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GENERAL SAFETY IN AN INDUSTRY-n.pptx Chemical as well as specialist chemicals
- 1. General Safety InIndustry QUEST MANAGEMENT SOLUTIONS
- 2. 2 5/7/2024 What is Safety? • Freedom from incident which can be achieved by identification of hazards and prevention of damage to men, Materials, machines, product and Environment
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- 4. WHY SAFETY • SaveHuman Life & avoid accidents • Improve quality of work • Create smooth & healthy atmosphere • Reduce time involvement • Built confidence internally & externally. • Save production cost & Improve productivity. • Prevent national loss. • Improve economical growth. • Healthy atmosphere to society.
- 8. 8 5/7/2024 • People donot want to meet with the accidents • Accidents are caused, they do not just happen • Primary responsibility of accident prevention lies with the Management. • There are multiple contributory factors for accident • Accidents occur after repeated violations • Root cause of almost all accidents is inadequacies in Management Control systems • All accidents are preventable • Proactive approach is better than reactive approach Philosophy
- 9. 9 5/7/2024 What is anIncident ? Event that gave rise to an accident or have the potential to lead to an accident. The term incidents includes “nearmiss” Types of Incidents • Accidents •Fire/ Property Damage •Damage to Environment reputation/ •Damage to local communities •Near miss •Close calls
- 10. 10 5/7/2024 What is anAccident ? Any event which results in harm to personnel, damage to property, production loss or causes damage to the environment Type of Accidents : First aid Case : Medical Treatment Case Lost Time injury Fatal
- 11. 11 5/7/2024 Near-miss is aWarning for ACCIDENTS !!!! What is Near miss?
- 12. 12 5/7/2024 Near-miss is anevent which could result in Accident.. But, Averted by Circumstances!! What is Near miss?
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- 19. 19 5/7/2024 Source, situation, oract with a potential for harm in terms of human injury or ill health), or a combination of these What is Hazard Examples : • Falling from height • Spillage of chemicals • Heat radiation • Falling of material, etc..
- 20. 20 5/7/2024 Combination of thelikelihood of an occurrence of a hazardous event or exposure and the severity of injury or ill health that can be caused by the event or exposure What is Risk Examples • Cut, blunt, crush injury • Fatal accident • Property damage • Environment affected, etc..
- 21. 21 5/7/2024 Theories of AccidentCausation HW Henriech- Analysis of 75000 accidents in 1931 24000 600 Near Miss / Unsafe conditions 300 No Injuries Minor Injuries 1 24000 600 Near Miss / Unsafe conditions 300 No injury 29 Minor Injuries 1 LTI •The above figures are averages. Injury can occur the first time also •No proactive methods •Activities are generally carried out for injury prevention than accident prevention •Should analyze root cause of problem than attacking the symptoms
- 22. 22 5/7/2024 CAUSES OF ACCIDENTS ACCIDENTCAUSES INDIRECT CAUSE DIRECT CAUSE PHYSIOLOGICAL UNSUITABILITIES PHSYCOLOGICAL UNSUITABILITIES LACK OF KNOWLEDGE & SKILL UNSAFE ACT UNSAFE CONDITION
- 23. 23 5/7/2024 Causes of Accident DirectIndirect Unsafe Act Unguarded or inadequately guarded machines / equipments Defective conditions of m/c’s, equipments, tools etc. Unsafe methods of storing, piling etc. Inadequate or incorrect illumination Inadequate Ventilation Improper House Keeping-- things not at their proper places Unsafe design or construction of machines and equipment etc. Operating without authority Bypassing safety devices Operating at unsafe speed Using wrong tool / equipment Unsafe Placing Unsafe Loading Taking unsafe position or posture Working on dangerous or moving equipment Not using PPE Horse playing at work place etc. Causes Unsafe Condition
- 24. 24 5/7/2024 Causes of Accident Physiological Unsuitability’s IndirectCauses Poor eye sight Hard to hearing Intoxicated Physiological disabled Psychological Unsuitability's Negative attitude towards safety Ignorance of safety rules and procedures Frustration & Conflict Morale Individual differences Acclimatization Motivation & aspiration Boredom & monotony Lack of Knowledge & Skill`
- 25. DSG 25 UNSAFE ACTS88 % UNSAFE CONDITIONS 10 % ACTS OF GOD 2 %
- 26. Hazard in ProcessIndustry • Physical hazards such as trip, slip and fall. • Fire hazard. • Chemical hazards • Electrical hazards • Mechanical hazard • Equipment and job related. • Tool related. • Area related.
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- 54. Electrical Injuries There arefour main types of electrical injuries: • Direct: Electrocution or death due to electrical shock Electrical shock Burns • Indirect - Falls OSHAX.org - The Unofficial Guide To the OSHA 54
- 55. Shock Severity • Severityof the shock depends on: –Path of current through the body –Amount of current flowing through the body (amps) –Duration of the shocking current through the body, • LOW VOLTAGE DOES NOT MEAN LOW HAZARD OSHAX.org - The Unofficial Guide To the OSHA 55
- 56. BODY RESISTANCE • BODYAREA RESISTANCE IN OHMS • DRY SKIN 1,00,000 TO 6,00,000 OHMS • WET SKIN 1000 OHMS • • INTERNAL BODY • HAND TO FOOT 400 TO 600 OHMS • EAR TO EAR (ABOUT) 100 OHMS
- 57. BODY CURRENT WET CONDITIONS I=V / R 230 / 1000 0.230 A 230 mA (enough to kill a person) DRY CONDITIONS I= V / R 230/100000 0.0023 A 2.3 mA
- 58. Dangers of ElectricalShock Currents above 10 mA* can paralyze or “freeze” muscles. Currents more than 75 mA can cause a rapid, ineffective heartbeat -- death will occur in a few minutes unless a defibrillator is used 75 mA is not much current – a small power drill uses 30 times as much OSHAX.org - The Unofficial Guide To the OSHA 58 * mA = milliampere = 1/1,000 of an ampere Defibrillator in use
- 59. Burns Most common shock-related injury Occurswhen you touch electrical wiring or equipment that is improperly used or maintained Typically occurs on hands Very serious injury that needs immediate attention OSHAX.org - The Unofficial Guide To the OSHA 59
- 60. Falls • Electric shockcan also cause indirect injuries • Workers in elevated locations who experience a shock may fall, resulting in serious injury or death OSHAX.org - The Unofficial Guide To the OSHA 60
- 61. Electrical Hazards andHow to Control Them Electrical accidents are caused by a combination of three factors: – Unsafe equipment and/or installation, – Workplaces made unsafe by the environment, and – Unsafe work practices. OSHAX.org - The Unofficial Guide To the OSHA 61
- 62. Hazard – ExposedElectrical Parts Cover removed from wiring or breaker box OSHAX.org - The Unofficial Guide To the OSHA 62
- 63. Control – IsolateElectrical Parts - Cabinets, Boxes & Fittings Conductors going into them must be protected, and unused openings must be closed OSHAX.org - The Unofficial Guide To the OSHA 63
- 64. Control - OverheadPower Lines • Stay at least 10 feet away • Post warning signs • Assume that lines are energized • Use wood or fiberglass ladders, not metal • Power line workers need special training & PPE OSHAX.org - The Unofficial Guide To the OSHA 64
- 65. Hazard – DefectiveCords & Wires • Plastic or rubber covering is missing • Damaged extension cords & tools OSHAX.org - The Unofficial Guide To the OSHA 65
- 66. Hazard – DamagedCords Cords can be damaged by: Aging Door or window edges Staples or fastenings Abrasion from adjacent materials Activity in the area Improper use can cause shocks, burns or fire OSHAX.org - The Unofficial Guide To the OSHA 66
- 67. Temporary Lights Protect fromcontact and damage, and don’t suspend by cords unless designed to do so. OSHAX.org - The Unofficial Guide To the OSHA 67
- 68. Clues that ElectricalHazards Exist • Tripped circuit breakers or blown fuses • Warm tools, wires, cords, connections, or junction boxes • GFCI that shuts off a circuit • Worn or frayed insulation around wire or connection OSHAX.org - The Unofficial Guide To the OSHA 68
- 69. Lockout and Taggingof Circuits • Apply locks to power source after de- energizing • Tag deactivated controls • Tag de-energized equipment and circuits at all points where they can be energized • Tags must identify equipment or circuits being worked on OSHAX.org - The Unofficial Guide To the OSHA 69
- 70. Safety-Related Work Practices Toprotect workers from electrical shock: – Use barriers and guards to prevent passage through areas of exposed energized equipment – Pre-plan work, post hazard warnings and use protective measures – Keep working spaces and walkways clear of cords OSHAX.org - The Unofficial Guide To the OSHA 70
- 71. EFCOG Electrical ImprovementProject One of the most common occurrences with electrical systems around the DOE complex is excavating, cutting or drilling into electrical systems. There are many methods of trying to identify buried or concealed electrical conduits and cables. None of them are fool proof. Electrical System Intrusions Facilities have developed methods and procedures to help prevent these occurrences. If you are involved in this type of activity, it is your responsibility to comply with facility requirements.
- 72. ELECTRICAL EQUIPMENT INSTALLATION ClearSpace for Switchboards :- 1. Width in front of panel - > 1 mtr 2. Back of the panel - < 0.3 mtr ( so that nobody can attempt to get there) or > 1 mtr clear to a height of 3 mtrs
- 73. ELECTRICAL EQUIPMENT INSTALLATION Earth pitvalue 1. Power stations - 0.5 ohms 2. Major Substations - 1.0 ohms 3. Other Substations - 2.0 ohms 4. Distribution Transformer stations - 5.0 ohms 5. Overhead line supports - 25.0 ohms
- 74. Preventing Electrical Hazards- Planning Plan your work with others Plan to avoid falls Plan to lock-out and tag- out equipment Remove jewelry Avoid wet conditions and overhead power lines OSHAX.org - The Unofficial Guide To the OSHA 74
- 75. EFCOG Electrical ImprovementProject Moisture provides a conductive path that could result in death. Never work with wet tools or clothing. Remove Your Jewelry.
- 76. •Legislations on chemicalsafety •Types of chemicals • Classification of chemicals • Health hazards of chemicals •Route of entry of chemical • Personal Control strategy • protective equipment • Chemicals fire and explosion hazards •Fire and explosion hazard control and prevention • Hazard communication •Material safety data sheet • Material Handling Chemical Safety Agenda
- 77. CHEMICAL SAFETY NEEDSMORE ATTENTION. BECAUSE, EACH CHEMICAL HAS, • MANY PROPERTIES. • MANY PROCESSES. • MANY HAZARDS. • MANY CONTROLS. • THE STATE OF C HEMICAL, PRESSURE, TEMPERATURE, PROCESS PARAMETERS ARE VARIABLE. • MANY HAZARD DATA AND COMPLETE REACTION DOCUMENTS ARE NOT AVAILABLE. • ENG-CONTROL,CONTROL DEVICES, PPEs ARE INADEQUATE • GAS LEAKAGES AFFECTS GENERAL POPULATION AS WELL.
- 78. TYPES OF CHEMICALS. 1POISONS. SOLID POISON-ARSENIC. LIQIUID POISON-ACRYLONITRITE. GAS-POISON-CARBON MONOXIDE. 2 OXIDISING AGENTS. BROMIC ACID. 3 REDUCING AGENTS. HYDRAZINE. 4 REACTIVE CHEMICALS. EPICHLOROHYDRINE. 5 CORROSIVES. ACIDS,PHENOL. 6 SOLVENTS. BENZENE.CHLOROFORM. 7 INFLAMMABLES. LIQUIDS-TOLUENE, SOLVENTS GASES-ETHYLENE OXIDE. ACETYLENE
- 79. 8 EXPLOSIVES. NITROGLYCERIN,TNT. 9 PESTCIDES, INSECTICIDES, FUNGICIDES, HERBICIDES, VERMICIDES. 10 ALCOHOLS. 11 REFRIGERANT GASES. 12 ESTERS. 13 ETHERS. 14 ENZYMES. 15 RESINS. 16 ACIDS. INORGANIC-ACIDS, ORGANIC-ACIDS
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- 145. Fire Chemistry • TheFire Tetrahedron. – The removal of any one element extinguishes the fire. 145 OXYGEN FUEL HEAT CHEMICAL CHAIN REACTION
- 146. Sources of Ignition •Smoking • Electrical equipment • Heaters • Contractors tools and equipment • Arson
- 147. 147 5/7/2024 FUEL Solid Liquid GasMetals ( Combustible) • Wood • Paper • Cotton • Textiles • Petrol • Diesel • Kerosene • Paint • Oils • LPG • Acetylene • Hydrogen • Methane • Sodium • Potassium • Magnesium • Lithium • Transformer • Welding M/C • Generators • Panel Boards Electrical (No class)
- 148. Classes of fire •Fires are classified by the material that is burning. • Fires are designated as: –Class A –Class B –Class C –Class D 148
- 149. Classes of fire •"Class A fire" means a fire involving ordinary combustible materials such as paper, wood, cloth, and some rubber and plastic materials, leaving an ash residue and burn with a white to gray smoke. 149
- 150. Classes of fire •"Class B fire" means a fire involving flammable or combustible liquids, flammable gases, greases and similar materials, and some rubber and plastic materials. 150
- 151. Classes of fire •"Class C fire" means a fire involving energized electrical equipment where safety to the employee requires the use of electrically nonconductive extinguishing media. 151
- 152. Classes of fire •"Class D fire" means a fire involving combustible metals such as magnesium, titanium, zirconium, sodium, lithium and potassium. 152
- 153. Water (Class “A”Agent) • Removes heat, best on Class “A” fires, best overall agent. • Very bad for Class “B” fires as it spreads the fuel. • Very bad for Class “C” fires as it conducts electricity. • Disastrous on a Class “D” fire, may cause an explosion. 153
- 154. Carbon dioxide (Class“BC” Agent) • "Carbon dioxide" means a colorless, odorless, electrically nonconductive inert gas that is a medium for extinguishing fires by reducing the concentration of oxygen or fuel vapor in the air to the point where combustion is impossible. 154
- 155. Carbon dioxide (Class“BC” Agent) • Displaces oxygen reducing its concentration to below the level capable of supporting combustion. • Good for Class “B” and “C” fires. • Not good for Class “A” fires. • Hazardous to humans. 155
- 156. Dry chemicals • Ordinarydry chemical powder (Class “BC” Agent)- – Siliconized Sodium Bicarbonate. – Airborne powder interrupts the chemical chain reaction. – Does not smother, cool or remove fuel. – Good for Class “B” and Class “C” fires. 156
- 157. Dry Chemicals • Multipurposedry chemical powder (Class “ABC” Agent) – Siliconized Ammonium Phosphate. – Performs as above, plus the powder melts when it contacts a hot surface, sealing the oxygen away from the fuel. – Good for Class “B” and Class “C” fires. – Fair for Class “A” fires. 157
- 158. Foam (Class “AB”Agent) –Water based detergent floats on surface of burning liquids, excluding oxygen from the fuel. –Excellent cooling qualities, same as water. –Not suitable for a Class “C” fire. 158
- 159. Dry powder (Class“D” Agent) –Only for Class “D,” metal fires. –Low velocity, sodium bicarbonate or sand. –Attempts to smother fire; however, some metal fires will continue to burn with no apparent source of oxygen. 159
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- 175. 175 5/7/2024 No specificpersonal protective equipments is named in Factories Act, but working conditioned mentioned in sections 14, 33, 35, 36, 37, 38, 87, 111 and 114 are such that free of charge Personal Protective Equipments should be provided by the Occupier for the protection from hazards due to dust fume, gas, vapour, flying particles, glare, revolving machinery, entry in to confine space, explosive or flammable atmosphere and dangerous operation and hazardous process. STATUTORY PROVISIONS
- 176. 176 5/7/2024 If anyworkers employed in a factory contravenes any of the provisions of this section or any rule or order made there under, he shall be punishable with imprisonment for a term which may extend to 3 months, or fine which may extends to one hundred rupees or both.
- 177. 177 5/7/2024 PERSONAL PROTECTIVE EQUIPMENT(PPE) It can be defined as any item of clothing or equipment which is used by employees to reduce their exposure to hazards in the work place.
- 178. Job Hazards • Examplesof Job Hazards are: • Noise • Chemicals • Accidental Impact • Sharp objects • Flying Particles • Dust & Mists • Bright Light • Vibration
- 179. Respiratory (Breathing) Air Purifying Chemical filters Mechanical Filters Combination of Chemical and Mech.filters Dust or Nuisance filters. Micro filters Chemical gas mask. Chemical cartridge. Self-rescue filters Non Respiratory For the Protection of Head Eyes Ears Face Hands Arms Feet Lags Supplied Air Air-lined Self contained Air line respirator. Suction hose mask. Pressure hose mask. Demand Type Recalculating Type Compressed air Compressed oxygen Compressed oxygen. Regenerated oxygen CLASSIFICATION OF PPEs.
- 180. 180 5/7/2024 Environmental Employees Maintenance EmployeesProduction Employees Fire & Safety Employees Contractor Employees HEAD PROTECTION
- 181. Foot Protection • Heavyobjects such as barrels or tools that might roll or fall onto your feet. • Sharp objects such as nails or spikes that might pierce the soles or uppers of ordinary shoes. • Molten metal that might splash • Hot, slippery or wet surfaces • Corrosive Chemicals
- 182. Hazardous conditions… • IMPACT- Carrying or handling materials such as packages, objects, parts or heavy tools which could be dropped • COMPRESSION - Work activities involving skid trucks (manual material handling carts, around bulk rolls, around heavy pipes • PUNCTURE - Sharp object hazards such as nails, wire, tacks, screws, large staples, scrap metal, etc • CHEMICAL - Check MSDS for protection
- 183. 183 5/7/2024 FOOT PROTECTION •Toeprotection Sole protection 183
- 184. 184 5/7/2024 HAND PROTECTION 184 Yourhands may well be the most valuable tools you have. To protect them from the many chemical compounds we use, you should always wear gloves. But choosing the right glove for the job takes some careful consideration. A variety of glove materials exist on the market today; such as rubber, neoprene, nitrile, latex, polyethylene, PVC, butyl, PVA...; which are specially designed to resist certain chemicals better than others. THERE IS NO UNIVERSAL GLOVE THAT WILL PROTECT YOU FROM ALL CHEMICALS!
- 185. 185 5/7/2024 TYPE OFHAND GLOVES 185 1. Cotton or Canvas Hand Gloves 2. Leather Hand Gloves a. Full Leather Hand Gloves b. Only Leather Palm Hand Gloves 3. Rubber Hand Gloves a. Ordinary Rubber Hand Gloves b. Latex Rubber Hand Gloves c. Electrical Resistance Hand Gloves 4. Cut Resistance Nitrile Dipped Hand Gloves 5. Kevler Material (Substitute of Asbestoses) Hand Gloves 6. Aluminised Fabric Hand Gloves
- 186. Hand Hazards • Cuts& punctures • Chemical exposure • Vibration • Electric shock • Burns • Heat & Cold • Biohazards
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- 188. FACE & EYESPROTECTION • Your eyes are very sensitive organs and may be easily injured. Eye Hazards include: – Chemical Splashes – Flying dist, chips, sparks – High Heat – Intense or UV light
- 189. Specific hazards include… •IMPACT - Chipping, grinding machining, masonry work, woodworking, sawing, drilling, chiseling, powered fastening, riveting, and sanding. • HEAT - Furnace operations, pouring, casting, hot dipping, welding • LIGHT or RADIATION - Electric arc welding, gas welding, gas cutting • IRRITANTS / CORROSIVES - mists, dusts, sprays, splashes
- 190. Face Protection • Usea faceshield when any of the following hazards exist: • Chemical splashes • Liquid spray • Flying chips or sparks • High Heat – Special face shield
- 191. 191 5/7/2024 FACE PROTECTION Full faceshield Adaptable on a helmet. The only overall protection for the face. Electric Arc Welding Face Shield
- 192. Types of EyeProtection • Zero Power Spectacle – for flying chips & low hazards
- 193. Types of EyeProtection • Polycarbonate – for dust and non- hazardous mist
- 194. HEARING PROTECTION • Usehearing protection when: • in high noise areas • using power saws, impact tools, etc. • off the job when shooting, using power tools, etc. • Replace damage hearing protectors immediately
- 195. EAR MUFFS Easierto use. Allow to communicate (radio, conversation, etc). HEARING PROTECTION • High noise can seriously damage the auditory system. Hearing protection are mandatory in areas where equipment is being operated and noise is above 90 dBA. 195 EAR PLUGS Be careful of the hygiene conditions when using it (clean hands, etc).
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- 198. RESPIRATORY PROTECTION • DustMask • Protect from large dust particles • Single use • Air purifying mask • Half mask - Full Face Mask • Do NOT use in oxygen deficient atmosphere. • Use in presence of gas and vapor contaminants Good maintenance of cartridge is essential. Adequate cartridge depends on the polluent. 198
- 199. Working on heightProtection 5/7/2024 199
- 200. Protect yourself… •Use theright PPE for the Hazard •Inspect your PPE before using •Replace damaged or worn PPE •Store your PPE properly so it will be ready for the next use •Keep your PPE clean •Notify your supervisor if you need new PPE
- 201. THANKING YOU Wishing youall the Best! BE SAFE & BE HAPPY