ACCIDENTS

INDUSTRIAL ACCIDENTS

When oil is spilt on the floor and a worker places his leg unknowingly over the spilt
oil it is likely that he fall down due to the slipperiness and break his leg, hand or head or any
other part of the body depending on the nature of fall.

A fall of bolt and nut, a plate, a pipe bit or a tool from overhead on a person may
cause injury to his head or body ranging from a mere scratch to a deep wound depending on
the height of fall and weight of the object.

Some persons carrying a pipeline may hit other person at some other job.

In the first circumstance good housekeeping is the requirement to prevent accidents.

In the third instance, good maintenance and safer manual handling are the needs to prevent
the accident.

In the second and third instances the need for proper manual handling is needed to
prevent the accident.

The causes of industrial accidents may be any one of the following. Improper
mechanical handling and electric systems without adequate protection, moving machinery
without guarding, improper maintenance and operation of chemical plants. Moreover the
causes may be fire, explosion, toxicity, corrosion or radioactivity ect.

1. The leakage of methyl isocyanate from giant storage vessels at union carbide
factory, which caused death of thousands of people in BHOPAL in 1984. After this incident
only wind direction was given proper consideration.

2. At Ny pro works, England, in 1974 a massive amount of cyclohexane vapours

escaped and ignited giving rise to a major explosion and killed 28 men and injured 36 men at
site and another 53 men off the site.

CLASSIFICATION OF ACCIDENTS

Accidents can be classified generally due to

1. Failure of equipments or machines

2. Unsafe operation/ Unsafe acts/ Unsafe conditions of machines
3. Employee behaviouristic cause
4. Environmental cause
5. Calamity due to natural causes
6. Due to fire – electrical failure
7. Due to chemicals/ explosive nature
 1. Equipments are usually designed for safe operations. At times, due to
continuous working or overworking, it may suddenly fail and cause an accident. Preventive
and periodical maintenance of the equipment will avert this type of accident.

2. Operating a machine without authority, entering dangerous zones without

authority, operating at more than rated speed, unsafe mixing, loading working on moving
equipments and failure toi use safety and protective devices

3. Improper attitude of the worker daliberate disobedience of safety rules lack of

knowledge and skill physical or mental defect.

4. Improper guarding defective parts, improper illumination, improper

ventilation and unsafe housekeeping.

5. Floods, storms, earthquakes lighting and external military bomb operations.

6. Due to improper housekeeping, negligence, storing of unwanted materials,

smoking, improper storage of fuels, sparks due to friction.

7. Chemicals are in general poisonous and corrosive. They cause –extreme

damage if safety precautions are not obeyed properly. They give rise to fumes and vapours
which may cause fires and explosion on mixing with air or oxygen. Also they leak in
pipelines and corrode entire equipments and areas causing deep wounds and slippage on
coming into contact with them. So they require careful storage and handling.

ACCIDENT COSTS

It can be divided into two types. (1) Direct costs. (2) Indirect costs.

Direct costs will involve compensation payment to the workers & medical expenses.
Indirect costs involve the lose happened due to the accidents. Usually it is found that indirect
costs are nearly 4 times the direct costs. The indirect costs can be

(1) The cost of time lost by the injured employee

(2) Cost of time lost by other employees who stop their work out of curiosity,
sympathy or to assist the injured employee.
(3) Cost of time lost by supervisors, engineers and other executives during the time of
assisting the injured employee or investigating the accident or arranging a new
person for the job.
(4) The cost of time spent by first aid attendants and hospital persons when the
amount is not paid by the insurance
(5) Cost due to damage to machines, tools, equipments or other properties
(6) Incidental cost due to interference with production failure to fill orders in time and
payment of forfeits
(7) Cost to employee under welfare and benefit systems
(8) Cost of employer to the injured employee, even after his return he may not be
fully fit for particular time
 (9) Cost due to the loss on idle machines.

IDENTIFICATION AND ANALYSIS OF CAUSES OF INJURY TO MEN

ANDMACHINE

The purpose of accident investigation is to discover causative factors, the hazardous

conditions and practices that brought about the accidents to happen so that proper action may
be taken to prevent a recurrence. The need is for full information as to the causes that led to
the accidents not just the major cause. This point brings the importance of eliminating the
factor of fixing blame. The investigation should include facts found from the workers, the
supervisors and management.

WHO SHOULD INVESTIGATE?

In case of smaller accidents, the supervisor or the departmental head along with the
safety director can conduct the investigation. A committee of supervisors is commonly used
to investigate in cases of more seriousness. In accidents of extreme men and material loss,
external body of specialists who are through with the type of industry are called for the
service.

The first requisite for starting an investigation is to have an open mind. When a
person is injured or dead, immediately an investigation starts. When an accident occurs and
someone is injured, the first concern should be given to the injured individual. He should be
placed in the hands of medical personnel for treatment. It’s a mistake to run into the danger of
pressing the victim with queries. It’s much better to wait until he has had a good chance to
recover and to collect his toughts. The investigator should get a fairly complete story from
those who were present and from the conditions of the environment. He should investigate in
such a way that what part of the injured person is involved, what was he doing at that time,
where was he, who was there with him and what was he doing at that time and what are the
findings of the medical practitioner who attended him. The investigation is to find out
optimum results and required good judgements, ability to collect facts, weigh the evidence
and arrive at concrete conclusions and select suitable remedies.

Familiarity with the equipment and the plant is essential for the investigating
personnel. Promptness of investigation is essential since conditions may change quickly and
details may be forgotten.

Investigation of accidents has become an established procedure to combat damage

claims under common law or under employer liability acts. The informations received from
investigators should be made open to all so that faults, errors, behavioural deeds leading to
accidents could be avoided in future.

STEPS OF INVESTIGATION

1. On the spot enquiry immediately after the accidents

2. Careful and impartial analysis
3. Enquiring proper personnel who had witnessed the accident
 4. Nothing is dismissed saying that the worker was careless
5. Avoid looking for excuses and find the real cause
6. Avoid trying to convict someone for negligence and it should be remembered that
the company, the supervisor and the worker are at fault to some degree.
7. Through knowledge of all the circumstances surrounding an accident is gathered.

B.A summation of all information usually indicate definite need for more information,
education and training of the worker as well as close follow- up systems by supervisor and
management.

ACCIDENT REPORTS

It’s a common practice to prepare a standard report on every accident or injury to the
worker, whether light or heavy. Reports will be written in the tabulation form. The accident
reports should include details such as the name of the injured, the age roll number,
department, nature of work involved, cause of injury and the action to be follow to prevent
the occurrence of such accidents in future.

NEED FOR THE ANALYSIS OF ACCIDENTS

Analysis of the causes of the accidents include

1. Chief person’s report regarding accidents to be secured, the supervisor’s report

and supervisor’s recommendations
2. Injured worker’s report
3. Reports of the eye witness
4. To record all the facts
5. Tabulate the facts of the present accident together with a similar accident
6. To determine what action should be taken
7. To assign responsibility to persons to carry out the plan of action.

REMEDIAL MEASURES

1. Discovering all the causes of the accidents

2. Analysing the records
3. Inspect all the equipments
4. Check plans, purchase orders and contracts for safety
5. Provide guards for existing hazards
6. Initiating proper maintenance
7. Inspection of defects in equipments and machines
8. Correction of these defects
9. Formation of safe procedures
10. Improve illumination and ventilation
11. Provide safety gadgets
12. Special safety gadgets for specific jobs. Initiate job training job analysis, initiate
proper discipline and proper placement of worker.
NEED FOR ACCIDENT PREVENTION

When an accident happens , a person becomes disabled. The first thing is that he
should learn to live with his handicapped parts, he can’t do the complicated works now and
even the simplest of works become complicated and worst of all the provider becomes
dependant.

METHODS ADOPTED FOR ACCIDENT PREVENTION

1. Regulation : Mandatory prescriptions concerning matters such as general working

conditions, the design, construction, maintenance, inspection, testing, medical supervision,
first aid and medical examination.

2. Standardisation : Laying down standards concerning safe construction of certain

types of industrial equipment, safe and hygienic practices of personal protective devices.

3. Inspection : Enforcement of mandatory regulations

4. Technical research : Investigation of matters such as characteristics of harmful

materials, study of machine guards, testing of respiratory masks, investigation of methods of
prevention of gas and dust explosions, search for more suitable materials and designs for
hoisting ropes and other equipments etc.

5. Medical research : Investigation of physiological and pathological effects of

environmental and technological factors and physical circumstances conducive to accidents.

6. Psychological research: Investigation of the psychological patterns conducive to

accidents.

7. Statistical research : To ascertain what kinds of accidents occur.

8. Education : Teaching safety as one of the subjects in engineering colleges, trade

schools and apprenticeship courses.

9. Training: Practical instructions to workers and especially new enterants in safety

methods.

10. Persuation : By employment of various methods of publicity appeal to develop

safety mindeness or consciousness.

11. Insurance : By way of reduction of premiums payable companies where safety

measures of high standards are adopted.

12. Safety measures within the individual undertaking.

PRINCIPLES OF ACCIDENT PREVENTION

1. Accident causes : An accident is an unplanned and unexp event which causes an

injury. These may be due to unsafe acts or unsand mechanical or physical conditions thus it
provides a basis accident prevention by correction of unsafe actions or repea exposure, the
safe mechanical or physical conditions that even injury accidents occur.

2. Accident sequence : Faults of persons are acquired for environment and the
reasons are a) anatomical or physiological unsuitability, b)improper psychological
characteristics, c) lack of and knowledge and d) improper mechanical and physical
environments.

Occurrence of injury is a national culminatiion of a ser of events or circumstances

which occur invariably in a fixed logical order, thus constituting a sequence. If the series
interrupted by elimination of even one of the several links to enterprise it, the injury cannot
occur. Knowledge of factors in the accident dequence guides us in select the point of attack in
prevention work permits simplification without sacrifice of effectiveness.

ACCIDENT PRONENESS

Examination of records show that out of all the workers doing the same job and being
subjected to the same physical environments, only a few have been reported to have more
acco than the rest. Such workers are found consistently to experience accidents that the
average of other employees and are classified accident prone employees. It’s defined as the
continuing tendancy this person to have more accidents then the others as a result of
persisting characteristics. Accident proneness is due to peculi psychological and
physiological makeup of certain persons.

1. Unattentiveness and day dreaming

2. Poor eye sight, hearing and lack of stamina
3. Poor adjusment of work, distaste for job
4. Too much sensitiveness and tendancy to get perturbed
5. Dislike of the supervisors
6. Lack of training, proficiency and skill to perform the jo b
7. Insufficient intelligence
8. Unsafe behaviour of the worker

Methods of Reducing:

1. Depending upon job conditions, select only those persons who posses the
appropriate standards of physical and mental ability
2. Transfer accident prone employees to comparatively low hazards areas
3. Impart adequate training to a recruit before putting him on the job.
4. Encourage employees working under you and see that they are not unnecessarily
perturbed, frustrated or emotionally disturbed.
CLASSIFICATION OF FIRES

Fires are commonly classified into ‘four’ basic types, according to the nature of
combustible materials

CLASS A FIRES Defined as the fires present in ordinary combustible materials such
as wood, cloth, paper etc.

CLASS B FIRES Defined as fires in flammable petroleum products or other

flammable liquids, gases etc. Technically flammable gases do not fall in any fire
classification category, but practically they should be treated as class B fires.

CLASS C FIRES Defined as fires involving energized electrical equipment where the
electrical non conductivity of the extinguishing media is of importance.

CLASS D FIRES Defined as fires present in combustible materials.

Causes of fires:

1. Spontaneous ignition of trash

2. Sparking duetoi short – circuiting
3. Friction in rotating equipments
4. Presence of open flames
5. Smokes and matches
6. Presence of hot surfaces
7. Static electricity
8. Lighting and
9. Leakage of flammable liquids, gases or vapours from flanges, glands and stuffing
boxes.

Fires can be extinguished by

1. Starvation or cutting of fuel supply and blanketing the oil surface with foam.
2. Cooling by water fog, spray or stream of water or foam
3. Smothering by application fo inert gases or inert vaporizing liquids or dry
chemical.

Extinguishing agents for

CLASS A FIRES : Water, foam, dry chemicals & automatic

Sprinkler systems

CLASS B FIRES : Foam, dry chemicals, carbon- di- oxide, water fog or spray.

\ CLASS C FIRES : Dry chemicals carbon- di- oxide

CLASS D FIRES : Special types are necessary

FIRE FIGHTING EQUIPMENTS

Fire fighting equipments can be manually or automatically operated depending upon

the situation.

1. Hand appliances such as buckets for water or sand, shovels for sand, asbestos or
other fire fighting blankets for smothering fires.
2. Portable fire extinguishers with various agents depending upon the nature of risks.
3. Hose reels with jet or nozzles
4. Foam making equipments such as mechanical foam generators.
5. Special appliances or hand operated installations for special fire risks.

FIRE FIGHTING AGENTS

These are used in hand operated extinguishers and equipments

1. Water, sometimes with additives to increase efficiency or to prevent freezing

2. Foams, including air, mechanical and chemical foams
3. Dry powders
4. Vapourizing liquids and inert gases
5. Carbon di oxide
6. High explosion foams based on synthetic compounds

FIRE EXTINGUISHERS

Water and water based fire extinguishers:

Fire extinguishers containing water, calcium chloride antifreezing solutions or soda

and acid solutions are effective in class A fires and on firesin wood soaked with oils or
greases.

Water or water solutions are used for extinguishing fires by manualy operated pump.
These extinguishers are usually equipped with a hose and a nozzle designed to throuw a solid
stream for distances ranning from 30 to 50 feet.

The main advantages of water are it’s ability to absorb large quantities of heat and to
evaporate to 1700 times it’s original liquid volume to give an inert atmosphere of steam. It’s
ready availability, freedom from toxicity and cheapness are the important factors to make it
highly useful in extinguishers.

Water may be treated with other additives to increase it’s effectiveness on various
types of fires. Wetting agents are sometimes added to assist penetration and let the water
reach the seat of fire. This is effective in baled materials.

Among with water usually potassium or sodium carbonate is used in class A and B
fires. The solution also has a depression freezing point. The other chemicals used to lower the
freezing point are of then based on sodium or calcium chlorides or Ethylene glycol. The
Sodium or Calcium chlorides increase the extinguishing power of the solution but lead to
corrosion and hence require an inhibitor. Ethylene glycol while reducing the freezing point
reduces the extinguishing power.

In extinguishing flammable liquid fires with water spray applied from hand lines,
most of the important factors are

1. Experience of the employee

2. Rate of application
3. Drop size of the water spray
4. Fire points of flammable liquid

Also the time for which the fire is burning before applying water and depth of the
liquid are important.

Water should not be used for electrical fires particularly those of high voltage unless
there is no suitable alternative available. When it is used, the electrical supply must be
disconnected before fire fighting and acre should be observed. Water pumps can sometimes
be used effectively on liquefied gas fires, althrough it is safer to delay fire fighting until the
source of leakage has been stopped. Water can rarely be used on flammable metal fires, since
the use of water can be highly dangerous due to sputtering of the molten metals when
applying water.

Dry powders

Dry powders are being effectively used to an increasing extent for extinguishing fires
in the solid, floammable liquids gases and combustiblematerials. They are used as a replace
of water and foam.

For usein flammable liquids, powders are usually based on potassium or sodium
carbonate or mixture of salts, he powder is treatede with additives to promote moisture
repellency and free flowing qualities and it’s particle size range is chosen to give an efficient
non packing powder. Since dry powders are effective only when they are applied, it is
necessary that appliance should be capable of extinguishing the whole of fire zone.

For use in class A fires, powders have to provide a surface inhibition property in order
to check flamming and smothering the powders are usually based on salts of ammonium
sulphate with appropriate flow and moisture repellant qualities. Metals have been developed.
These powders are generally available in extinguishers or in thin packs for use on radio active
metal fires in glove boxes etc. Powders for metal fires are based on common salt with a
plasticizing agent, graphite, ternary eutectic chlorides, mixtures of powdered PVC and
sodium borate or on boron tri oxide. The agents generally operate by forming a molten layer
on the surface of the metal excluding air and inhibiting further combustion.

Vaporizing liquids are generally used against class B fires but they do also provide
some cooling and can be effective in class A fires. They can be used in electrical equipments
but the acid gases formed may lead to corrosion problem.
FOAMS

Fires in water miscible flammable liquids can be extinguished by using foams, which
consist of a bubble structure formed from an aqueous solution of the foaming agent filled
with a gas. The foaming liquid for air or mechanical foam is produced from waste protein
material such as blood, horn meal, soya been and chicken feathers.

Foaming liquid is mixed with water to a concentration of 4- 6% by volume. Air is

induced into it in a foam making branch pipe which serves to mix the air and the solution to
form a stable bubble structure. The foam is applied to the surface of the flammable liquid as a
blanket which can protect the liquid surface sufficiently from the flame radiation to reduce
the foam in a similar action but it is formed by mixing aluminium sulfate and sodium
bicarbonate together with a foam forming additive, so that the Co2 produced generates a foam
in the residual solution. The foaming agents are usually saponin, Liquorice etc.

CARBON DI OXIDE

Being a gas it leaves no residue when it is used on a fore amd it is not decomposed by
the flames to produce corrosive chemicals. Being a non conductor of electricity, it therefore
an excellent extinguishing agent for the use where there are delicate low voltage relays or
where an electronic equipment is involved in a fire.

There are two types of liquid carbon dioxide storage used for both hand hose line
systems and fixed nozzle systems. One is a high pressure system and the other one is a low
pressure system. In high pressure Co2 is kept at 300 psi and 00F the temperature is being
maintained by refrigeration systems. In hand hose reel systems, Co2 is used in either high
pressure or in low pressure systems. Fized nozzle systems are useful in protection of rooms or
buildings by flooding. Co2 is used for extinguishing fires in spaces that are tight enough to
prevent the leakage of Co2 or entrance of air after the space has been flooded. Fixed nozzle
systems are disigned to deliver Co2 at specific rates of application.

VAPORIZING LIQUIDS

Vaporizing liquids have either Carbon tetra chloride or chloro bromo methane as
major components. Along with these additives are added to depress the freezing point to – 50
F. Even though they are applied in liquid form, they readiliy vapourize to form heavy gases,
that assist in the extinguishing of fires by smothering of flames. When vaporizing liquids are
used, corrosive gases are liberated as the result of decomposition of halogenated compunds.
They are not recommended for use in electrical contacts or where fine tools or precision
metal parts used may be affected by corrosion.

AUTOMATIC CONTROL OF FIRES

These equipments play a great part in saving life and property from fire hazards in
industry. These extinguishers make use of water of extinguishing fire to protect the buildings
and many other classes of risks against the extensive damage resulting from a fire. They can
be divided into 3 types.
 1. Automatic sprinkler systems
2. Drencher systems
3. Water spray systems

Automatic sprinkler system

These are installed in side a building and operate automatically when a fire occurs
These use water to extinguish or control a fire. Pipe work fitted with sprinkles placed at
regular intervals is installed throughout the protected building and is connected to a source of
reliable water supply. When fire occurs only the sprinkler in the immediate vicinity
automatically operate and discharge water to control a fire and the operation of any one
sprinkler causes an audible alarm to sound.

In an automatic sprinkler system water is carried to every part of the plant in pipes
graded in size and generally kept suspended from the ceiling or the roof. Water is held back
in the pipes until a fire occurs. By automatic valves which form an integral part of the
automatic sprinkler systems, when the temperature raises above a predetermined value, heat
sensitive element incorporated into the sprinkler ruptures and fuses and allow the valves to
open under the influence of water pressure. The modern design of sprinkler incorporates an
operating element which like the earlier designs of sprinkler held by metal struts held
together by a fusible solder is immune from effects of corrosion.

Water should not be allowed to freeze in sprinkler systems. For this reasons there are
in general three types of sprinkler installations.

1.Wet system 2.Dry systems 3. Alternate wet and dry systems

In wet systems, the sprinkler pipes are charged with water under pressure constantly,
the system is employed in cases where there is no danger of freezing- in climates where
freezing is unknown.

In dry systems, the pipe by a differential valve which releases the air in the pipes
when the sprinkler opens. The dry system has contributed largely to the wide adoption of
automatic sprinklers. It is applied in premises where the water is liable to freeze. In alternate
were and dry systems the building will be set on dry systems during winter and will be set on
wet systems during summer. These are used in buildings were freezing occurs in part of the
year alone.

Drencher systems

Drencher systems are designed to throw water over windown, doors or other openings
to prevent the transmission of fire from adjacent premises. Drancher systems have proved
their value on numerous occasions by preventing the spread of fire across streets which are
congested.

Some drencher systems are designed to come into operation automatically under the
influence of heat from any other nearby building which may be on fire. Under these situations
sealed drenchers are used. The sealed drenchers are mounted at intervals on a pipe wor
system which is fized to the extension of the projected building an is charged with air under
pressure. Each drencher contains a valve which is kept closed by a bulb until heat from the
fire causes the bulb to to shatter into pieces. On collapse of the bulb, the valve opens and air
escapes from the pipe work system. The resultant drop in air pressure brings about the
opening of a special valve through which water is free to flow and ultimately to discharge
water from any drenchers which have opened due to fire. An automatic warning of fire will
be given immediately before the opening of control valve.

Spray water systems

Some of the worst fire accidents have occurred in case oils and flammable liquids,
until tackled properly at the source such fires can rapidly grow to catastrophic proportions,
often with irreparable damage to the valuable plant.

Spray water systems are developed to tackle the risks to these type. Water is applied
in the form of conical spray consisting of water droplets travelling at a very higher velocity.
Three principle. Emulsification, cooling and somthering are applied in the extinguishement.

The high velocity discharge of water breaks up the surface of the oil or similar
flammable liquids to form an emulsion which will not support combustion.

UNIT -7

HEALTH HAZARDS AN LEGAL ASPECTS

OCCUPATIONAL HEALTH HAZARDS

Occupational health hazards are due to

1. Abnormal air pressure

2. Abnormal temperature and humidity
3. Defective illumination
4. Radiation energy
5. Vibration and noisy operation

Chemicals by nature are toxic and unsafe for easy handling. Industries by nature emit
fumes and poisonous gases and pollute the environment

1. People working in mines are prone to lung diseases

2. People working in cement and refractory units are affected by dust problems
3. People working in paint and lacquer industries are prone to lung and eye problem
due to organic solvents and pigments
4. People working in atomic establishments are likely to suffer blood cancer,
complete body weakness and sterility problems
5. People working in furnaces and not zones are affected by early fatigue and
exhaustion
 In general occupational health hazards are common. Slowly they erode the health of
the working personnel and also the environment.

Prevention Methods:

1. Periodical medical checkup of the employee

2. Early diagnosis of the disease followed by effective treatment
3. If medical checkup is positive , the affected personnel should be given periodical
rest or transferred to a less hazardous situation.
4. Employees must obey the safety practices thy should wear the safety devices,
adopt the safety techniques and behave with a sense of responsibility while
working in hazardous areas.

INDUSTRIAL HEALTH HAZARDS

Irritant gases. May cause extreme burning of eyes and cause

tears. May also cause difficulty in breathing and
coughing
Effects may be serious if exposed for a longer
duration
Explosives Fires may produce irritant gases
Nonflammable gases May cause suffocation or dizziness if breather
Non flammable gases May cause suffocation or dizziness if breathed
Nonflammable corrosive. Gases Very irritating. Contact with skin may cause
burns.
Flammable gases May cause suffocation or dizziness if breathed
Flammable corrosive gases Very irritating. Contact with material may
cause burns to skin and eyes.
Nonflammable poisonous gases Can lead to fatality if breathed in higher
concentration. Contact with material may cause
burns to skin and eyes. Water may be polluted
Oxidizer, poisonous -------------- do ------------------
Flammable, poisonous , gases, Breathing causes little irritation and lead to
fatality. Water may be polluted.
Combustible liquids Vapours may cause suffocatioin or dizziness.
Fires may cause irritant gases.
Flammable, corrosive Vapours may be irritating if breathed. Contact
with material may cause burns to skin and eyes.
Water may be polluted.
Pyrophoric liquids Contact with material may cause severe burns
to skin and eyes.
Flammable solids ------------------------ do --------------------
Radio active, low hazard Degree of hazard will vary. It’s not of
immediate threat to life.
Radio active Prolonged exposure pay be or threat to life or
health
Corrosive Vapours may be irritating if breathed. Contact
with materials may cause severe burns to skin
and eyes.
Corrosive, combustible Contact with materials may cause severe burns
to skin and eyes. Vapours may cause irritation.
Water may be polluted. Poisonous hazards may
be created.

SAFE WORKING ENVIRONMENTS

The need to build safe working environments has lead to enormous increase in the
proportion of design time devoted for safety studies. Plants must function as planned safely
carry out the operations. The requirements of acceptable quantity values on the parameters
and which are also affected by such factors as experience, operability, good practice and the
meeting of guarantees, operating limits of the parameters are concerned with safety on
operation.

Design implies selection of proper materials of construction, proper reaction volumes,

simulation of reaction conditions, reaction time with safety considerations in all these parts.

Materials must stand both corrosion and erosion at the operating conditions. Metallic
materials used for equipments are tested for tensile strength, ductility, hardness, impact
strength and fatigue. It’s physical properties like thermal, electrical and magnetic
characteristics, density, dimensional accuracy are clearly taken for consideration during
design of equipments.

Also fabrication procedures like heat treatment, hardening methods, stress relieving in
weldings, surface finish are given due importance before the equipment is installed.

Generally in the design of process or equipments, the variables like temperature of

operation, pressure, flow and velocity conditions, level, chemical reactivity, mechanical
stresses are mentioned clearly for enabling process operations.

Margins of the variables like upper limit, lower limit and normal operating limit are to
be specified for each of the parameters. Also during designing, an allowance for safety should
be added normally (ie) design pressure must be maximum pressure plus 10% operating
pressure.

Other variables to be included are chemical composition corrosion, vibrations and

shocks, water hammer, expansion or contraction and environmental conditions so that safe
operation of the equipment is possible.

LEGAL ASPECTS OF SAFETY

The primary objective of any act is to ensure adequate safety measures and provide
and promote for the health and welfare of employees in factories. Under the directive
principles of the constitution of India, health and welfare of the workers are required to be
guarded by providing safe and healthy working conditions in work places. This is achieved
through legal lesislations enacted through parliament.

Both state and central governments have therefore enacted various legislatioins which
are required to be strictly enforced. Following are some of the legislations regulating various
industrial activities.

Factories act.1948. Amended in 1987

This statutory regulations are governed by the chief of inspector of factories, Ministry
of labour and government of each state in our country.

1.1 Section 6 Approval licensing & Regulation of factories

This section deals with approval drawing plans for a new factory or exeansion of a n
existing one. Application shall be made in form no.1 along with a flowchart of the
manufacturing process, brief description of the process, plant layout along with elevation,
location of machines and equipments etc.in site plan.

Factory manager shall apply in form no.2 for the registration of the factory
accompanied by an application in form no.3 for the grant of license. The chief inspector in
term registers the factory and grants the license in form no.4.

Section 7 A. General duties of occupier and manufacturer.

The general duties cast under section 7A(1) of the factories act 1948 states that every
occupier of the factory so far as can reasonably practicalbe shall ensure that health, safety and
welfare of all workers while they are at work in the factory. A written statement of safety &
health policy can be formed and implemented.

Section 7. B General duties as regards article and substance for use in factories:

This section lays down general duties on the designers, manufacturers, importers or
suppliers of any article for use in factories. This section envisages principle of built in safety
or product safety.

Section 14. Fumes and Gases

If the manufacturing process gives out dusts or fumes or other impurities which may
be injurious or offensive to the workers employed in the process then effective measures
should be taken to prevent hazard of inhalation and accumulation in one room.

Section 31. Pressure Plant

Time schedule and method of testing of pressure vessels and lines is dealt with in this
section.

Section 32. Floors Stairs & Means of access

 Maintenance of floors, stairs and means of access in good condition at every place of
work considering the emergency requirements.

Section 33. Pits, Sumps, Openings in floors

Adequate protectiion at pits, sumps and opening in floors is to be provided while

working at it.

Section 36.Precautions against dangerous fumes, gases etc.

Persons are required to enter into confined space. Hence method of entry permit in the
form of document is to be followed along with other requirements. Also electrical appliances
exceeding 24 volts should not be used.

Section 37.Explosives or Flammable gases

For safety against flammable gases, fires and explosive effective enclosure of the
plant, eliminatiion and accumulation hazardous dust, gas etc. And confining the spaces (ie)
sources ignition etc. Measures are to the taken. Hot jobs may be convered documented
clearances.

Section.38. Precantions against fire.

Possibility of fires cannot be ruled out. Practicab measures to prevent the outbreak of
fires and it’s spread are to this taken.

Sections 41 A to 41 H are added in the factorias act 1946 during the amendments
done in the year 1987. These sectiions deal with requirements of chemical industries.

Section 41 A. Constitution of Site Approval Committee

Clearance is required for initial location of the hazarding process industries or

expansion of existing industries from SAS constituted under this section.

Section 41 B & C

Information about the hazards involved in the plart an chemicals used in the plant are
to be disclosed to the authority. Safety policy, Waste disposal mothods, on & off site disaste
plans are some of the requirements. Apart from it related measures like providing necessary
facilities for the protection fo workers medical examination of the workers at various stages
are to be taken.

Section 41. F. Permissible limits of exposure of chemicals toxice

Factories act lists about 117 chemicals and their maximum possible limits of exposure
in the manufacturing process which should be indicated in plants.

Section 41. Workers participation in safety management

 The company has to setup a safety committee consisting of equal number of
reprementatives of active workers and managemnt promote safety.

EMPLOYEES STATE INSURANCE ACT

This act is the first major effort in out country to provide social security to workers. It
was passed in 1948, and is operation since 1952.

Under this act every employee in specified industrles and establishments is insured.
Each worker has to make a certain percentage of his salary as contribution, and the corrde
ponding amount is paid by the employer. For udminstration of thre Act, the Government have
istitued, a corroratiion, which to managed by govenment oppointees and representatives of
employers and employees.

The major benefits of this Act are 1. Sickness benefit. 2. Maternity benefits 3.
Disablement benefits 4. Medical benefits and dependent benefits.

WORKMEN’S COMINESATION ACT

Workmone compensations act is introdued in the year 1923. This Act is introduced as
a social security measure to products public welfare. The comporation Act deasl with the
concequrect of an Industrial injury. Industrial injury means, the injury eased to an employee
while he 10 in work in the industry this act 10 applicale to worknon

According to this law the employer is not liable in the follow circumstances

1. The dis- abloment or incompecity does not lost for more than three days
2. The injury does nto result in death and it is easo direaly by the workers drantaneess of
wilful disobedience of safety rules to
3. The acident causing or death of the workman does not uzlec in course of employment.
4. The workman has already filed a civil sult for demages for the some injury against the
employer or another controller.

AMOUNT OF COMPERSATION

Compensation depends upon the nature of the accident resulting in death partial
disablements, comperary diosulment and permanent disablement. According to this law, the
award of compensation should be same both for adults and minors.

PERMANENT TOTAL DISBLEMENT

For the corporation the percentage of earning capacity should be taken, into coconut
permanent total disablement -----loss of full earning ------------ for life. In such a case full ----
------ must be paid

TEMPORARY DIS- ABLEMENT

In such cases a half monthly payment is payable

CALCULATION OF WAGES FOR COMPENSATION

The following procedures has been followed in calculation of wages for compension
1. Where the worman has during a continous period of not less than 12 months immediately
preceeding the accident been in the service of the employer who is liable to pay
compensation, themonthly wages of the workman shall be 1/12 th total wages which have
fallon due for payment to him by the employer in the last 12 month of that peiod.

2. Where the whole of the continuous service immediately proceding the accident is less than
one month themonthly wages of the worksan shall be the average monthly amount which was
being earned by a workman employed on the some work under the same employer or by a
workman employed on similar work in the same locality.

3. In othe cases, the monthly wages shall be thirty times the total wages earned in respect of
the last, continuous period of service immediately precedding the accident divided by the
number of days comprising such period..

4. Lumpsum compensation payable to a workman or a person under legal disability or

compensotion in case of death of a workmen is to be doposited with the commissioner
propertly,if employer donios liabilities for compensations, the depondents are informed
accordingly and it is for them to judge whether to mark a claim or not.

5. Payment of advanced compensatioin by the employer pay conpenttion to the dependents is

permittied to the extent ofRs.100/-. The commissioner may allow payment of actual expenss
upto Rs.50/- from the compensatiion for a deceased workman before distribution of
companesection to the dependents.

MEDICAL EXAMINATION

The workmen should produce the medical certificated to the comisoioner. If he

refuees to do so, his right to receive compention is suspended. If the accident is caused by a
the employer after paying compensation can recover it teem the third party.

The Act is administered in every state by ------------ for workmans compensation

appointed by the state Government. It Tamil Nadu the duties are performed by the ‘Labout
Commisaioner’.

FACTORIES ACT 1948

After Insustrial Revoltion to improve wrlfare -------------- an other facilities like

housing, educatioin for children of the employees, the factories. Act was introduced in the
year 1948.

REGISTRATION OF A FACTORY

An application in writing with the plans and specifications to be made to the

appropriate government or to the chief Inspector of Factores for the constructioin extension
of factory as well as the purpose of replacfing the plants. A licence will not be grant unless a
proper notice in writing according to sec 7 of the Act.

Notice should be given at least 10 days before the factory starts the work to the
Inspector of Factories regarding.

1. The name and situation of the factory

2. The name and address to which the communication to be sent.
3. The name and address of the occupier
4. The naute of the manufacturing process
5. The natjre and guality of power to be used
6. The name of the Manager
7. The number of workers employed using the last 12 months in the case of factory
in existence
8. Any other relevant particulars

FACTORY INSPECTOR AND THEIR POWERS

The enforecment of the provisions of the act is done by the chief Inspector of factories
assisted by several inspectors. The Government may appoint any person who possess the
prescribed qualifications to the inspectors.

POWERS OF THE INSPECTION

1. Surprise chock of the factories

2. Examination of the prescribed register and other document charts, layout,
machinery etc.,
3. Inspection of the canteen and other parts of the company

Every Inspector duly appointed is a public servant and the employer will be
criminally lable if he obstructs the Inspector is lawfully discharging duties

CERTIFYING SURGEONS

The state Government may appoint qualified medical practitioners to be certifying

surgeons for the purposes of this act. He will discharge the following duties.

1. To examins children and adolescent who are employed in the factory for their
fitness of health
2. To examine persons engaged in factories in dangerous occupations
3. To investigate the causes of illness which is pecuillar or recurring in a particular
factory
4. Surprise visit of the Factory within his jurisdictioin once in every 3 months.
 UNIT – I PART – B- QUESTION

ELEMENTS OF SAFETY PROCESS

Effective Safety and Health Programs

 It has been found that effective management of worker safety and health programs
 Reduce the extent and severity of work related injuries and illness
 Improves employee morale and productivity
 Reduce workers compensation costs

Common characteristics of Exemplary work places

 Use of organised systematic methods to

 Assign responsibility to managers, supervisors and employees
 Inspect regularly for and control hazards
 Orient and train all employees to eliminate or avoid hazards
 An effective program which includes provisions for systematic identification,
evaluation and prevention or control of hazards. It goes beyond specific requirements
of the law to address all hazards.
 Written program
 “In writing” less important than its effectiveness
 As size and complexity of worksite or process increares, so does need for written
guidance

MAJOR ELEMENTS

An effective Occupational safety and health program will enclude the following your
elements

 Management commitment and employee involvement

 Worksite Analysis
 Hazard prevention and control
 Safety and health training

(i) Management commitment and employee involvement

 Management commitment and employee involvement are complementary

 Management committee provides the motivating force and resources for organizing
and controlling activities with in an organization
 Employee involvement provides the means through which workers develop and
express their own commitment to ------- protection

Recommended Actions
  State clearly a worksite safety and health policy
 Establish and commenieate a clear goal end objective for the safety & health program
 Provide visible top management involvement in implementing the program
 Encourage employee involvement in the program and in decisions that affect their
safety and health

For Example

Inspection or hazard analysis learns, developing oir revision safe work rules, training
new hires or co-workers, assisting in accident investication)

 Assign and communicate responsibility for all aspects of the program

 Provide adequate outhority and resource to responsible parties
 Hold managers, supervisors and employees accountable for meeting their
responsibilities
 Review program operations at leart annually to evaluate, identify deficiencies and
revise an needed

(ii) Worksite Analysis

Worksite Analysis involves a variety of worksite examinations, to identify not only

existing hazards, but also conditions and operations where changes might occur to create
hazards. Effective management actively analyzes the work and worksite to anticipate and
prevent harmful occurrences

Recommended Actions

So that all hazards are identified

- Conduct comprehensive baseline and periodic surveys for safety and health
- Analyze planned and new facilities processes, materials and equipment
- Perform routine job hazard analyses
- Provide for regular site safety and health inspections
- Provide a reliable system for employs, without year of reprisal, to notify
management about apparent hazardour conditions and to receive timely and
appropriate responses
- Provide for investigation of accidents and “near miss” incidents, so that their
cause and means for prevention are identified
- Analyse injury and illness trends overtime, so that patterns with common cause
can be identified and prevented

(iii) Hazard prevention and control

- Triggered by a determination that a hazard or potential hazard exists

- Where feaible, prevent hazards by effective design of job or job site.
- Where elimination is not possible, control hazards to prevent unsafe and
unhealthful exposure
 - Elimination or control must be accomplished in a timely manner

Recommended Actions

- Establish procedures for timely correction or control of hazards, including

- Engineering techniques, where feasible and appropriate procedures for safework
which are understood and followed as a result of training positive rainforcement,
correction of unsafe performances and enforcement
- Provision of personal protetive equipment
- Administrative controls
- Provide for facility and equipment maintenance
- Plan and prepare for emergencies
- Training and drills as needed
- Establish a medical program
- First aid on site
- Physician and emergency care nearby

(iv) Safety and Healthy Training

 Addresses the safety and health responsibilies of all personnel, whether salaried or
hourly
 Most effective when incorporated into other training about performance requirements
and job practices
 Complexicity depends on size and compllexity of worksite and nature of hazards

Recommended Actions

 Ensure that all employers understand the hazards to which they may be exposed and
how to prevent harm to themselves and others from exposure to these hazards
 Ensure that supervisors carry out their safety and health responsibilities including
 Analyzing the work under their supervision to identify unrecognised potential hazarde
 Maintaining physical protections in work areas
 Reinforcing employee training through continual performance feedback and if needed
enforcement of safe work practices
 Ensure that managers understand their safety and health responsibilities such as
described under the management commitment and employee involvement element of
the guidelines.

SAFETY AWARNESS & TRAINING AT VARIOUS LEVEL

Training of employees in safety has been traditionally recommended as a means for

improving safety performance. Investigation into most of the accidents which take place on
the shop floor- irresfective of whether thay arise out of unsafe physical working conditions
prevailing or actions of persons reveal underlying causes which relate to inadequacy or lack
of training. In sharp contrast, success of stories of industrial units with good safety
performance give evidence of planned training efforts.
BENEFITS FROM GOOD TRAINING EFFORTS IN SAFETY

 Training activities indirectly demostrate company’s interest in employees. This leads

to good human relations at work
 Gaining knowledge and skill helps to improve perceptions and hence improve safety
performance
 Training rever the time spent by the supervisor to instruct and correct
 Training helps personalise the attitude of persons and is one of the best practical
means available to the managers for effective communication with groups.

The analysis also identifies the training requirements in safety in the organisations

Level Training Needs

Helper - Need for safety at work, hazards
connected with this work, ways to
safeguard
Operator - Need for safety, safety requirements
of his job, his responsibilities
Supervisor - Hazards in the operation supervised
and the technical skills to identify
and prevent them
- Human relations and
communication skills
Managers - Responsibility for safety
- Company’s policy and direction
- Techniques to identify and control
hazards
- Human relations and
communication

At higher management level also, knowledge on safety is needed, but this is confined
to a good concept of occupational safety and health in the prevailing social context and broad
under standing of the principles to be followed.

To meets the training needs it will be necessary to plan and implement a

compretensive programme for training covering different levels

Assessment of Training Needs

The first step in developing a programme for training with a view improving safety
performance is an objective assesment of training needs. In the first method the concept that
“Safety training is a must for each and every one” is the key.

The second method also starts with a few standard training is concerned is well taken
care of. In both the caues above, the breaking of ice, as for as safety training is concerned, is
well taken care of . If the programmes are satisfactory conducted, and generally accepted,
even a specific demand for training which paves ways to scientific selection process later can
result.

There are of course more objectives methods which can be used to access the training
needs and select persons for training. They are,

(i) Based on man power planning

A compretensive data on manpower planning can be quite helpful. This analysis can
yield objective conclurions as to who needs what type of training andin what priority.

(ii) Based on safety information

Information relating to safety activities and performance can provide useful

information regarding training needs. The record of first aid throus light on the type of
accidents and the persons involved. Correctly catogorized and logically analysed, this data
can be a very useful tool to assess the training needs.

(iii) Choice by Managers

This process can be made effective by the following additional measures

 Full participation and serious involvement of the managers is ensured by the chief
executive
 The managers get the benefit of a professional advice in his decisions either from
within the organisation or outside
 Information on safety, manpower planning and training modules are made available to
the managers
 Providing oppurtunity for the managers to consult each other
(iv) Data collection and Analysis
Another possible method is a professional survey of training needs. While the plan for
training in safety for the organisation is decided it would be desirable to clasify the needs in a
convenient way some heads under which the needs can be classified are.

Level of training (Rank) : 1. Managers and above

Type of programme
Duration
Specific target groups
2. Asst. Managers and Dy. Managers
3. Supervisors
4. Jr. Supervisors
5. Skilled workmen
6. Unskilled workmen
: 1. General programme
2. Specialised programme for specific group
: 1. Long programme (more than 2 weeks)
2. Medium programmes ( 5 day to 2 week)
3. Short programme (Less than 5 days)
: New employees. Employees on transfer of
jobs. Employees in high age groups
Method of Instruction

Training involves transfer of knowledge skill or information. This can be actieved by means

 On the job instructions

 Lecture method
 Discussions
 Learning By doing
 Demonstratioin/ visits

SAFETY CONSCIOUSNESS IN INDIAN CHEMICAL INDUSTRY

The concept of providing safe working conditions for the manage in industry is not limited to
making available safe plant and equipment. It include ensuring safe operations through safe method of
work, system and procedures

Machine Safety : Ensuring safety in the operation of machine and equipment

Layout, plant Design :- Ensuring layout, arrangements, hence keeping and general conditions of
work around the employees are basically safe and also conductive to safe working.

Working Environment : Ensuring physical work environment around the employee is not hazarders.
Exercise noise level, poor lighting, exposure to heat strees, poor ventilation and precence of toxic,
constitute poor work environment.

Work status Design : Work station design and providing tasks which fit the persures who perform
them, taking into account their physical and mental capabilities and limitations.

Major Hazard Control : Making process safe and free from chances of major hazards like fire
explesion and toxic releases and exercising effective control on process which may prove to be
hazarders.

A recent review of plants indicate many differences in safety organisation and a wide variance
of outhority and interest from top management down through the organization.

The following paints should be considered first

(i) Safety must have top mgt approval, sanction and rupport
(ii) Responsibility for safety must rest with the rupervisory personal
(iii) Safety must be given equal important to other factors

We may clarify the safety organisation in three general types namely

Type ‘A’ firm

Type ‘B’ firm

Type ‘C’ firm

Type ‘A’ firm : Too small industry

No full time safety engineer. It will be carried out by functional head

Type ‘B’ firm Large firm. Seperate safety officers will be there to look after safety work. Here safety
progress depends on the ability of safety officers and attitude of top management.

Type ‘C’ firm : Safety is carried out by committees

It has the advantage of binary together the view points of the group and it will be be. Her than
individual. But the dis advantage is the fact that a committee is the weakest execution.

TOLERANCE LIMIT OF THE SOCIETY

Exposure limits have been established for a wide variety of chemicals sensitive individuals
may ruffer adverse effects at levels much better than the exposure limits.

JLV- JWA

Thresold limit value. Time weigted Average are exposure limits recommended by a
committee of the American conference of Governmental Industries Hygienists and are published
yearly after review. TLV- JWA is the level to which a worker may be exposed for an eight hours stift
without suffering and adverse effects.

TLV – STEL

Some substances have a short term exposure limit. The STEL is a 15 minutes exposure limit
that should not be exceeded even if the eight hours TLV remains within the limit.

TLV – C

A TLV with celling notation ‘C’ represents the conen should not be exceeded at any time.
Ceiling values are used for substances known to be for such are irritating gaces.
 PSYCHOLOGIAL ATTITUDE TOWARDS

SAFETY PROGRAMMES

I. SYNOPSIS

 Psychology at work

 Individual Difference
 The employee as an Individual
 Perception of DANGER
 Risk Taking Attitudes
 Knowledge
 Responsibility
 Employee as a Member of the Group
 Employee as an employee
(i) Lack of communication
(ii) Defective Communication
(iii) Negative communication
 Psychology of learning
 Some useful lints for Trainers

SLOGANS ASSOCIATED WITH SAFETY

“Be safe follow safety Instructions”

“ Preventioin is Better than Cure”

“ Expected & Un Expected

PSYCHOLOGY AT WORK

Industry employs persons in large group. These persons should be consicions about
their own safety. This does not happen so in practise. So on the other hand managers in
factories has a lot top say about workers who habitually break safety rules & create safety
problems for them.

During the past lew decades, good amount of information has been generated by
reasearch on behaviour of people in factories.

Theries in psychology, however has the following limitations.

 Psychology does not provide answers on solutions to problems of behaviour of

people in factories
 Theriers in psychology mostly are formulated on the basis of experiments in
mental hospitals
  The groups and the social environment influence the behaviour of people in
factories considerably.
 Influence of trade union & their leaders, is considerable
 Work itself and work organisation also influence peoples behaviour

Individual Difference

People do not behave in a set manner or in a preditable pattern. Perhaps this can be
explained

It started from

Childhood ---------- Food ------ spit

Two- year – Old boy – light & sound – Pleasant – Hearing unpleasant – off

The same person can behave differently under different situations.

A worker known to be very indisciplined inthe factory may be a highly disciplined

worker for his political party. A person who is irresponsible in the workplace may be a very
responsible and respected person in his community or village.

While analysing safe behaviour this necessiates working into the performance or
behaviour of persons in three dimensions.

1. Behaviour as an individual
2. Behaviour as a member of the group
3. Behaviour as an employee

Employee As an Individual

Philasophy and approach to safety

Compare two persons E& F.

1. E born to loving parents he falls down and gets hurt but has his mother to take
care of him immediately with handages, consoling words.

2. F has to compete with others to get what he wants he had more than his quota of
purnishment in school. He gets injured in games but learns to take care of himself.

Both join in a factory

E is likely to accept the supervisor as a friend and his advice to near gloves.

F may not likely to obey that easily and may book suspiciously at the gloves

PERCEPTION OF DANGER
 Perception means seeing and understanding child – hot – electric iron – not able to
understand its hazardness “Seeing” a danger makes the “Difference”

Eg:. Safety manager – Grinding wheel – Goggles

Worjer – “Nothing has happened so far I have been working for 10 yrs” – Lack of
knowledge and experience.

Preception of danger – Qualitative aspects but also Quantative

Jumping over Belt – Fatal accident

(conveyor)

Investigation revealed that it was a common practise for workers toi crossover the belt
instead of taking a longer route.

Knowledge of dangers associated with work and preception of danger go together.

Positive efforts to explain the dangers to workers is one good remedy.

RISK TAKING ATTITUDES

Persons in situations C& D persons working for monetary gains & accepts risks and
persons working for incentives.

Persons working for with over confidence leads to amputation of his whole hand or
death.

Risk taking and attitudes should be curbed by identifying risk taking habits of
persons, Personnel conselling and supervision.

Knowledge:

Welder – good knowledge of welding technology – knowledge about the safety

precautions indifferent welding operations and knowledge on fine and explosion are essential.

On shop floor – lack of efforts in training, half hearted job instructions allotment of
jobs to new faces due to exigencies & unskilled persons trying to do skilled jobs lead to
persons without required knowledge levels performing tasks which in turn result in accidents.

RESPONSIBILITY:

Worker exposed to involving wheel. The fixed guard was opened and kept down.
Worker questioned agreed that he knew he is exposed & that he knew how to fix the guard in
position.

“It’s not my job, the maintaneance man should have done it”.

Responsibility for safety is a function of knowledge on safety. Here again emphasis is

to be laid on efforts directed at education and training of employees.
 Three objectives is to ensure safe behaviour

1. Efforts in training of employees in safety as well as the job itself.

2. Establishing correct work methods through adequate job instructions and checks
3. Good, close supervision & counseling

Employee As a member of the group

Many ways are open to obtain constituent of groups

  Influencing the leaders. Taking these leaders into confidence and in listing their
support it s sure way to succeed .
  Identifying the strong members of group & in listing their support involving them
in safety activities
 Influencing the group as a whole through organized group cont act .(I e) discussions,
training programmes & mass communication programmers.

Arranging visits for whole group or a few strong members to unit s which have a good
record of workers participation in safety .

Employee As an employee

 Lac k of communication
 Negative communication
 Defective communication

SAFETY POLICY

An objective need in t his regard & perhaps a good s tarting point is a formal or
ganisation policy statement on safety . A perequiste to this is a decision n by the
management a t the top executive level or board level & o n the safety standards, safety
activities is targets for safety performance of the organization. The decision should be
realistic & practical & not merely plilosophical.

A dear public statement by the chief executive oir the chairman of the board
explaining the policy & also why & how the policy is beingimplement is necessary, such a
statement should put the intentions of the managrement beyond the scope of any speculation
& clearly spell out the following

 Why the management cosiders it necessary to introduce the policy

 What action the management is taking to implement the policy including targets for
performance fixed & standards etc.,
 What it expects from the managers, supervisors and workmen, in unambiguous terms

The public statement should be followed up by:-

 A written policy document which is made available to every employee

  Internal communications through regular channels in the form of office orders or
memos. Thisis necessary to ensure that employees and supervisor take serious cognise
of policy, which othervise may tend to be ignored.
 Review of and suitable changes in the existing documents relating to employee/
employer relations.
 Indentification of key result personnel involved (selected managers, supervisors, trade
union leaders) and arrangements for their training
 Steps directed towards managing the change effectively Declaration of a safety policy
or fixing targets or standards themselves have no significance or consequence unless
the followup is effective. There is need for arrangements for getting information (or
feed bacl), monitoring oif performance, encourage those who perform well & correct
those who do not. In short, it is to be ensured that the decisions taken are
implemented.

Safety and health activities call for coordinated efforts throughout the organisation as
each & everyone has a contribution to make. The manage through good communication,
systems & procedures for monitoring and control, adequate, staff assitance & forums for
discussions & consultancy. The managerial & supervisory staff play a crucial role andtheir
responsibility and accountability should be fixed beyond doubt.

HAZARD IDENTIFICATION TECHNIQUES

There are conditions, circumstances which can cause accidents, health hazards,
discomfort or other types of harm to the persons working. These may be in the form of

 Unsafe physical working conditions (e.g. unguard machines, poor

illumination,exposure to chemicals, defectives wire ropes.)
 Unsafe work methods (eg. Unguarded machines exceeding safe speed limits,
unauthorised operation unsafe postures, not wearing google).
 M----- adjustment between machine & men (physical strength intellectual demands
etc.,) or
 Factors relating to organisation & management of work (eg. Poor supervision, poor
levels of communications).

The starting point for the safety management programme and one of its crucial
components is arrangement for systematic identification of all known causes and their
correct craluation. This should be followed by evolving & developing a stategy for corrective
action.

The concept of a ‘cause’ is to be clearly understood. A cause is different from a

symptom. Taking a simple example, a ladder has a defective rung and a person climbing it
falls down. Traditionally two causes are identified for the accident the defective ladder and
the careless worker who did not notice the defect.
 In the case of the ladder accident the defective rung in the leader and the fact that the
worker did not notice it are, by the same token, the symptoms of something among in the
organisation and the management of work just as the headache of executive.

The accident attracts a number of questions like

 Who purchased theladder?

 Who is responsible forit up keep?
 What kind of inspections theladders are subjected do?
 Where is it kept?
 How many accidents involving ladders have taken place in the past?
 Was the worker involved given instructions on the safe use of ladder?
 What checks are mode to ensure that persons follow safe methods at work?
Workmen compensation act:-

This act was introduced in the year 1923. This is introduced as a social security
measure of public welfare.

The act deab with the consequences of an industrial injury. An industrial injury may
be defined as the injury caused to an employee during his work.

The employer is not liable in following circumotances

1) Does not loot out for more than 3 days

2) Injury occured to an employee out of his work place
3) Asking compersation to already suited case.

Amount of compensation

Depends on

 Nature of injury
(Should be same for both adults & elders)
 Temperary disablement
 Permanent disablement
 Death

Temporary disablement

A half monthy payment

Permanent diablement

Full earnings

Death:-

Lumpsum compensation amount

Registration

Employee should submit Mc to the labout commiostioner. He will sent the amount to
be paid to the employer. If he denies to pay, then victions are unfornced accordingly, it is
upto them to decide to suit a case or not.

This act is adminstrated in every state by a labour communstioner.

Temporay Disablement

In this case haly monthly payment is payable.

Calculation of wages for compensation

The following procedure is followed

 When the workmen during his continous period of work not less than 12 months
immediately after the accident will be liable to pay compensation, the monthly wags
shall be 1/12th of the total wages
 Medical compersation ( Registration of compersation)

The workmen should produce the medical certificate to the commissoner. If he

fefurses, his right to recieve compersation is surpended. If it is caused by third party,
employer after paying compersation can recover it from the third party.

This act is administered in every state by commissence for workman’s compersation

appointed by the state government.

Workment’s Compensation Act

It was introduced in the year 1923.

The compersation deals with the covequence of an Industrial injury.

According to this law the employer is not liable in the following c---------

1. Injury does not result in death and it is caused directly by the workers wilful
disobedience of safety rules.
2. The accident causing (or) death of the workman does not happen in course of
employment
3. Asking compersation a heady suited case

Amount of compensation

Compensation depends on the nature of the accident rerulthing in death, partial disablement,
temporary disablement and pumenant disablement.

According to this law, the compensation should be same both for adults and elders.

Permentent Total disablement

 Percentage of earning capacity should be taken into account for a full earning capacity
full compersation should be paid.
DANGEROUS AND HIGHLY TOXIC CHEMICAL AND HIGHLY RADIOACTIVE
MATERIALS

DANGEROUS AND HIGHLY TOXIC MATERIALS

The effect of chemical substances on human body and safety precautions are closely related.
Chemical substances affect the body by ingestion, inhalation and adsorption through skin
contact.

INGESTION

If it is in light dose, when the detoxicating effect the liver exerts has a protective effect in
such cases. When massive coses are taken, it can lead to fatalities in case of absence of
immediate medical action.

INHALATION

It is a common route for entry of dangerous chemicals.These impurities affect the lung
directly while are obsorbed in thye blood atream through lungs.

DUSTS AND FUMES

INERT DUST

Carbon dust is present in plants manufacturing and using carbon black and graphite products.
Carbon dust causes blackening of lung tissues.

HARM FULL DUST

Silica dust is used in rubber refractories and in abrassives, on breathing it stimulate the
production of fibrous tissues in lungs, which cause of time interfere the passage of air to lung
causing shortness of breath and leading to tuberculosis.

Vanadium dust is present as catalyst and also in fuel iols and is also used in alloys, pigments
and electroplating.Uranium is a vital raw material in nuclear industries.

GASES AND VAPOURS

SIMPLE ASPHYRIANTS

These gases cause reduction of oxygen by dioplacing it to a level where it doesn’t support ...
and cause ...

eg:N2,CO2,CH4

CHEMICAL ASPHYRIANTS

Co damages the oxygen carrying capacity of the blood causing permanent brain damage or
death.
PULMONARY IRRITANTS

This affect the lungs in addition to cause irritation to upper respiratory.

eg:cl,pg,SD3,Br

UPPER RESPIRATORY IRRITANTA

These irritate the vapour respiratory passages and the eyes, Lungs may not be affected if the
reaction id able to escape quickly as the irritaton is severe even at low concentration.

eg: NH3,SO,Furfural

TOXIC CHEMICALS

Lead,Manganese and Mercury dusts:

Lead : effect is entered on the blood , bones and nervous system. It cause anemia, colic and
constipation and paralysis muscles of the hand and foot.

Manganese: Affects the brain causing tremor of hands saliration etc

Mercury : affects the skin, effect are oxcossive, salivation, gum inflammation and loss of
teeth.

HALOGENATED HYDROCARBONS

1. chloroform - bad effect on the lungs, liver damage

2. carbon tetra chloride - damage liver and kidney

3. tetra chloro ethane - damage kidneys

4. chlorinated aromatics - poisonous for nervous system

5. carbon di sulphide - poisonous for nervous system

6. aniline, phenol - blood poisoning

HIGHLY RADIO ACTIVE MATERIAL

ACTIONTO BE TAKEN IN CASE OF FIRES

 fire fighting equipments should be used

 damaged package

 in small fires use carbon di oxide or dry chemical

ACTION TO BE TAKEN IN CASE OF SPILLS

avoid contact with leacking or damaged packages

gloves should be used for moving the damage packages

entries to the hazardous are should be stopped for material minimun possible time

in case of corrosive rate active materials, attempt to plug releases from containers opening
modes.

plugs or freeze leakage by cooling with water stream at point of opening.

ROLE OF TRADE UNION
Functions:-
 It encourages the workers to involve
themselves in the organisation of safety
meetings, contest etc.,
 Good instruction contribute to safety
especially on the safe practices in Industries.
 The main objective is protecting the
workers and their rights to higher better life.
 All organisation, tradeunion &
management are aimed to Zero Accident
The promotion of safety is not one man’s
safety.
Role is in promotion & implementation
of safety.
It Represents people at work
Purposes:-
To protect & improve worker’s pay
conditions of employment & working safety
& welfare.
They compaign for laws & policies which engineers in order to promore safety.
will benefit working people.
Trade union of India:-
 Madras labour union – 1918
 Textile labour association – 1920
 Indian Federation of free trade unions
 ATU – All Indian Trade union congress
: 1920
 To appoint the safety Engineers & with
ensure safety permit & work permir in the
organisation.
 Promotion of safety organisation
ROLE OF ORGANISATION
It must insist companies to follow the
safety procedures.
They should encourage & appleciate the
worker those who follow the safety rules that
they should be awarded.
Some organisations:-
 National safety council
 British safety council
 All Indian Institute Hygine & public
health.
 It should encourage the workers by
conducting safety awarness, programs like
mettings, contest, conferences
 It must appoint people with well
knowledge on safety, to do periodic
inspections.
 It must appoint trained physician
surgeons, in the treatment of occupational
diseases health to --- to full time safety
 To conduct safety day celebration
 To check whether the it contains fire
fighting equipment, PPE, lighting,
ventillatioin & first aid etc.,
 Following are some of the legislations
regulations various Industrial activities which
is used to promote safety in Industry
 Factories act 1987
 It should be done by
Safetu dau celebration
Awarmess of safety
Safety movies etc.,
 Safety aadit
It is system & procedures of safety in
industries should verified by certified
authorities of Government.
They give suggestions about safety
 HAZOP Study
All the employees should know about
the MAJOR EVENTUALLITY IN
INDUSTRIES.
 It places a duty on employers to assess
& manage risks to their employees and other
arising from work activities.
 It places a duty on employers “ To
ensure so for as is reasonably practicable, the Industrial safety for its works.
health safety & welfare at work.
 To give training to employee.
Significance of training is to gain knowledge
about safety.
 The management should minimize
theunsafe act & unsafe conditions.
 Thise are governed by the chief of
inspector of factories & ministry of labour &
govt of each state of our country
1. Approval of drawing plans for a new
factory
2. General duties of occupiers &
manfactures are specified under sec
7(A) of factories act 1948
3. Effective measures should be taken to
prevent inhalation & occumulation of
hazard fumes.
4. Permissible limits of exposure of
chemicals & toxins are fixed by govt.
For controlling pollution.
 Government plays a vital role in
promotion of safety in industries.
 Govt. Of India has enacted may essential
acts (or) suitable legislations related to
 The primary offective of any act is to
ensure adequate safety measures & provide &
promore for the good health & welfare of
employees in factories.
 These are achieved through legal
legislation enacted through parliment
 Both the state & contral governments
have therefore enacted legislations which are
required to be strictly followed.