Accident Prevention In Industry

BY SURESH PATIL

JSW STEEL LIMITED, TARAPUR

SAFETY
FOR SAFETY

S A F E T Y

STANDARDS AWARNESS FULLFILLMENT. EFFICIENCY TRAINING YOU.

INDUSTRIAL SAFETY :It is an activity carried out to minimize the contact of workers with the existing danger in factory and thus reducing accidents.

SAFETY

WHAT IS AN ACCIDENT

Accident is an unplanned and Unexpected event which causes or is likely to cause an injury or results into property damage or causes interruption in production activity. It Damages Three MMan Material Machine.

CAUSES OF ACCIDENTS

1. 2.

UNSAFE ACT UNSAFE ACTION

UNSAFE ACTS
Operating without authority.

Working at unsafe speed. Making safety device inoperative. Using unsafe equipment. Unsafe loading. Taking unsafe position. Teasing,abusing . Failure to use of PPE.

ACCIDENT MODULE DUE TO UNSAFE ACT

If someone committed 360 unsafe acts. Out of 360 he found, 1 330 are no accident, 29 29 are minor injury or near misses, 1 is lost time injury. 330

UNSAFE CONDITIONS (MECHANICAL/PHYSICAL)

Inadequate guarding. Unguarded moving parts. Defective conditions. Unsafe design. Hazardous arrangement: Layout,Storage,Exits .Overload. Inadequate illuminiuation. Inadequate ventilation. Unsafe working dress. Unsafe Practices and Procedures.

LOSSES DUE TO ACCIDNET

Loss of LIFE Loss of limbs i.e.Temporary/permanent disability. Loss of great magnitude in the form of pain Financial losses. Hidden losses are like iceberg

HUMAN
Suffering to the injured. Loss of life. Suffering to the family members,relatives & friend . Loss of earning Medical expenses.

ECONOMIC

Direct cost / Indirect cost. Loss of production. Cost of medical treatment. Damage to property: Equipment, Building, Materials. Time loss by other employees. Interruption in production. Cost of training new employees. Loss of morale. Loss of efficiency. Cost of repair / replacement.

LEGAL

Obligations for both to worker & management at various act.

COST OF AN ACCIDENT.
INJURED PERSON 1)Suffering &pain. 2)Worry. 3)Incapacity to perform normal output of work 4)medical expenses. 5)loss of life. SUPERVISOR 1)worry. 2)loss of prestige. 3)good man lost. 4)selecting &training substitute. 5)more supervision 6)loss of output. 7)loss of morale. DIRECT COST 1)compensation payment. 2)medical expenses. INDIRECT COST 1)lost time of injured employees 2)lost time of injured other employees. 3)lost time of foreman,supervis or,executives. 4)cost of time spent by first aid attendant. 5)cost due to damage. 6)costs under employees welfare & benefit scheme. SOCIETY. 1)Lives lost. 2)maydays lost 3)cost of maintenan ce of the disabled & dependent.

MISCONCEPTION

Accident happen-they are inevitable.

When there are huge machinery & fast moving production lines accidents are inevitable. Safety rules are for new comer. It will not happen with me as I am experienced person..

ADVANTAGE
Human safety Increase productivity Ensure quality of product

Time saving

DO NOT FORGET.

Prevention is better than cure. Safety is key to success You are responsible for your safety. Lean safety teach safety practice safety Act with will to make accidents nil.

BASIC THEORY.
-Unsuitable anatomical& physiological characteristics -lack of knowledge -Improper phy.condition -faults/Failures of person -Unsafe act -Unsafe condition -Mech./Physical. -Accident -Injuries.

HARZADS

PHYSICAL
CHEMICAL BIOLOGICAL

MECHANICAL HAZARDS

Due to rotating machines. Due to operating machines in wrong manner. Due to absence of guards to rotating parts

CHEMICAL HAZARDS
Due to exothermic runaway reactions Due to overconfidence Due to lack of knowledge Due to lack of safety measures Due to failure of control systems Due to mis-operations Due to unattended reaction premises during reaction

ELECTRICAL HAZARD

Due to improper earthing continuity Due to poor maintenance of switches. Due to open live ends Due to absence of precautionary measures

RADIATION HAZARDS
Due to emission of radiation of radioactive rays Due to lack of using required PPE Due to prolonged contact with radiations Due to lack of safety systems Due to process itself

HAZARD ASSESSMENT PROCEDURE

A number of methods are available for the various steps of Risk assessment procedure. HAZOP study. SAFETY Audit. PLANT Inspection.

AVAILABLE METHODS OF HAZARD ASSESSMENT.

Method
Safety review (What if Analysis?)

Priciple

Quantification
No

Review of components of the process by an experinced multidiciplinary team Check - List Comparison of materials and equipments with data & codes established by experience. Hazard & Operability Detection of cause and studies. (HAZOP) effects of deviations by use of guide words. Failure Mode and Detection of critical faults in Effect Analysis. the functioning of individual (FMEA) component.

No

No

Possible

AVAILABLE METHODS OF HAZARD ASSESSMENT.

Method
Fault Tree Analysis (FTA)

Principle

Quantification

Event Tree Analysis. (ETA) Cause & Consequence Analysis (CCA) Job Safety Analysis

Deductive description of event Possible leading from failure of components to a hazardous situation. Inductive determination of Difficult pathway of disturbance having led to a hazardous situation. As Above Possible Detection of potential hazardous interactions. No

INCIDENT RATE
The no. of accidents per 1000 workers in all manufacturing industries in India,UK & USA are as follows.
YEAR INDIA UK USA 1976 68.62 0 0 1979 1980 1981 62.19 66.92 72.54 0 0 0 0 0 0

REASONS FOR BAD RECORD

More manual operations. Lower education standards of our employees. Management being not sufficiently conscious . Lack of training. Lack of installing required safety systems.

REASONS FOR ACCIDENT PREVENTION

Economic.

Humanitarian.
Legal.

SAFETY TARGETS
No fires. No loss time injury. No accident.

RESPONSIBILITY.

Management--to initiate the work of Accident Prevention.

Workers--every at every level should share the responsibility.

HUMAN LIMITATIONS
Capabilities. Knowledge. Personnel characteristics. Age. Job experience. Visual functions Psychological characteristics. Adequate attentions to be paid to -proper selection, training. Placement, Education. Supervision.

FIVE ES.
Engineering :proper system & layout. Education: relevant job & safety education. Enforcement:clear cut procedure & their enforcement. Enthusian:keeping the workforce motivated. Evaluation:continues evaluation of program & procedures & updating them to meet current needs.

PREVENTION METHOD.

Engineering revision.
Personal adjustment. Instruction ,Appeal. Discipline

MANAGEMENT CONTROL.

Eliminating unsafe conditions. Personal adjustment.

Safety educations.

Supervision
Discipline.

MANAGEMENT CONTROL.
Eliminating unsafe act. Safe guarding. Rectifying preventing defective conditions. Suitable,safe design construction. Safe arrangement process. Adequate & suitable illumination. Adequate & suitable ventilations. Safe dress. Personal protective equipment. Good housekeeping. MSDS.

MANAGEMENT CONTROL.
Discovering causes. Job safety analysis. Hazop study. Safety audits. Inspection of plant. Investigation of accident. Recording data. Analysis of data.

SELFSAFETY
HOW TO PROTECT YOURSELF!

SELF SAFETY

Follow the Safe Operating Procedure to avoid Accident.

SAFETY MANAGEMENT PRACTICES.

Accident/incident report, analysis & follow up. Training requirement. Safety audits. Plant documentation. Critical instrument system. Control over safety device bypassing. Relief device program. Control of changes. Work permits system.

SAFETY MANAGEMENT PRACTICES.

Formation of HSE policy. Various safety audits. Safety induction program. Disaster plant -Mock drill &updating. MSDS. TREM cards. Employees involvement. Safety meetings. Suggestion scheme. Off the job safety. Family involvement. Minimum storage. Learning's from incident.

WORK PRACTICES
1. 2.
3.

4. 5. 6. 7.

Store MATERIAL in their respective places. While charging chemicals respective PPEs are to be used. While pouring solvent from bigger container to small container which develop static charges from both of them must be earthed and bonded in order to prevent fire and explosion. Prevent spillage Label all chemicals. Follow the SOP for unloading tanker. Smoking strictly prohibited.

WORK PRACTICES
Regular checking of instrumentation calibration Fire protection system to be checked Avoid wrong sequential operation Prepare SOP for power failure Do not sudden start and restart of agitation. Delay in starting cooling.Vent should be checked Audiovisual alarm system to be checked

GENERAL INSTRUCTIONS
1. Operation mistake can result in disaster in most such a plants and hence it is quite essential to ensure that all operating staff scrupulously and systematic the operation instruction given to them by supervisory staff Developing safe procedures and practices is an intelligent exercise those who have to follow them must understand its necessity and know-how to follow them for ensuring safety Ensure use of proper tool Avoid unsuitable method Avoid equipment failure as a misoperation

2.

3. 4. 5.

GENERAL INSTRUCTIONS

Ensure that there should not be lack of alertness, negligence, overjudgement, improper physical or mental condition While shift changeover extra care to be taken for critical operation Avoid poor communications Avoid poor housekeeping status Operator should be always prepared Alertness play big role Alert person smell danger promptly, knows dangerous condition exists, appraise seriousness, take requisite correct action

PRODUCT SAFETY

By following safe operating practices one can ensure the product safety.

There will be no cross contamination.

The quality of product will be improved. Customer satisfaction.

DO NOT FORGET.

Learn Safety,
Teach Safety Practice Safety.

DO NOT FORGET.