Industrial hazards

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

A Hazard is an existing or potential condition in the work place, that if left uncontrolled, which by itself or by interaction with other factors result in unwanted affects of injuries, property damage or other losses.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Occupational Health Is Essentially A Preventive Medicine

It is a science of the anticipation, recognition, evaluation and control of hazards arising in or from the work place which could impaired the well being of the workers also taking into account the possible impact on the surrounding community and the general environment

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

At the first session of joint committee of ILO and WHO held in 1950, occupation health was defined as Occupational health should aim at the
promotion and maintenance of the highest degree of physical, mental and social well-being of workers in all occupation

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Types Of Occupational Hazards

Physical hazards Chemical hazards Biological hazards Mechanical / Electrical hazards Psychosocial hazards

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Types Of Occupational Hazards

Physical hazards
Heat Cold Light Vibration Radiation Noise

Chemical Biological Mechanical-electrical Psychological

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
HEAT
The direct effects of heat exposure are Heat exhaustion heat stroke [civil works] Burns [boiler area, electrical flash over] Heat cramp [civil works, boiler area]

COLD
[[[[[[

Important hazards associated with cold work Frost bite Chilblains Immersion foot General hypothermia as a result of cutaneous vasoconstriction

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
HEAT- As a hazard in power stations can cause
1. 2. 3. 4. Heat stress-it is the aggregate of environmental & physical work factor i.e. Total heat imposed on the body. Heat strain- it is the physiological responses to the heat stress. Heat disorders-these result in heat cramps, heat exhaustion, heat stroke. Heat cramps: painful intermittent spasms of voluntary muscles after hard physical work in hot environment. Cramps usually occur after heavy sweating. Heat exhaustion: profuse sweating, weakness, rapid pulse, dizziness, nausea & headache. Skin is cool/pale. Body temperature is normal, nausea, vomiting and unconsciousness may occur.

5.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Heat can be of two types 1. Dry hot 2. Wet warm Our body gains/loses heat due to: 1. Heat of metabolism (m) 2. Radiation heat from environment (r) 3. Conduction from hot body (c) 4. Heat loss by evaporation (e) 5. Heat gain= m+r+c-e,

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Effective work temperature in a work environment can be measured by wag index; One degree rise in effective temperature reduces work efficiency of a worker by 2.5% Effective temperature in a work environment should be 29 0C.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Effective temperature and heat effect in an environment can be controlled by: Increasing air changes Reducing radiated heat by insulation Reflection of heat Drinking plenty of water and intake of salt Use of personal protective equipments

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Fire hazards in power stations can cause losses and can cause burn injuries to the persons. Different types of fires can be controlled by extinguishing the fires at starting stage and by taking fire protection measures.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
LIGHT Effect of poor illuminations are : Headache Eye pain Lachrymation Congestion around the cornea Eye strain Eye fatigue

Exposure to excessive brightness is associated with discomfort, visual fatigue, blurring of vision and may lead to accidents.
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Light as a hazard in working condition can be due to: Less lighted areas when the light is insufficient person strains his eyes to see the work object/area. Light requirements are increasing with age of a person to see and work on the object. Excessive lightit is dangerous for eyes when light in work area is excessive since it causes glare.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
Normally light requirements are provided as required for different work areas as given in national building code and also as per the Factories Act 1948. This Act says that there should be sufficient light provided in all areas of work so that the worker does not have to strain his eyes while at work. Further factories rules require that there be at least one foot candle light which is equal to 10.76 lux in all corridors. National building code provides lighting requirements for all work areas of a thermal power plant, e.g....
100 lux in TG hall, 100 lux in boiler area, 300-900 lux in machine shop as per work etc.
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
VIBRATION
Vibration especially in the frequency of 10 to 500 Hz, can affect hand and arm after month of years of exposure Ill effects: The fine blood vessel of finger becomes increasingly sensitive to spasm (white fingers). Injuries of the joints, of the hands elbow and shoulders may take place

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
VIBRATION Continuous working should be avoided and rest pauses after some time of work must be allowed to workers. The driving force of vibrating surfaces may be reduced by;
1. Reducing the forces 2. Minimizing rotational speed 3. Isolating

The response of vibrating surfaces may be reduced by

1. 2. 3. 4. Damping Additional Increasing mass of vibrating surfaces Changing size to change resonance frequency

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
NOISE Industrial noise can give rise to deafness Non auditory effects are irritation, nervousness, annoyance, fatigue, inefficiency etc. Telephones are not audible visual aids may be required (TG, Boiler area] Hearing impairment due to Noise is, as per the schedule of the Factories act, is reportable as well as compensable. Hearing loss in most cases is not sudden but increases with the length of the work time in the noisy zone.

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Physical Hazards
NOISE Threshold Limit Value for noisy working conditions: (An 8 hour shift in all following cases) 8 hours work 90 dBA 4 hours working 95 dBA 2 hours working 100 dBA 1 hour working 105 dBA half hour work 110 dBA

Threshold of hearing 125 dBA Sudden deafness/rupture of ear drum can occur at 140 dBA

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Physical Hazards
NOISE Noise affects us due to its loudness as well frequency Human ear can hear frequency range of 400 c/sec. to 20000 C/sec. Noise is transmitted to our brain through
i) head ii) outer ear iii) ear canal

Its transmission to brain can be controlled by use of PPEs like helmet, ear plugs, ear muffs.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical Hazards
NOISE

Noise can be controlled by; 1. Reducing vibrations 2. Enclosing the noise producing equipment 3. Enclosing the operator 4. Moving away from the noisy area 5. Use of personal protective equipments

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Physical Hazards
RADIATION
A. Ultraviolet Radiation hazardSeen in work with arc welding and mainly affects the eyes. Exposure to such radiation may lead to Conjunctivitis and Keratitis (Welder s flash) Ionizing radiation hazards[X room USG CT] Anemia Leukemia Cancer Sterility Foetal Malformation in case of pregnancy Ulceration In extreme cases death can take place

B.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical / Electrical Hazards

y Accident y Fall y Injury y Electricity burn y Electric shock.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Type of safety
Material handling safety
Definition: Material handling is preparation, placing and positioning of materials so to facilitate their movement and storage.

Material handling accounts 36 % of production cost 40% Industrial accidents are in material handling.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Safety in the Movement of Men & Materials

The day-today working needs following for performing duty Ladders, scafolds, working platforms, manual lifts, lifting attachments (slings, shackles, eye bolts, ropes etc.) Lifting machines (lifts, lifting tackles, jacks, winches, cranes mobile and stationary, chain pulley blocks, fork lifts, hydra, etc.) Mobile machineries (trucks, dumpers, tractors, vibrators, road rollers, etc.) Transport of hazardous materials (petrol, diesel, naphtha , LPG, acids, alkalies, and other inflammable liquids and gases)
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Safety Check List For Chains, Ropes & Slings

Sl.NO

POINT TO BE CHECKED Condition of lifting tackles ? Adequacy of the strength of lifting tackles with respect to the weight to be lifted. Is all ropes, slings are tested by competent person? If yes, record is being maintained? Is lubrication found is adequate? Whether all the wire ropes,. slings etc., are stored properly? Handling of wire ropes, slings against sharp edges, excessive loading is done properly? Falling of welding sparks, gas cutting spatters on the ropes & slings All ropes & Slings are anchored properly wherever it is done? Whether ropes or slings are subjected to crushing loads between hard surface & load being loaded or unloaded? Condition of the surface near ferrule provided on the slings?

STATUS

REMARKS

01 02 03 04 05 06 07 08 09

10

Working at heights possibilities of accidents

Fall of materials Fall of persons Working on false ceilings/fragile roofs Working over water Working ON SCAFOLDING Working on ladders, staircases, escalators, tower cranes, EOT cranes Working on slippery floors Working on construction lifts & hoists

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazard PREVENTION

Preventive maintenance Adequate job training Ensuring safe working environments Establishment of safety department with qualified safety engineer Periodic survey for finding out hazards Application of ergonomics

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazards
MACINERY HAZARDS: These are due to revolving parts of the machines. These can be controlled by providing machine guards which are a statutory requirements under Sections 21 to 26 of the Factories Act 1948. As per section 21 of the Factories Act- provide guards at following;
Moving parts of the machinery including fly wheels Transmission machinery Point of operation Any other dangerous part

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazards
BASIC REQUIREMENTS OF A GUARD
Protect the operator Protect others Not interfere with efficiency Fool proof Allow repairs Allow oiling Be well constructed Be well secured Create no new hazards

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazards
TYPES OF GUARDS
Safety by construction Fixed guards Automatic guards Interlock guards Trip guards Positional or distance guards Safety by position Other types

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazards
FIXED GUARDS
They are stationery There are no moving parts Very little maintenance required. Safe distance of a guard from danger point for different size of openings Up to 15 cm distance More than 15 cm distance.

Y=X/8-6mm Y=X/12+6mm

Y-Vert. opening, X- Distance from danger point

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Mechanical Hazards
SAFETY OF MAINTENANCE PERSONNEL
Safety precautions are required to safe guard the maintenance personnel from getting involved in machinery accidents owing to inadvertent starting of machinery by; Design of control switches Safe guards for the operating levers Interlocking of power system

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Electrical Hazards
Injury from direct contact 1. Injury by shock 2. Injury from internal burns

Injury without current flow through body 1. Direct burns from electrical arcs 2. Radiation burns from very heavy arcs 3. Injury from fire & explosion from electrical arc 4. Physical injury from false starting of machinery, failure of controls 5. Eye injury from electrical arc welding
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Electrical Hazards
Injury from current flow induced in or near the human body by intense electric magnetic fields: 1. Injury from elevation of whole body temperature 2. Local injury such as cataract formation in the eye 3. Burns due to metallic objects such as rings etc. In close contact with local parts of the body

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Fundamentals of Electrical Hazards

More than 3 ma
painful shock

More than 10 ma
muscle contraction no-let-go danger

More than 30 ma
lung paralysis- usually temporary

More than 50 ma
possible ventricular fib. (heart dysfunction, usually fatal)

100 ma to 4 amps
certain ventricular fibrillation, fatal Over 4 amps heart paralysis; severe burns. Usually caused by >600 volts

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Fundamentals of Electrical Hazards

Human resistance to electrical current
BODY AREA DRY SKIN WET SKIN EAR TO EAR RESISTANCE (OHMS) 100 000 TO 600 000 1000 ABOUT 100

For the same voltage different effects

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Chemical Hazards

Chemical hazards liquid and gaseous hazards 1. Dust 2. Smoke 3. Fumes 4. Poisonous gases 5. Acids 6. Alkalis

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
Chemical Safety
There are thousnands of chemical compounds, which presents some form of hazards either major or minor incidents usually termed as chemical accidents. To avoid chemical accidents some points to be kept in mind.
1. 2. 3. knowledge of chemicals knowledge of pocessing plant knowledge of operator

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Chemical Hazards

They enter our body through Skin Inhalation Mouth They can cause internal as well external injuries Skin diseases Lung diseases Internal blood and other diseases

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Chemical Hazards
Local Action
Eczema Dermatitis Cancer

Inhalation 1. Organic Dust

Size ranging from 0.1 to 150 Microns. Particle smaller than micron is called respirable dust and is directly inhaled into the lung and mainly Responsible for Pneumoconiosis in the different form depending upon the type of dust like : Organic dust Silica- Silicosis Asbestos- Asbestosis Iron Siderosis Coal Anthracosis
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Inorganic dust Cane fiber - Bagassosis Cotton Byssinosis Tobacco Tobacossis

Chemical Hazards
Pneumoconiosis
Incidents of pneumoconiosis depends upon the following factors Size of dust particle Chemical composition Duration of exposure- incubation period may range from few months to 6 yr Individual susceptibility

Sign and Symptoms

Irrigative cough Dysnoea (difficulty in breathing) Pain in the chest

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
Coal/silica dust is major health hazard in power station These dusts enter our body through inhalation Respirable dust particles can enter our lung sacks and reduce our breathing capacity since this reparable dust settles there, Normally coal dust particle less than 1 micron only can enter in our lung sacks. Bigger dust particles either remain in our nose or get stuck in throat. Then they go into stomach and get removed from our body system in natural way. Coal dust is non toxic and as such no effects are caused on body due to the particles of dust in stomach.

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Chemical Hazards

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
Reparable dust particle which enter into our lungs can not be removed and they remain settled there. Disease which can occur due to inhalation of coal dust is known as pneumoconiosis and is irreversible till person is shifted from job Silica dust can cause silicosis Both are reportable as well as compensable diseases under the schedule of the factories act

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
Control of coal dust by Reduction of dust emission by suppression by wetting coal in wagons, at the time of tippling, water spray in coal conveyors... Suction of coal dust from environment in above areas. Use of personal protective equipments like filter respirators which can filter out reparable coal dust particles. Continuous monitoring of environment by measuring and keeping it below.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
2. Gases
Gases are the common hazards in many industries leads to suffocation and asphyxia. Asphyxiating gases are CO, Cyanide, SO2, Chlorine etc.
Smoke: inhalation of smoke which can contain poisonous gaseous fumes also and can have effects on our health; Fumes: fumes emanating from liquid chemicals can cause ill effects on our health when inhaled; Vapor: vapors of chemicals liquids are also dangerous to our health when inhaled. Vapours of hydrazine hydrate can cause unconsciousness when inhaled.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
3.Metals and compounds
Toxic hazards are seen from Lead, Mercury, Chromium, Arsenic etc

4.Chemicals
Acid (water treatment/ chemistry), Alkali and Pesticides.

Hazardous chemicals used in thermal power stations:

Chlorine Hydrochloric acid Euphoric acid Hydrazine hydrate Liquor ammonia Sodium hydroxide

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Chemical Hazards
Chlorine It is the most hazardous chemical used It is used in water treatment plant It is procured in toners for use in chlorinationation When more than 10 tons of chlorine is stored/ handled/used in any industry, a Disaster Management Plan (DMP) is required to be prepared and submitted to statutory authorities. This DMP is required to be practiced through mock drills periodically and review meeting are to be conducted for checking discrepancies.

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Chemical Hazards
Chlorine Chlorine vapor is poisonous when inhaled Will cause burn in eyes Chlorine liquid can cause burn on skin and eyes Threshold Limit Value (TLV) for chlorine is 1 ppm At 100 ppm it can be fatal.

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Chemical Hazards
Release Of Gases / Dust
Chlorine in water treatment plant Hydrogen in turbo generator area of main plant Pulverized coal dust from mills and associated piping Emissions and discharges, fly ash Coal dust in transfer points, chip, crusher & mill area.

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Chemical Hazards
Release Of Liquid
Acid and alkali tanks in water treatment plants Fuel oil tanks in fuel oil handling section Naphtha handling and storage Ash dyke Control fluid in 500 MW turbine system Turbine oil and seal oil leakage

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Plant / sections which are prone to emergencies

1. 2. 3. 4. 5.

Coal handling plant Main plant Water treatment plant Hydrogen generation plant Mgr transpiration system

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Prevention of Chemical Hazard (Pneumoconiosis) 1.Dust control Proper Ventilation Exhaust Enclosed apparatus Good house keeping

2.Personnel protection
Mask, clothing, cloves, apron, boots barrier cream etc

3.Personal hygiene 4.Health education about respiratory evolvement and personal protection 5.Medical control
Periodic medical check up for early detection

6. Bagasse control Spraying with 2% propionic acid Keep the moisture content around 20%
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Type of safety
Fire hazard
Fire is a chemical reaction or series of chemical reaction accomplished by heat, light, smoke or other gases.

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Fire Hazards In Power Plants

Coal handling plant: coal dust accumulation on conveyor decks, cable trays, head & tail pulleys, jamming of idlers and pulleys, belt sway, belt tension, dust & coal deposited at tops, crusher house and vibrating scene floors, bunker house , failure of belt joints, snapping of belts, partially damaged belt in operation, smoldering fire in bunkers

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Fire Hazards In Power Plants

Cables in cable galleries and on trays in all plant sections, coal dust deposited on cable trays in mill area Fuel oil handling and oil tanks (hsd,hfo,lshs, naphtha, petrol, diesel oil ) Transformer oil, turbine oil, control fluid, seal oil, Natural gas Electrical system Heat path damaged insulation Grass Accumulation of waste material etc.

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Explosion Hazard In Power Plant

Hydrogen plant Turo generators where hydrogen is used for cooling of Generator. Boilers

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Biological Hazards
Exposure to infective and parasitic agents Inset bite y Dog bite y Snake bite

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Psychosocial Hazards
FACTORS Maladjustment with work environment. Lack of job satisfaction Insecurity Emotional tension Poor human relationships

Behaviors changes
Anxiety/Depression Sickness absentees

Health problems
yFatigue yHeadache yHypertension yHeart disease yPeptic ulcer

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

PREVENTION
Physical hazards
Application of ergonomics Maintenance of temperature- 69 to 80 deg. F is the comfortable zone Proper ventilation Good housekeeping Proper illumination Personal protection Personal hygiene Health education Job rotation Periodic health Check up
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Bursting Of Pipe Lines And Vessels In Power Plants

Water pipes due to high pressure Steam pipes due to high pressure

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Biological Hazards
PREVENTION
Personal Protection

Post Control

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Psychosocial Hazards
PREVENTION
Good induction program. Management by participation. Establishment of Proper communication channel. Establishment of Healthy personnel policies Establishment of healthy HR relationship. Regular stress management program.

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Psychosocial Hazards

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Psychosocial Hazards

STRESS
Stress is produced when the human body or mind is acted upon by forces that disrupt its equilibrium and produces strain. When our system is unable to handle this it produces pathological changes and disease.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Psychosocial Hazards STRESS MANAGEMENT TIPS

Ways to tune out, calm down and revitalization. Zero In On Stresses Summarizing whats Wrong in two or three word Keep a Diary Time Your Troubles Drive Yourself to Diversion Dont pressurize yourself Establish Your Priority Set Mini Goals
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Psychosocial Hazards
STRESS MANAGEMENT TIPS
Learn to say polite No Live within Your Means Look on the Bright Side Feed Your Body Right Less Fat and Avoid Alcohol Stroll To De-Stress Squeezing for Release Keep The Beat Stretch for Relief Take a Break
Safety Module: Industrial hazard, Rev 0.0, Mar 2007

.cont

How to Control Hazard ?

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Step 1: Hazard Identification Techniques

Hazard Identification Techniques

Safety audit Safety survey Safety inspection Safety tour Safety sampling Job safety analysis Hazard & operability studies Fault & event tree analysis Failure mode & effect analysis (FMEA)
71

Hazard Identification Techniques

Safety audit A systematic & independent examination of all or part of a total operating system to determine whether safety activities comply with planned arrangements for ensuring safety and health of workers and other interested parties who may be affected and whether these arrangements are effective and are suitable to achieve objectives.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Safety survey Safety survey is a detailed & in-depth examination of a narrow field of activity eg... Major key areas revealed by safety audit, Individual plants, Procedures or A specific problem.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Safety inspection A routine scheduled unit inspection which may of a be department or carried out During by

personnel

within the unit. from safety

inspection

deviations

standards, employees unsafe work practices and unsafe conditions are checked.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Safety tour Safety tour is an unscheduled examination of a work area, carried out by any personnel from manager to safety committee members to ensure that companys safety standards and procedures are being observed.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Safety sampling A specific application of safety inspection / tour designed for random sampling of any

activity posing serious accident potential. During safety sampling number of defects Are observing for immediate corrective

actions.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Hazard and operability studies Hazop is essentially a examination procedure takes full description questioning of of the every process, part of systematically

process to discover how deviations from the intention of the design can occur and decides whether these deviations can give rise to hazard.

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Hazard Identification Techniques

Principles of examination Full description of the process, systematically questions on every part of the process Discover deviations from the intention of the design can occur Decides weather these deviations rise to Hazards can give

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Failure Mode and Effect Analysis (FMEA) Failure or Malfunction of each component is considered Effect or Consequences of failure traced Frequency of Occurrence, Severity of Failure and detecting the problem Impact on the System Functioning is evaluated Remedial method for Possible Impact

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Fault Tree Analysis Starts with Undesired event. All possible happenings contributing Undesired event is listed. Put these happenings in the form of tree with logic signals OR and AND.

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Hazard Identification Techniques

Note: Because examination is so systematic and highly
structured, it is necessary for the team members to use following terms in a precise and disciplined way; Intention The intention defines how the part is expected to operate. Deviations These are departures from the intention which are discovered by systematically applying the guide words. Causes Causes are the reasons why deviations might occur. Once a deviation has been shown to have a conceivable or realistic cause, it can be treated as meaningful. Consequences These are the results of the deviations should they occur.
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Hazard Identification Techniques

Hazards Hazards are the consequences which can cause damage, injury or loss. Guide words Guide words are simple words which are used to qualify the intention in order to guide and stimulate the creative thinking process and so discover deviations

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Failure Mode and Effect Analysis (FMEA) Failure or Malfunction of each component is considered Effect or Consequences of failure traced Frequency of Occurrence, Severity of Failure and detecting the problem Impact on the System Functioning is evaluated Remedial method for Possible Impact

Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Fault Tree Analysis Starts with Undesired event. All possible happenings contributing Undesired event is listed. Put these happenings in the form of tree with logic signals OR and AND.

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Steps to Control Hazard

Step 2. List, rank and set priorities for hazardous jobs List jobs with hazards that present unacceptable risks, based on those most likely to occur and with the most severe consequences. These jobs should be your first priority for analysis.

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Steps to Control Hazard

Step 3. Controlling Hazards Solutions to the Control of Hazard are identified and measures are executed Hazard can be eliminated (i) At the Source (ii) Along the path from hazard to the Worker (iii) At the level of the worker

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Hazard Removal at the Source

1. Elimination - Getting rid of a hazardous job, tool, process, machine or substance is perhaps the best way of protecting workers. 2. Substitution - Sometimes doing the same work in a less hazardous way is possible. 3. Redesign - Jobs and processes can be reworked to make them safer. 4. Isolation - If a hazard cannot be eliminated or replaced, it can sometimes be isolated, contained or otherwise kept away from workers. 5. Automation - Dangerous processes can be automated or mechanized.

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Hazard Removal along the path from Hazard to Worker

1. Barriers - A hazard can be blocked before it reaches workers. Proper equipment guarding will protect workers from contacting moving parts. 2. Absorption - Baffles can block or absorb noise. 3. Dilution - Some hazards can be diluted or dissipated. For example, ventilation systems can dilute toxic gasses before they reach operators.

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Hazard Removal at the Level of Worker

Work procedures, supervision and training Administrative controls Job rotations and other procedures can reduce the time that workers are exposed to a hazard. Housekeeping, programs repair and maintenance

Contd
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Hazard Removal at the Level of Worker

Hygiene - Hygiene practices can reduce the risk of toxic materials being absorbed by workers or carried home to their families. Personal protective equipment (PPE) and clothing - This is used when other controls arent feasible and where additional protection is needed. Workers must be trained to use and maintain their equipment properly.

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Thank You

Safety Module: Industrial hazard, Rev 0.0, Mar 2007