M.G.M’S COLLEGE OF ENGG.

AND TECHNOLOGY CHEMICAL ENGINEERING DEPARTMENT

A REPORT ON ADVANCES
IN INDUSTRIAL SAFETY

10/8/2017

SUBMITTED TO:

SUBMITTED BY:

H.O.D: PRINCIPAL:

c
 PREFACE
As Chemical Engineers, it is very important for us to know about
Industrial safety, which being unaware of, will pose a threat when we
join the industry as an employee. This report has been prepared
purely for academic purpose, under the guidance of prof. Nikhil
Nilange. Economics is a governing factor in any chemical industry, as
the entrepreneur invests huge sums of money on the plant. So,
performing any chemical process without checking on the safety can
lead to a loss, not only economically but also physically, like injuries
caused to employees,etc. Given all these above facts, industrial safety is
a must in every chemical plant.
Despite the best efforts put in by us, it is possible that some
unintentional errors night have eluded us. We welcome the new ideas,
developments, revisions if any from readers, teaching staff members
and wellwishers which will definitely be incorporated.
 ACKNOWLEDGEMENT

We would like to thank our Prof. Nikhil Nilange for providing us

the opportunity to create this report and also for entrusting us
with it. We also thank all our colleagues for guiding us
throughout.
 TABLE OF CONTENTS

Sr.No. Content
1.
2.
3.
4.
5.
6.
7.
LIST OF ILLUSTRATIONS
 ABSTRACT
This report consists of information on chemical plant
safety. It includes significance of industrial safety with its
objectives. Then comes plant hazards & its types
followed by records of accidents which have occurred.
Safety equipments are also included which is the main
part of the report. It is followed by safety audit and plant
maintainance.
 INTRODUCTION
Accidents on industrial sites may cause injury to employees, contractors, or
members of the public adjacent to those sites, especially in the context of major
releases of chemical substances. Accidents involving employees or third-party
individuals on sites are generally linked to a failure of safety management
relating to risks at the workplace. Accidents involving contractors include falls
during work at height, in construction and maintenance activities, use of tools,
and interaction with equipment during maintenance, as well as accidents due to
non-compliance with work permit procedures.Risks of causing injury to
neighbors or the public are mostly a consequence of major process accidents at
manufacturing sites or during transport activities.
This report is useful, mainly, for all the students of Chemical Engineering and
also other branches of Engineering. Besides it is also of great use to all the
employees working in the industry.
 Chp.1: PLANT HAZARDS

Causes of Industrial accidents

The main reasons for industrial accidents are:
 Unsafe physical condition: Inadequate ventilation, broken guards,
unsafe clothing .
 Unsafe acts: Working at unsafe speed, not using safety devices,
improper tools
 Personal Factors: Lack of knowledge, physical weakness, age,
health.

Safety measures while setting

new plants:
Plant Location: Selection of plot from the point of view of safety is
necessary. Geographical and natural
advantages should be considered
Process Design: Physiochemical and thermodynamic properties of
the process elements are to be considered from the point of view of
safety. Fail safe process routes are very necessary
Equipment and structure design: MOC of equipment should be
properly chosen. Equipments have to be designed to withstand
overload and high level parameters so that they do not cause
accidents.
TYPES OF HAZARDS
Fire hazard
Causes of fire hazard:
1. Leakages
2. Hot jobs
3. Short Circuiting
4. Electrical Sparks
5. Static Electricity and Friction

Explosion hazard
This causes greater damage and loss of property as
compared to fire hazard.
Common Causes:
1. External use of energy
2. Internal exothermic reaction
3. Result of sudden release of internal energy
4. Dust explosion
5. Salt bath explosion

Toxic hazard
Hazards caused due to exposure of toxic chemicals is
called toxic hazards.
Common Causes:
1. Investigation
2. Inhalation
3. Contact with skin
4. Contact with eyes

Corrosion hazards
Corrosion causing chemicals constitute to the corrosion
hazards
Common causes:
1. Splash of Corrosive chemicals
2. Exposure to corrosive chemicals
3. Leakage from valves, pipelines.
4. Escape from vent of chimneys.
5. Release of gases at start-up.
Hazard control
o Low inventory of chemicals
o Time factor
o Exposure factor
o Temperature factor
o Good Design and area installation
o Pressure Vessels
o Inspection and Maintenance
o Training
o Utilities
o Storage and disposal of waste
o Instrumentation
o Laboratory Safety
o Emergency procedures

First-aid
• A First-AID box must be provided to a person who will
be available through-out the working hours so that the
workers and take advantage of the given facility.
DTEL 22
• The First-AID box should have adequate amount of
supplies to fulfill the needs of their workers.

Chemicals and human body:

ROUTE OF DESCRIPTION EXAMPLES

ENTRY
Inhalation Chemicals entering Gases, dust,
the body trough fumes
breathing
Ingestion Through mouth Dissolved in
water
Skin absorption Skin contact Benzene affects
blood cell
RADIATION HAZARDS:
Two types of nuclear forces bind particles together:
1.Very short range.
2.Protons are repelled by electromagnetic force


Radioactive Decay: Half-Life

Half-Life and Hazard
• Very short half-life (days or less)
– Extremely high radiation hazard
– Decays very quickly
– Probably won’t move far during lifetime
DTEL 44
• Extremely long half-life (geological)
– Radiation hazard negligible
– Chemical toxicity is worst hazard
– Daughter products (radon) can be a problem

Alpha Radiation
• Given off by decay of uranium and thorium and
daughter products (including radon and radium)
• Cannot penetrate skin
DTEL 46
• +2 electric charge = high ionizing ability
• Least dangerous externally, most dangerous
Internally.

Beta Radiation
• Given off by light and medium nuclei, including most
fission products (fallout and reactor waste)
• Can penetrate a few mm into tissue
DTEL 47
• Electrons, -1 charge = moderately high ionizing ability
• Minor external hazard, fairly serious internal hazard
Gamma Rays
• Produced by all nuclear decays
• Need not be accompanied by particle emission
• Penetrates tissue easily, requires 1 cm lead to reduce
Dby ½
• Most serious external hazard
 Chp2: PERSONAL PROTECTIVE
EQUIPMENT
Definition: Devices used to protect an employees
from injury or illness resulting from contact with
chemical , radiological, physical, electrical,
mechanical, or other workplace hazards.
The need for PPE and the type of PPE used is
based on hazard present; each situation must be
evaluated independently.

Types of equipments:

•Head protection
•Eye and Face protection
•Hearing protection
•Respiratory protection
DTEL 80
•Arm and Hand protection
•Foot and Leg protection
•Protective clothing

Respiratory Protection
• Protects users by removing harmful materials that
may enter the body via the lungs
• Inhalation is one of the quickest, most efficient ways
to introduce lethal levels of hazardous materials into
the body.

Respirators - types
• Air Purifying Respirators (APR)
– Half-face
– Full Face
• Powered Air Purifying Respirators (PAPR)
DTEL 99
• Self Contained Breathing Apparatus (SCBA)
 Chp.3: FIRE PREVENTION
Fires Are Classified by the
type FUEL they burn.
The 4 Types are
–A
–B
–C

Class A Fires
•Wood
•Paper
•Plastic
•Rags
Class B Fires
Gasoline
Oil
Grease
Paint
Class C Fires
Electrical Fires
– Office Equipment
– Motors
– Switchgear
– Heaters
Fire triangle:
Fires require air, fuel & heat
Air Fuel Heat
Air is required as a For a fire to start For a Fire
catalyst there must be to Start,
Can be oxygen from something to Burn there must
the air or be a heat or
From the Fuel ignition
itself source
  Types of Extinguishers
Class A
 Used on Wood, Paper,
 Plastic
 Class A Fires
Class B
 Used on Flammable
 Liquid Fires

Class C
 Used on Electrical
 Fires

Class D
 Used on Metal
 Fires

Using A Fire Extinguisher

Use the PASS system:
Pull
Aim
Squeeze
Sweep
Pull the Pin
This will allow you to
discharge the extinguisher.
Aim
Aim at the base of the fire. If you aim at the flames, the extinguishing agent
will fly right through and do no good. You want to hit the fuel.
Squeeze
Squeeze the top handle or lever. This depresses a button that releases the
pressurized extinguishing agent in the extinguisher.
Sweep
Sweep from side to side until the fire is completely out.
Fire Rules
1.Never Fight a Fire if you don't know what is
Burning:
If you don't know what is burning, you don't know
what type of extinguisher to use.
Even if you have an ABC extinguisher, there may be
something in the fire which is going to explode or produce highly toxic
smoke.
Never Fight a Fire if the fire is spreading rapidly
beyond the spot where it started
The time to use an extinguisher is in the incipient, or
beginning, stages of a fire. If the fire is already
spreading quickly, it is best to simply evacuate the
building, closing doors and windows behind you as
you leave.
Never Fight a fire if you don't have adequate or
appropriate equipment
If you don't have the correct type or large enough
extinguisher, it is best not to try to fight the fire.
Never fight a fire if your instincts tell you not to.
If you are uncomfortable with the situation for any
reason, just let the fire department do their job.

The final rule is to always position yourself with

an exit or means of escape at your back before you
attempt to use an extinguisher to put out a fire.
In case the extinguisher malfunctions, or
something unexpected happens, you need to be able
to get out quickly, and you don't want to become
trapped. Just remember, always keep an exit at your
back.
 Chp.4: SAFETY AUDIT
Benefits of Good Safety Management
• Reduction in the cost of medical and workers’
compensation
• Greater productivity
• Improved product or research quality
• Overall operation improvement.

PPD’s Audit Program

• An opportunity to spend a few minutes observing
activities in the workplace and then discuss what you’ve
seen with your employees
• This is done with an eye towards safe, and unsafe,
behavior
• Mitigate hazards
• Record observations

Purpose of PPD’s Safety Audit

– Identify safe and unsafe, acts or conditions
– Identify areas for improvement
– Follow up when mitigating actions are indicated
– Accumulate data for tracking trends related to safety

Benefits of safety audits

• Promote safe behavior
• Test for compliance with standards
• Establish standards
• Identify weaknesses
• Accumulate data
• Prevent injuries

Proposed frequency of audits

• Division Office – Quarterly
• Department Heads, Level 1 Project Managers – Quarterly
• Group Leaders, Level 2 Project Managers – Monthly
• ES&H Staff – Monthly
• Supervisors, Level 3 Project Managers – Weekly
What to look for during an audit
• Reactions of people
– Does anyone adjust PPE, change position, or
rearrange job when the safety auditor appears?
– Does anyone abruptly stop work, attach grounds, or
perform LOTO?
DTEL
• Positions of people
– Is anyone in danger of injuring himself by pulling or
lifting heavy objects?
– Is anyone in a position where he or she could fall, be
trapped, collide with anything, or be hit?

• Tools and equipment

– Are they being used properly?
– Are they in safe condition?
– Are homemade tools (not properly
designed) being used?
DTEL
• Procedures
– Are they adequate? Do they prevent all
unnecessary risks?
– Are they followed?

When Someone is Working Unsafely

• Observe; then get the person’s attention
• Comment on what the employee was doing safely
• Discuss with the employee
D – The possible consequences of the unsafe act
– Safer way to do the job.
• Get the employee's agreement to work safely in the future
• Discuss other safety issues of the job.
• Ask the employee what you the supervisor could do to make the
employee’s job safer
• Thank the employee
 Chp.5:PLANT MAINTAINANCE
Importance of Plant Maintenance
• Avoid heavy loss
• Leads to inevitable loss of production
• Poor maintenance leads to
• Loss in production time
• Rescheduling
• Overtime
• Work shortage

Duties, Function & Responsibility of Plant

Maintenance Engg. Dept.
• Inspection
• Engineering
• Maintenance (including preventive Maintenance)
• Repair
• Overhaul
• Construction
• Salvage
• Clerical Work

Types of maintainance:

1.Preventive maintainance

Characteristics of maintenance

 Maintenance and reliability is important

 Maintenance and product quality
 Maintenance and productivity
 Failure cause disruption, waste, accident, inconvenience and
expensive
 Maintenance and safety
 Operators less able to do repairs themselves
 Machine and product failure can have effect on company’s operation
and profitability
 Idle workers, facility7
 Losses due to breakdown
All actions necessary for retaining an item, or
restoring to it, a serviceable condition, include
servicing, repair, modification, overhaul, inspection
and condition verification. Increase availability of a system.
Keep system’s equipment in working order.

• Advantages:
–Reduces break down and thereby down time
–Lass odd-time repair and reduces over time of
crews
–Greater safety of workers
–Lower maintenance and repair costs
–Less stand-by equipments and spare parts
–Better product quality and fewer reworks and
scraps
–Increases plant life
–Increases chances to get production incentive
Bonus.

2.Corrective or Breakdown Maintenance

• Corrective or Breakdown maintenance implies that
repairs are made after the equipment is failed and
can not perform its normal function anymore
• Quite justified in small factories where:
– Down times are non-critical and repair costs are
less than other type of maintenance
– Financial justification for scheduling are not felt

Disadvantages of Corrective Maintenance

• Breakdown generally occurs inappropriate times
leading to poor and hurried maintenance
• Excessive delay in production & reduces output
• Faster plant deterioration
• Increases chances of accidents and less safety for
both workers and machines
• More spoilt materials
• Direct loss of profit

3.Scheduled Maintenance
• Scheduled maintenance is a stitch-in-time
procedure and incorporates
– inspection
– lubrication
– repair and overhaul of equipments
• If neglected can result in breakdown
• Generally followed for:
– overhauling of machines
– changing of heavy equipment oils
– cleaning of water and other tanks etc.

4.Predictive (Condition-based) Maintenance

• In predictive maintenance, machinery conditions are
periodically monitored and this enables the
maintenance crews to take timely actions, such as
machine adjustment, repair or overhaul
• It makes use of human sense and other sensitive instruments, such as
–audio gauge, vibration analyzer, amplitude meter,
pressure, temperature and resistance strain
gauges etc.
CONCLUSION
REFRENCES