1. Industrial Hazards

7/31/2019 1. Industrial Hazards

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Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Industrialhazards


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


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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 possibleimpact on the surrounding community and the

general environment


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At the first session of joint committee of ILOand WHO held in 1950, occupation health wasdefined 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


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Types Of Occupational Hazards

Physical hazards

Chemical hazards Biological hazards

Mechanical / Electrical hazards

Psychosocial hazards


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Types Of Occupational Hazards

Physical hazards Heat Cold Light Vibration

Radiation Noise Chemical Biological

Mechanical-electrical Psychological


7/91Safety Module: Industrial hazard, Rev 0.0, Mar 2007

Physical HazardsHEAT 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



Physical HazardsHEAT- As a hazard in power stations can cause

1. Heat stress-it is the aggregate of environmental & physicalwork factor i.e. Total heat imposed on the body.

2. Heat strain- it is the physiological responses to the heatstress.

3. Heat disorders-these result in heat cramps, heat exhaustion,heat stroke.

4. Heat cramps: painful intermittent spasms of voluntarymuscles after hard physical work in hot environment. Cramps

usually occur after heavy sweating.5. Heat exhaustion: profuse sweating, weakness, rapid pulse,

dizziness, nausea & headache. Skin is cool/pale. Bodytemperature is normal, nausea, vomiting and unconsciousnessmay occur.



Heat can be of two types1. Dry hot1. 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,

Physical Hazards



Effective work temperature in a work environmentcan 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.

Physical Hazards



Effective temperature and heat effect in anenvironment 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

Physical Hazards



Fire hazards in power stations can cause lossesand can cause burn injuries to the persons.

Different types of fires can be controlled byextinguishing the fires at starting stage and bytaking fire protection measures.

Physical Hazards


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Light as a hazard in working condition can be due to:

Less lighted areaswhen the light is insufficient person strains hiseyes to see the work object/area. Lightrequirements are increasing with age of a personto see and work on the object.

Excessive light-

it is dangerous for eyes when light in work area isexcessive since it causes glare.

Physical Hazards



Normally light requirements are provided as requiredfor different work areas as given in national buildingcode and also as per the Factories Act 1948.

This Act says that there should be sufficient lightprovided in all areas of work so that the worker doesnot have to strain his eyes while at work.

Further factories rules require that there be at leastone foot candle light which is equal to 10.76 lux in allcorridors.

National building code provides lighting requirementsfor 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.

Physical Hazards



VIBRATION Vibration especially in the frequency of 10 to 500 Hz, canaffect 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

Physical Hazards



Continuous working should be avoided and restpauses after some time of work must be allowed toworkers.

The driving force of vibrating surfaces may bereduced by;

1. Reducing the forces 2. Minimizing rotational speed 3. Isolating

The response of vibrating surfaces may be reduced

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

Physical HazardsVIBRATION


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Hearing impairment due to Noise is, as per theschedule of the Factories act, is reportable as wellas compensable.

Hearing loss in most cases is not sudden butincreases with the length of the work time in thenoisy zone.

Physical HazardsNOISE 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]


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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

Physical HazardsNOISE


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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) headii) outer eariii) ear canal

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

Physical HazardsNOISE


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RADIATION

A. Ultraviolet Radiation hazard - Seen in work with arc welding and mainly affectsthe eyes.Exposure to such radiation may lead to

Conjunctivitis and Keratitis (Welder s flash)B. Ionizing radiation hazards [X room USG CT ]

AnemiaLeukemia

CancerSterilityFoetal Malformation in case of pregnancyUlcerationIn extreme cases death can take place

Physical Hazards


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Mechanical / Electrical Hazards

Accident

Fall

Injury

Electricity burn

Electric shock.


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Material handling safety

Definition: Material handling is preparation, placing and positioningof materials so to facilitate their movement and storage.

Material handling accounts36 % of production cost

40% Industrial accidentsare in material handling .

Type of safety


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The day-today working needsfollowing for performing duty

Ladders, scafolds, working platforms,manual lifts, lifting attachments(slings, shackles, eye bolts, ropesetc.)

Lifting machines (lifts, lifting tackles, jacks, winches, cranes mobile andstationary, chain pulley blocks, forklifts, hydra, etc.)

Mobile machineries (trucks, dumpers,

tractors, vibrators, road rollers, etc.) Transport of hazardous materials

(petrol, diesel, naphtha , LPG, acids,alkalies, and other inflammableliquids and gases)

Safety in the Movement of Men & Materials


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Safety Check List For Chains, Ropes & SlingsSl.NO POINT TO BE CHECKED STATUS REMARKS

01 Condition of lifting tackles ?

02 Adequacy of the strength of lifting tackles withrespect to the weight to be lifted.

03 Is all ropes, slings are tested by competentperson? If yes, record is being maintained?

04 Is lubrication found is adequate?

05 Whether all the wire ropes,. slings etc., arestored properly?

06 Handling of wire ropes, slings against sharpedges, excessive loading is done properly?

07 Falling of welding sparks, gas cutting spatters

on the ropes & slings08 All ropes & Slings are anchored properly

wherever it is done?

09 Whether ropes or slings are subjected tocrushing loads between hard surface & loadbeing loaded or unloaded?

10 Condition of the surface near ferrule providedon the slin s?

W ki t h i ht ibiliti f id t


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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

M h i l H d


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Mechanical Hazard

PREVENTION Preventive maintenance Adequate job training Ensuring safe working

environments

Establishment of safetydepartment with qualifiedsafety engineer

Periodic survey for finding outhazards

Application of ergonomics

M h i l H d


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Mechanical Hazards

MACINERY HAZARDS:

These are due to revolving parts of the machines. These can be controlled by providing machineguards which are a statutory requirements underSections 21 to 26 of the Factories Act 1948.

As per section 21 of the Factories Act- provideguards at following; Moving parts of the machinery including fly wheels Transmission machinery Point of operation Any other dangerous part

M h i l H d


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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

Mechanical Hazards

M h i l H d


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TYPES OF GUARDS

Safety by construction Fixed guards Automatic guards

Interlock guards Trip guards Positional or distance guards Safety by position

Other types

Mechanical Hazards

M h i l H d


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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

Y=X/8-6mm Up to 15 cm distanceY=X/12+6mm More than 15 cm distance.

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

Mechanical Hazards

M h i l H d


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SAFETY OF MAINTENANCE PERSONNEL

Safety precautions are required to safe guard themaintenance personnel from getting involved inmachinery accidents owing to inadvertent startingof machinery by;

Design of control switches Safe guards for the operating levers Interlocking of power system

Mechanical Hazards

El i l H d


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Electrical Hazards

Injury from direct contact1. Injury by shock2. Injury from internal burns

Injury without current flow through body1. Direct burns from electrical arcs

2. Radiation burns from very heavy arcs3. Injury from fire & explosion from electrical arc4. Physical injury from false starting of machinery,

failure of controls

5. Eye injury from electrical arc welding

El i l H d


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Injury from current flow induced in or near thehuman body by intense electric magneticfields :

1. Injury from elevation of whole body temperature2. Local injury such as cataract formation in the eye3. Burns due to metallic objects such as rings etc. In

close contact with local parts of the body

Electrical Hazards

F d t l f El t i l H dFundamentals of Electrical Hazards


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More than 3 ma

painful shock More than 10 mamuscle contraction no-let-go danger

More than 30 malung paralysis- usually temporary

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

100 ma to 4 ampscertain ventricular fibrillation, fatal

Over 4 ampsheart paralysis; severe burns. Usually caused by >600 volts

Fundamentals of Electrical HazardsFundamentals of Electrical Hazards

F ndamentals of Electrical Ha ardsFundamentals of Electrical Hazards


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Human resistance to electrical current

BODY AREA RESISTANCE (OHMS)

DRY SKIN 100 000 TO 600 000

WET SKIN 1000

EAR TO EAR ABOUT 100

For the same voltage different effects

Fundamentals of Electrical HazardsFundamentals of Electrical Hazards

Ch i l H d


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Chemical Hazards

Chemical hazards liquid and gaseous hazards1. Dust

2. Smoke3. Fumes4. Poisonous gases5. Acids

6. Alkalis

Chemical Hazards


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Chemical Safety

There are thousnands of chemical compounds,which presents some form of hazards either majoror minor incidents usually termed as chemicalaccidents.

To avoid chemical accidents some points to bekept in mind.

1. knowledge of chemicals

2. knowledge of pocessing plant3. knowledge of operator

Chemical Hazards

Ch i l H d


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They enter our body through Skin Inhalation

MouthThey can cause internal as well external injuries Skin diseases Lung diseases

Internal blood and other diseases

Chemical Hazards

Ch i l H d


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Chemical HazardsLocal Action

Eczema

Dermatitis Cancer

Inhalation1. Organic Dust Size ranging from 0.1 to 150 Microns.

Particle smaller than micron is called respirable dust and isdirectly inhaled into the lung and mainly Responsible for Pneumoconiosis in the different form depending upon thetype of dust like :

Organic dustSilica- SilicosisAsbestos- AsbestosisIron SiderosisCoal Anthracosis

Inorganic dustInorg anic dustCane fiber - BagassosisCane fiber - BagassosisCotton - ByssinosisCotton - ByssinosisTobacco - TobacossisTobacco - Tobacossis

Ch i l H d


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Incidents of pneumoconiosis depends upon thefollowing 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

PneumoconiosisChemical Hazards

Chemical Hazards


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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 andreduce our breathing capacity since this reparable dustsettles there,

Normally coal dust particle less than 1 micron only canenter in our lung sacks.

Bigger dust particles either remain in our nose or getstuck in throat. Then they go into stomach and getremoved from our body system in natural way.

Coal dust is non toxic and as such no effects arecaused on body due to the particles of dust instomach.

Chemical Hazards

Ch i l H d


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Chemical Hazards

Chemical Hazards


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Reparable dust particle which enter into our lungscan not be removed and they remain settled there.

Disease which can occur due to inhalation of coaldust is known as pneumoconiosis and isirreversible 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

Chemical Hazards

Chemical Hazards


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Control of coal dust by

Reduction of dust emission by suppression bywetting 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 dustparticles.

Continuous monitoring of environment bymeasuring and keeping it below.

Chemical Hazards

Chemical Hazards


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2. Gases Gases are the common hazards in many industries

leads to suffocation and asphyxia.

Asphyxiating gases are CO, Cyanide, SO 2 , Chlorine etc.

Chemical Hazards

Smoke : inhalation of smoke which can contain poisonousgaseous fumes also and can have effects on our health;

Fumes : fumes emanating from liquid chemicals can cause illeffects on our health when inhaled;

Vapor : vapors of chemicals liquids are also dangerous to ourhealth when inhaled. Vapours of hydrazine hydrate can causeunconsciousness when inhaled.

Chemical Hazards


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

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

Chemical Hazards

Hazardous chemicals used in thermal power stations: Chlorine Hydrochloric acid

Euphoric acid Hydrazine hydrate Liquor ammonia Sodium hydroxide

Chemical Hazards


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Chemical Hazards

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 ManagementPlan (DMP) is required to be prepared and submitted tostatutory authorities.

This DMP is required to be practiced through mockdrills periodically and review meeting are to beconducted for checking discrepancies.

Chlorine

Chemical Hazards


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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.

Chemical Hazards

Chlorine

Chemical Hazards


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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.

Chemical Hazards

Chemical Hazards


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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

Chemical Hazards

Plant / sections which are prone to


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Plant / sections which are prone toemergencies

1. Coal handling plant

2. Main plant3. Water treatment plant4. Hydrogen generation plant5. Mgr transpiration system

Prevention of Chemical Hazard


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(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 protection5.Medical control

Periodic medical check up for early detection6. Bagasse control- Spraying with 2% propionic acid- Keep the moisture content around 20%

Type of safety


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Fire hazard

Fire is a chemical reaction or series of chemicalreaction accomplished by heat, light, smoke orother gases.

Type of safety

Fire Hazards In Power Plants


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Coal handling plant:coal dust accumulation on conveyor decks, cabletrays, head & tail pulleys, jamming of idlers andpulleys, belt sway, belt tension, dust & coaldeposited at tops, crusher house and vibratingscene floors, bunker house , failure of belt joints,snapping of belts, partially damaged belt inoperation, smoldering fire in bunkers



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Cables in cable galleries and on trays in all plantsections, coal dust deposited on cable trays in millarea

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.

Explosion Hazard In Power Plant


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Explosion Hazard In Power Plant

Hydrogen plant Turo generators where hydrogen is used for

cooling of Generator. Boilers

Biological Hazards


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Biological Hazards

Exposure to infective and parasitic agents Inset bite Dog bite Snake bite

Psychosocial Hazards


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yFACTORS - Maladjustment with work environment. Lack of job satisfaction Insecurity Emotional tension Poor human relationships

Health problems FatigueHeadacheHypertensionHeart diseasePeptic ulcer

Behaviors changes Anxiety/Depression Sickness absentees

PREVENTION


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PREVENTIONPhysical 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

Bursting Of Pipe Lines And Vessels


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Bursting Of Pipe Lines And VesselsIn Power Plants

Water pipes due to high pressure

Steam pipes due to high pressure

Biological Hazards


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PREVENTION Personal Protection Post Control

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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 .

y



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y



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Stress is produced when the human body or mind is actedupon by forces that disrupt its equilibrium and produces strain.

When our system is unable to handle this it producespathological changes and disease.

y



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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

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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

STRESS MANAGEMENT TIPS.cont


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How to

ControlHazard ?


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Step 1: Hazard Identification Techniques

Hazard Identification Techniques


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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)

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Safety auditA systematic & independent examination of all or partof a total operating system to determine whether

safety activities comply with planned arrangementsfor ensuring safety and health of workers and otherinterested parties who may be affected and whetherthese arrangements are effective and are suitable toachieve objectives.




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Safety surveySafety survey is a detailed & in-depthexamination of a narrow field of activity eg ...

Major key areas revealed by safety audit,Individual plants,

Procedures or

A specific problem.

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Safety inspectionA routine scheduled inspection of a department

or unit which may be carried out by

personnel within the unit. During inspectiondeviations from safety standards, employees

unsafe work practices and unsafe conditions

are checked.

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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.

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Safety samplingA 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.

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Hazard and operability studies

Hazop is essentially a examination procedure takes

full description of the process, systematicallyquestioning of every part of process to discoverhow deviations from the intention of the design canoccur and decides whether these deviations cangive rise to hazard.

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Principles of examination

Full description of the process, systematicallyquestions on every part of the process

Discover deviations from the intention of thedesign can occur

Decides weather these deviations can giverise to Hazards

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Failure Mode and Effect Analysis (FMEA)Failure Mode and Effect Analy sis (FMEA) Failure or Malfunction of each component is

considered Effect or Consequences of failure traced

Frequency of Occurrence, Severity of Failure anddetecting the problem

Impact on the System Functioning is evaluated Remedial method for Possible Impact


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Fault Tree AnalysisFault Tree Analys is

Starts with Undesired event. All possible happenings contributing Undesired

event is listed.

Put these happenings in the form of tree withlogic signals OR and AND.



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Note: Because examination is so systematic and highlystructured, it is necessary for the team members to usefollowing terms in a precise and disciplined way;

IntentionThe intention defines how the part is expected to operate. Deviations

These are departures from the intention which arediscovered by systematically applying the guide words.

CausesCauses are the reasons why deviations might occur. Oncea deviation has been shown to have a conceivable or

realistic cause, it can be treated as meaningful.

ConsequencesThese are the results of the deviations should they occur.

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Hazards

Hazards are the consequences which can cause damage, injuryor loss .

Guide wordsGuide words are simple words which are used to qualify theintention in order to guide and stimulate the creative thinkingprocess and so discover deviations

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Failure Mode and Effect Analysis (FMEA)Failure Mode and Effect Analy sis (FMEA) Failure or Malfunction of each component is

considered Effect or Consequences of failure traced

Frequency of Occurrence, Severity of Failure anddetecting the problem

Impact on the System Functioning is evaluated Remedial method for Possible Impact


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Fault Tree AnalysisFault Tree Analys is

Starts with Undesired event. All possible happenings contributing Undesired

event is listed.

Put these happenings in the form of tree withlogic signals OR and AND.

Steps to Control Hazard


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Step 2. List, rank and set priorities forhazardous jobs -

List jobs with hazards that present unacceptable

risks, based on those most likely to occur and withthe most severe consequences. These jobs shouldbe your first priority for analysis.

Steps to Control Hazard


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Step 3. Controlling HazardsSolutions to the Control of Hazard are identifiedand 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

Hazard Removal at the Source


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1. Elimination - Getting rid of a hazardous job, tool,process, machine or substance is perhaps the bestway of protecting workers.

2. Substitution - Sometimes doing the same work in aless hazardous way is possible.

3. Redesign - Jobs and processes can be reworked tomake them safer.

4. Isolation - If a hazard cannot be eliminated orreplaced, it can sometimes be isolated, contained or

otherwise kept away from workers.5. Automation - Dangerous processes can beautomated or mechanized.

Hazard Removal


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along the path from Hazard to Worker

1. Barriers - A hazard can be blocked before itreaches workers. Proper equipment guarding willprotect workers from contacting moving parts.

2. Absorption - Baffles can block or absorb noise.

3. Dilution - Some hazards can be diluted ordissipated. For example, ventilation systems candilute toxic gasses before they reach operators.

Hazard Removal at the Level of Worker


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Work procedures, supervision and training

Administrative controls

Job rotations and other procedures can reduce thetime that workers are exposed to a hazard.

Housekeeping, repair and maintenanceprograms

Contd

Hazard Removal at the Level of Worker


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Hygiene - Hygiene practices can reduce the risk of toxic materials being absorbed by workers orcarriedhome to their families.

Personal protective equipment (PPE) andclothing - This is used when other controls arentfeasible and where additional protection is needed.Workers must be trained to use and maintain theirequipment properly.


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Documents

1. Industrial Hazards