
etc.
o Vibration: Prolonged exposure to machinery that causes harmful vibrations.
o Pressure: High or low-pressure environments that may lead to injuries.
2. Chemical Hazards
 Definition: These involve exposure to harmful chemicals, gases, vapors, or liquids that
can cause health problems.
 Examples:
o Toxic Chemicals: Substances that can cause poisoning or other severe health
issues (e.g., asbestos, lead).
o Flammable Substances: Chemicals that can catch fire easily (e.g., gasoline,
propane).
o Corrosive Substances: Chemicals that can destroy tissues or materials (e.g.,
acids, alkalis).
o Reactive Substances: Chemicals that can react violently with other substances
(e.g., explosives).
3. Biological Hazards
 Definition: These are risks arising from exposure to biological agents like bacteria,
viruses, fungi, or other living organisms.
 Examples:
o Infectious Diseases: Pathogens like influenza, COVID-19, or tuberculosis.
o Molds and Fungi: Exposure to harmful molds that can cause respiratory issues.
o Insects and Animals: Stings, bites, or the spread of diseases like Lyme disease.
4. Ergonomic Hazards
 Definition: These are risks associated with improper body mechanics and workstation
design that can lead to injuries.
 Examples:
o Repetitive Motion: Activities that require repetitive movements, leading to strain
(e.g., carpal tunnel syndrome).
o Poor Posture: Sitting or standing in awkward positions for extended periods.
o Manual Handling: Lifting or carrying heavy objects incorrectly can cause
musculoskeletal injuries.
5. Psychosocial Hazards
 Definition: These are hazards related to stress, mental health, and interpersonal
relationships in the workplace.
 Examples:
o Workplace Stress: Long working hours, excessive workload, or lack of support.
o Bullying or Harassment: Psychological harm due to aggressive behavior,
bullying, or harassment.
o Fatigue: Extended periods without rest or sleep, leading to exhaustion or
impaired decision-making.
6. Electrical Hazards
 Definition: These hazards arise from the presence of electricity in the workplace, which
can cause fires or electrocution.
 Examples:
o Electric Shock: Contact with live wires or faulty electrical equipment.
o Arc Flash: Explosive release of electrical energy, which can cause burns or
injuries.
o Overloading Circuits: Improperly maintained electrical systems that may lead to
fires.
7. Mechanical Hazards
 Definition: Risks related to moving machinery, equipment, or tools that can cause injury.
 Examples:
o Moving Parts: Gears, belts, and other mechanical parts that can catch clothing or
body parts.
o Equipment Failure: Malfunctioning machinery or tools that could lead to
accidents.
o Sharp Edges: Tools or machinery with sharp components that may cause cuts or
lacerations.
8. Environmental Hazards
 Definition: These include natural or man-made environmental conditions that pose a
threat to safety.
 Examples:
o Flooding: Water damage or hazardous conditions due to flooding.
o Earthquakes: Risk of injury or damage from seismic activity.
o Extreme Weather: Exposure to dangerous weather conditions, such as hurricanes
or extreme heatwaves.
9. Workplace Hazards
 Definition: These are any conditions in a work environment that could lead to injury or
illness.
 Examples:
o Slips, Trips, and Falls: Wet floors, uneven surfaces, or obstacles in walkways.
o Confined Spaces: Working in areas with limited ventilation or movement, which
can lead to suffocation or toxic exposure.
Each type of hazard requires specific safety measures, equipment, and procedures to prevent
accidents or injuries.
Risk & Hierarchy of Hazard Control Measures
1. Risk
A risk is the probability or likelihood that a hazard will cause harm and the severity of its
potential consequences. Risk depends on:
Likelihood – How probable it is that harm will occur.
Severity – The extent of injury, illness, or damage if the hazard materializes.
Risk = Likelihood × Severity

Managing risk effectively requires identifying hazards, assessing risks, and implementing
control measures to reduce or eliminate harm.

2. Hierarchy of Hazard Control Measures

The Hierarchy of Controls is a systematic approach used to minimize or eliminate risks. It
follows a structured order, from most effective to least effective methods:

1. Elimination (Most Effective)

Completely remove the hazard from the environment.
Example: Replacing a hazardous machine with a safer alternative or discontinuing a
dangerous process.
2. Substitution
Replace the hazardous material or process with a safer alternative.
Example: Using a less toxic chemical instead of a highly toxic one.
3. Engineering Controls
Physically isolate people from the hazard through design modifications.
Example: Installing ventilation systems to remove toxic fumes or using machine guards to
prevent contact with moving parts.
4. Administrative Controls
Implement policies, training, or work procedures to minimize exposure.
Example: Rotating workers to reduce repetitive strain injuries, implementing safety training,
or enforcing standard operating procedures (SOPs).
5. Personal Protective Equipment (PPE) (Least Effective)
Use protective gear to reduce exposure when other measures are not feasible.
Example: Wearing gloves, safety goggles, helmets, or respirators.
Why Use the Hierarchy of Controls?
Prioritizes hazard elimination rather than just protection.
Reduces reliance on PPE, which is the least effective measure.
Improves workplace safety by systematically reducing risks.
By following this hierarchy, organizations can create a safer environment and minimize risks
effectively.
In workplace safety, lead indicators and lag indicators are used to measure and improve
safety performance. They help organizations track progress, predict risks, and implement
preventive measures.

1. Lead Indicators (Proactive Measures)

Definition:
Lead indicators are proactive, predictive measures that help identify and prevent hazards
before incidents occur. They focus on actions taken to improve safety performance.
Examples of Lead Indicators:
 Number of safety training sessions conducted
 Frequency of hazard inspections and audits
 Near-miss reports submitted and investigated
 Employee participation in safety programs
 Maintenance schedules followed for equipment
 Compliance with safety procedures and PPE usage
2. Lag Indicators (Reactive Measures)
Definition:
Lag indicators are reactive, outcome-based measures that track incidents and accidents
after they have occurred. They provide historical data on safety performance.
Examples of Lag Indicators:
 Number of workplace injuries or illnesses
 Lost Time Injury Frequency Rate (LTIFR)
 Fatality rate
 Days lost due to workplace incidents
 Workers’ compensation claims
  Equipment damage incidents

Flammability
Flammability refers to the ability of a substance to catch fire and burn when exposed to an
ignition source, such as heat, sparks, or flames. It is an essential safety consideration,
especially in industries dealing with chemicals, fuels, and construction materials. Flammable
substances can ignite easily and sustain combustion, posing fire and explosion hazards.
Flammability Classification:
Materials are classified based on their flammability:
1. Highly Flammable – Ignites easily and burns rapidly.
o Example: Gasoline, alcohol, propane, acetone.
2. Flammable – Can catch fire but requires more effort to ignite.
o Example: Paper, wood, certain plastics, diesel fuel.
3. Combustible – Requires higher temperatures to ignite.
o Example: Engine oil, coal, heavy-duty fabrics.
4. Non-Flammable – Does not catch fire under normal conditions.
o Example: Water, certain metals like steel, concrete.

Toxicity

Toxicity refers to the degree to which a substance can cause harm to humans, animals, or the
environment. It is a key concept in occupational safety, chemical safety, and environmental
health.

Types of Toxicity:

1. Acute Toxicity – Harmful effects occur shortly after a single exposure.

o Example: Inhaling carbon monoxide can cause immediate poisoning.
2. Chronic Toxicity – Harmful effects develop over long-term exposure.
o Example: Prolonged exposure to asbestos can cause lung diseases.
3. Local Toxicity – Damage occurs at the site of contact (skin, eyes, lungs).
o Example: Acid burns on the skin.
4. Systemic Toxicity – Affects internal organs or bodily functions.
o Example: Lead poisoning affects the nervous system.
5. Reproductive Toxicity – Affects fertility, pregnancy, or offspring.
o Example: Certain pesticides and industrial chemicals.
6. Neurotoxicity – Damages the nervous system and brain.
 o Example: Mercury exposure causing cognitive issues.

Time-Weighted Average (TWA) in Safety and Toxicity

Definition:
Time-Weighted Average (TWA) is the average exposure to a hazardous substance (such as
toxic chemicals or noise) over a specified period, typically an 8-hour work shift or a 40-hour
workweek. It helps determine whether exposure levels remain within safe limits set by
occupational health standards.
Threshold Limit Value (TLV) in Safety and Toxicity
Definition:
Threshold Limit Value (TLV) refers to the maximum airborne concentration of a substance
to which workers can be exposed daily without experiencing adverse health effects over a
working lifetime. TLVs are guidelines established by the American Conference of
Governmental Industrial Hygienists (ACGIH) and are widely used for occupational exposure
assessment.
Short-Term Exposure Limit (STEL)
It is the maximum concentration of a hazardous substance to which workers can be exposed
for a short period (usually 15 minutes) without experiencing:
 Irritation
 Chronic or irreversible tissue damage
 Narcosis (dizziness, unconsciousness) that could lead to accidents
 STEL values are established by ACGIH (Threshold Limit Values - TLV-STEL) and
other regulatory bodies like OSHA (Permissible Exposure Limits - PEL-STEL).

"Immediately Dangerous to Life or Health" (IDLH)

It is a term used to describe an atmosphere or environment that poses an immediate threat to a
person's life, health, or could cause irreversible effects or impair their ability to escape. In these
environments, exposure to harmful substances or conditions—such as toxic gases, oxygen
deficiency, or extreme temperatures—can lead to serious harm or death in a very short period.

Acute Effects
Definition:
Acute effects occur immediately or shortly after a single exposure to a hazardous substance.
These effects are usually severe and noticeable but may be temporary or reversible if treated
quickly.
Characteristics:
 Develop rapidly (minutes to hours).
 Caused by high exposure in a short period.
 Effects can be mild to life-threatening.
 Often reversible with proper medical treatment.
Examples of Acute Effects:
 Inhalation of chlorine gas → Immediate breathing difficulty.
 Exposure to strong acids or bases → Skin burns or eye damage.
 Carbon monoxide poisoning → Dizziness, nausea, unconsciousness.
 Overdose of toxic chemicals → Vomiting, seizures, or death.
Chronic Effects
Definition:
Chronic effects develop over a long period of time due to repeated or continuous exposure to
a hazardous substance, often at lower doses. These effects may take years to appear and are
typically irreversible.
Characteristics:
 Develop slowly (months to years).
 Caused by long-term, repeated exposure.
 Effects may not be immediately noticeable.
 Often irreversible or progressive over time.
Examples of Chronic Effects:
 Asbestos exposure → Lung diseases like asbestosis and mesothelioma.
 Lead poisoning → Brain damage, developmental disorders.
 Long-term pesticide exposure → Increased cancer risk.
 Smoking or air pollution exposure → Chronic lung diseases (e.g., COPD).

Routes of Chemical Entry into the Human Body

 Chemicals can enter the human body through various pathways, leading to potential
health risks. Understanding these routes helps in implementing safety measures to
minimize exposure.

1. Inhalation (Breathing In)

Most common and dangerous route of exposure.

 Chemicals in the form of gases, vapors, fumes, dust, or aerosols can be inhaled.
 These substances can quickly enter the bloodstream through the lungs.

🔹 Examples:

 Inhaling carbon monoxide → Oxygen deprivation.

 Exposure to asbestos dust → Lung diseases.
 Breathing in chemical fumes from solvents → Dizziness, respiratory damage.

🔹 Prevention:
✅ Use proper ventilation systems and exhaust fans.
✅ Wear respirators or masks in high-risk areas.

2. Absorption (Skin or Eye Contact)

 Chemicals can pass through the skin or eyes and enter the bloodstream.
 Some chemicals, like solvents and pesticides, can penetrate the skin without visible
damage.

🔹 Examples:

 Strong acids or alkalis → Skin burns or eye damage.

 Pesticides and industrial solvents → Nerve damage or poisoning.
 Oil-based chemicals → Chronic skin irritation or dermatitis.

🔹 Prevention:
✅ Wear gloves, protective clothing, and goggles.
✅ Wash exposed skin immediately with soap and water.

3. Ingestion (Swallowing Chemicals)

 Can occur through contaminated food, drink, or hands.

 Usually happens due to poor hygiene or improper handling of chemicals.

🔹 Examples:

 Swallowing lead-containing dust → Lead poisoning.

 Eating food with pesticide residues → Nausea, organ damage.
  Accidental ingestion of household cleaners → Internal burns, poisoning.

🔹 Prevention:
✅ Wash hands before eating or drinking in workplaces with chemical exposure.
✅ Store chemicals away from food and drinks.

4. Injection (Puncture into the Skin)

 Occurs when a sharp object contaminated with chemicals punctures the skin.
 This is less common but can be serious, as the chemical directly enters the bloodstream.

🔹 Examples:

 Needle-stick injuries with toxic drugs or biological hazards.

 Injection of pesticides through high-pressure sprayers.

🔹 Prevention:
✅ Use proper disposal methods for needles and sharp objects.
✅ Wear puncture-resistant gloves when handling dangerous materials.

Personal Protective Equipment (PPE)

Definition:

Personal Protective Equipment (PPE) refers to specialized clothing or equipment worn by

workers to minimize exposure to hazards that can cause injuries, illnesses, or fatalities. PPE acts
as a last line of defense when hazards cannot be eliminated through engineering or administrative
controls.

Types of PPE and Their Uses:

1. Head Protection

Purpose: Protects against falling objects, head injuries, and electrical hazards.
Examples:

 Hard hats (for construction, industrial work)

 Bump caps (for minor impact protection)
 Insulated helmets (for electrical work)

🔹 Prevention: Reduces head injuries from impacts, falls, and flying objects.

Eye and Face Protection

Purpose: Shields eyes and face from chemical splashes, dust, radiation, and flying debris.
Examples:
  Safety glasses (general eye protection from dust and minor impacts)
 Goggles (for liquid splashes, chemical exposure)
 Face shields (for welding, grinding, or chemical handling)
 Welding helmets (protects from UV radiation and sparks)

🔹 Prevention: Protects against eye injuries, vision impairment, and burns.

3. Hearing Protection

Purpose: Prevents hearing loss from loud noises and prolonged exposure.
Examples:

 Earplugs (disposable or reusable, for high-noise areas)

 Earmuffs (better protection against loud machinery noise)

🔹 Prevention: Reduces risk of noise-induced hearing loss (NIHL).

4. Respiratory Protection

Purpose: Protects lungs from dust, fumes, vapors, and hazardous airborne substances.
Examples:

 Dust masks (for minor dust exposure)

 Respirators (N95, P100) (for toxic dust, fumes, and chemical exposure)
 Self-Contained Breathing Apparatus (SCBA) (for firefighting and confined space
entry)

🔹 Prevention: Reduces the risk of lung diseases, poisoning, and respiratory infections.

5. Hand and Arm Protection

Purpose: Prevents cuts, burns, chemical exposure, and electrical hazards.

Examples:

 Leather gloves (for handling rough objects, welding)

 Rubber gloves (for chemical resistance)
 Cut-resistant gloves (for handling sharp objects)
 Insulated gloves (for electrical work)

🔹 Prevention: Protects against cuts, burns, and chemical absorption.

6. Body Protection

Purpose: Shields the body from chemicals, heat, radiation, and physical hazards.
Examples:
  Coveralls and lab coats (for chemical or biological exposure)
 High-visibility clothing (for roadwork and construction safety)
 Fire-resistant clothing (FR clothing) (for welding and electrical work)
 Aprons (for chemical and food industry workers)

🔹 Prevention: Reduces exposure to burns, toxic substances, and cuts.

7. Foot Protection
Purpose: Protects feet from impact, punctures, electrical hazards, and slips.
Examples:
 Steel-toe boots (for impact protection in construction and factories)
 Rubber boots (for chemical protection and wet conditions)
 Electrical hazard (EH) boots (for protection against electric shocks)
 Slip-resistant shoes (for restaurant and hospital workers)
🔹 Prevention: Reduces foot injuries from falling objects, slips, and electrical shocks.

Health and Safety Policy

1. Introduction
A Health and Safety Policy is a formal statement outlining an organization's commitment to
ensuring a safe and healthy work environment. It establishes responsibilities, procedures, and
preventive measures to protect employees, visitors, and the workplace from hazards.
2. Purpose of a Health and Safety Policy
✅ Prevent Workplace Accidents and Injuries
✅ Ensure Compliance with Legal and Regulatory Requirements
✅ Promote a Safety-Conscious Work Culture
✅ Protect Employees, Visitors, and Assets
✅ Reduce Financial and Operational Risks

Material Safety Data Sheet (MSDS) / Safety Data Sheet (SDS)

1. Introduction
A Material Safety Data Sheet (MSDS), now commonly referred to as a Safety Data Sheet (SDS),
is a document that provides essential information about hazardous substances. It is designed to
ensure safe handling, storage, and emergency response for chemicals used in workplaces.
2. Purpose of an MSDS/SDS
✅ Identifies chemical hazards (physical, health, and environmental).
✅ Provides safety precautions for handling, storage, and disposal.
✅ Guides emergency response in case of spills, fires, or exposure.
✅ Ensures regulatory compliance with OSHA, GHS, and other safety standards.

3. Sections of an MSDS/SDS
A standard MSDS/SDS consists of 16 sections, based on the Globally Harmonized System
(GHS).
Section 1: Identification
 Product name and chemical identifier.
 Manufacturer/supplier contact details.
 Recommended use and restrictions.
Section 2: Hazard Identification
 Classification of hazards (flammable, toxic, corrosive, etc.).
 GHS Pictograms (e.g., skull & crossbones for toxicity).
 Hazard statements and precautionary measures.
Section 3: Composition/Ingredients
 Chemical name and CAS (Chemical Abstracts Service) number.
 Mixtures: List of hazardous ingredients with concentration levels.
Section 4: First Aid Measures
 Procedures for inhalation, ingestion, skin contact, and eye exposure.
 Symptoms of exposure and medical treatment recommendations.
Section 5: Fire-Fighting Measures
 Suitable extinguishing media (water, foam, CO₂).
 Fire hazards and combustion by-products.
  Special protective equipment for firefighters.
Section 6: Accidental Release Measures
 Emergency response procedures for spills and leaks.
 Containment and cleanup methods.
 Personal protective equipment (PPE) requirements.
Section 7: Handling and Storage
 Safe handling precautions.
 Proper storage conditions (temperature, ventilation, incompatibilities).
 Avoiding sources of ignition or contamination.
Section 8: Exposure Controls/Personal Protection
 Occupational exposure limits (OEL, PEL, TLV).
 Engineering controls (ventilation, fume hoods).
 PPE recommendations (gloves, respirators, eye protection).
Section 9: Physical and Chemical Properties
 Appearance, odor, melting/boiling points, pH.
 Solubility, vapor pressure, flash point, and autoignition temperature.
Section 10: Stability and Reactivity
 Stability under normal conditions.
 Possible hazardous reactions.
 Incompatible materials (e.g., acids reacting with bases).
Section 11: Toxicological Information
 Health effects (acute and chronic toxicity).
 LD₅₀ (lethal dose for 50% of test population).
 Symptoms of overexposure.
Section 12: Ecological Information (Environmental Hazards)
 Impact on water, soil, and air.
 Bioaccumulation potential.
 Toxicity to aquatic life.
Section 13: Disposal Considerations
 Safe disposal methods for chemicals and containers.
 Regulatory waste classifications.
Section 14: Transport Information
 UN number and hazard classification for shipping.
 Transportation precautions (air, sea, land).
Section 15: Regulatory Information
 Compliance with OSHA, GHS, REACH, and other safety regulations.
 Labeling and reporting requirements.