Control Engineering

Prof. Inderdeep Singh

Department of Mechanical and Industrial Engineering
Indian Institute of Technology, Roorkee

Module - 4
Lecture - 19
Industrial Safety

A very warm welcome to all of you in this lecture on industrial safety. In the series of
lectures on industrial engineering, we have been discussing a large number of topics
related to the different aspects of industrial engineering. We have covered inventory
management, we have covered other topics related to sales forecasting, we have covered
product design and development reliability and a large number of other topics which
come under the broad umbrella of industrial engineering.

So, the topic for today is industrial safety. Safety: as we all know is a very important
aspect of any particular activity. Suppose, we are playing a game, we have to play it in a
very safe mode otherwise, we will get injured. If we are driving a vehicle; we have to be
very safe while driving, otherwise we may encounter an accident. Similarly, if we are
doing some household work; we have to keep into the account the safety aspects. But,
whenever a manufacturing activity is taking place; there are always chances of certain
accidents that may take place.

Therefore, we have to design the systems in such away so that even if a worker is not
performing his duties according to the laid out principles in the manual, he may not
encounter any accident. Because if an accident takes place, it has large number of
implications; the material loss, the man hours lost, as well as the person may also suffer
some injuries. So, we have to take into account all these points and we have to design the
systems in such away, so that the accidents are minimal or we should say the accidents
are to a closing to 0 or the number of accidents is closing to 0.

How that is possible? That is possible; if we design the system, if we educate our
workers in order to follow the safety norms and practices, as well as we keep into
account that whenever there is an accident, whenever there is a problem, then that
problem does not escalate into a catastrophic manner or into a catastrophe. Sometimes, 1
accident leads to another accident and another accident leads to another accident those
kind of effects we have to check. How those can be check? Those things are very simple;
we have to follow certain design principles, whenever we are laying out the machines,
whenever we are laying out the buildings. And if we follow those principles religiously,
then the accident prevention can be done.

So, in today’s lecture, it is a very simple lecture, in which we will see that what
precautions, what are the important guidelines that we should keep in mind, while we are
laying out a plant or when we are doing a plant layout? Similarly, we have to keep in
mind certain things in order to check the fire, in order to check the explosions. Then we
will towards the end, see a case study in which there was a accident and what were the
things those are found out which should have been done in order to avoid the accident.
So, let us start the discussion that the regarding the topic on industrial safety.
(Refer Slide Time: 03:52)

Management is keenly aware of the costs of accidents, as are the victims of the accidents.
So, a person who is a victim or who has suffered some accident, he knows that what cost
he has paid for go undergoing that accident. Similarly, the management is also keenly
aware of the cost of accident. So, the management knows that if a accident takes place,
what are the costs involved? There are direct costs involved, there are indirect costs
involved.

Whenever, there is a accident the person may suffer a injury, the machine may get
damaged. So, the management has to do the troubleshooting of the machine or
sometimes they may have to get a new machine. Similarly, they have to bear the cost of
hospitalization of the worker. Then, there are other workers who are involved in getting
that worker or transporting or putting that worker into the hospital. In those cases also,
the man hour is lost the productivity is less and there are other indirect costs also, like the
company may have to pay the compensation to the worker or the insurance companies
may come in picture at that point.
But, all in all if we say whatever we have been discussing till now, there are costs
involved in accidents which may be direct costs or the indirect costs and the management
is keenly aware of these costs of accidents. And similarly, the person also knows that if
he meets an accident what is going to happen. He may sometime loose a part of his body,
which is completely undesirable from the company point of view, as well as from the
workers point of view. So, the great problem is to be resolved and how this can be
resolved? This can be resolved to get the individual worker at the point of operations, to
realize his personal responsibility.
So, although we have started the discussion related to industrial safety by saying that we
have to layout the system in such a way that the accidents do not happen. But, the
majority of the accidents usually take place by the negligence of the workers or due to
the failure of the equipment. So, the first important point is the negligence of the worker
If each and every worker knows, that according to his negligence or because of his
negligence some particular accidents may take place, then if he is vigilant, he is
performing the operations religiously, he is following the instructions religiously, then
there are no chance, there are no chances sorry which would relied into an accident.

Although, still there are chances that the equipment may fail and some accident may take
place, but that is beyond the control, but the important point is to educate the worker so
that they take the personal responsibility in avoiding the accidents. The management also
has to pay an important role in the design of the system
(Refer Slide Time: 06:53)

In such a manner, that it is not prone to accidents. So, the design of the system or the
design of the plant or the design of the building should be such that no accidents take
place. Now, which guidelines, what precautions or what rules and regulations have to be
followed while laying down the building or a plant? That we will see in subsequent
slides.
The plant layout and the machines, as well as the tools should be designed with accident
prevention criterion in the mind. So, always we should design the tools, machines, plant
layout in such a way so that the accidents do not take place. Now, subsequently in the
subsequent slides, we will see that how these criterions can be incorporated into the
design. These are simple things, but sometimes we do not give adequate attention to
these things.
So, initially we will see that in a general layout, whenever we are putting the machines
and the other paraphernalia in place. What are the precautions? What are the guidelines
that we should keep in mind? So, the general principles of a plant layout. So, what are
the general principles that should be kept in mind whenever we are designing a plant
layout? If you remember in one of the lectures, on facility layout design, we have seen
what are different types of layout? We have seen that there is a product type of layout,
there is a process type of layout, and there is a fixed position type of layout. Also, there
are certain cells that fall under the category of cellular manufacturing or group
technology.
So, we have seen different types of layouts are there. So, the basic guidelines that we
have seen there is that there should be minimum transportation of the material within the
plant because, it adds to the cost as well as, here we will see that it may result into
accidents also. So, we have to minimize the transportation of materials within the plant.
(Refer Slide Time: 08:53)

So, the very first point on your screen you can see, that need to keep minimum distances
for transfer of materials between plant or storage units, to reduce the costs and risks So,
first thing when we were discussing plant layout, we have seen that the transportation of
material in between the storage and the shop, as well as between thus in between the
shop also should be minimum why because, it involves cost.
So, cost was the main criteria there, but keeping in mind the industrial safety point of
view we will say, that the risk involved is also more. So, we have to minimize the risks
of accident. So, therefore, the transportation of material should be such. So, we should
layout the plant in such a way so that this transportation is avoided or it is minimal.
Then, the geographical limitations of the site; interaction with existing or plant facilities
on site such as: existing roadways, drainage and utilities routings. So, we have to see the
geographical limitations of the site as well.
So, those things should be kept in mind. So, sometimes if we are placing our industry or
our plant on hills, those things we have to keep in mind that what are the types of
accidents, that may take place in such a area or such an area. Then interaction with
existing or plant facilities, already we have a building suppose, and we want to increase
the capacity, we want to make another roof or another floor. Then, we have to see that
whether the existing facilities can bear the load of that particular floor or not or what
kind of machines we should put on those floor? Or the extra of roof that we are adding or
extra floor that we are adding?
So, all these things have to be kept in mind; the first thing is minimization of the
transportation of material, the second point is the geographical location we have to keep
in mind, third point is the interaction between the existing facilities and the new facilities
that we are creating, then interaction with other plants on site. So, we have to see that
there are some plants already existing, we are adding some more plant or some more
factory or some more particular shop we are adding. So, how it is going to interact with
this particular existing facility?
Then, the need to locate hazardous materials, know hazardous materials are those: which
are prone to accidents or prone to fire or prone to we can say explosion. So, the need to
locate hazardous material, facilities as far as possible; from the site boundaries and
people living in the local neighborhood. So, wherever hazardous kind of material has to
be stored, we have to keep in mind that this should be at a distance from the existing
plant or from the neighborhood where people are staying.
If, you take an example of the fire crackers that are burst during the diwali season; we
will see that these days the government is taking adequate steps that all the shops which
are having the fire crackers would be set up at a distance from the neighborhood or from
the site or from the location where people are staying. Why this has been done? Because,
there are always chances of an accident or the risk involved is very high.
So, same thing or same principle we have to follow in the factories, as well as in the
industries which states, that the hazardous material should be kept, always kept at a
distance from the plant as well as from the site where people are staying. Then, keeping
in regularity, the principles of plant layout take talking about those principles.
(Refer Slide Time: 12:43)
We will further go to discuss some more important principles like the need for plant
operability and maintainability; we have to keep in mind this particular need that what is
the operability what is the maintainability of the plant. The need to prevent confinement;
where release of flammable substances may occur. So, we have to see that wherever
there is a release of flammable substances the confinement should not be there. Which
means: that there should be adequate ventilation, there should be adequate open space
that whenever the flammable substances, they are released into the environment or there
are released into the atmosphere, they should get a path to go out. If, they do not get a
path to go out, there are always chances of fire as well as explosion.
So, the need to prevent confinement, where release of flammable substances, may occur.
So, wherever there are chances, we should restrict the confinement, we should make it
open as open as possible. Then, the need to provide access for emergency services, so
wherever we there are chances, there are risks of accidents; the plant layout should be
such design that emergency services could be provided at that point. If the access is not
there to the emergency services; the emergency service is or the emergency team will,
not be able to reach to the accident side and will not be able to rescue the workers or the
machines whatsoever may be the case.
So, that is also an important aspect that has to be born in mind. So, the access to the
emergency services should always be there in the, in case of an accident or whenever we
are designing a plant, whenever we are laying out the plant, we have to keep all these
things in mind. Then, the need to provide emergency escape routes for onsite personal,
so the people who are working on that particular site. They should have an escape route;
they should have a route from in, from which they can go out.
Suppose, an important example to mention here is; that if you are flying by air; in the
very beginning or at the start of the flight only you would be told, that these are the
escape routes in case of an accident. So, those things help you to react in case of an
emergency. So, similarly in a plant or in a building, whenever accident or whenever a
problem arises or whenever there is a catastrophe that has struck the industry or the plant
there should be escape routes available. First thing is we have to ensure the availability
of the escape route and second thing which is not mentioned on your screen is that there
should be adequate know how to the workers that yes these are the escape routes. Even
on the floor also, you can mark certain linings which would help the workers to go out of
the plant in case of emergency.
Sometimes, whenever there is a problem, whenever there is a fire or whenever there is an
explosion, usually if the power is switched off. So, when the power is not there and if it
is the night shift, there be there would be complete darkness, the workers would not be
able to know which direction they should rush out. So, the facility could be provided that
there is a certain fluorescent path or we can say some guidelines or some strips of
fluorescent light, which would help the workers to trace out the path and go out of the
plant.
So, the need to provide emergency escape routes for onsite personal is very important,
whenever we are laying out a plant. Then, the need provide acceptable working
conditions for operators. So, sometimes the humidity levels are very high, somewhere
the heat that is generated is very high. So, the important point is that the plant layout
should be such that acceptable working conditions are provided to the operators
Sometimes the workers have to do some minute task and if the adequate lighting
arrangement is not there, the worker may not feel comfortable and his eyes may not be
lasting for too long or his eye sight may get defected or impaired.
So, important thing is that whenever the plant layout is done or the designing of the plant
is done, these particular important aspects, that is the need to provide the acceptable
working conditions to the operator should be addressed. Now, from safety point of view
some important things that have to be born in mind, that we are going to see in
subsequent slides, but the important point that we have seen till now from a general
principles of a plant layout is that there are certain guidelines, there are certain
principles. If we keep those principles in mind, then they always there are chances that
the, number of accidents that take place in a well designed plant are minimal or we can
say are very close to zero. Now, from safety point of view we have to see, we have to
prevent limit.
(Refer Slide Time: 17:48)

And or mitigate means, lesson escalation of adjacent events or the domino effect. So,
basically this point states: that if one event happens, it should not lead into another event
and another event should not lead into the third event. Suppose, let us take an example of
a cycles parked in row; if we push 1 cycle the 1 first cycle will fall on the second cycle,
second cycle will fall on the third cycle and similarly, the whole row of cycles would be
on the ground and that kind of conditions we do not want. Because, whenever there is a
accident that has taken place or fire that has taken place or explosion that has taken
place; it should not spread to the other parts of the factory or other parts of the plants. So,
that is the domino’s effect.
So, we have to prevent or even if, it takes place we have to limit it is, we can say limit its
extent; the extent to which it is going to cause the damage. So, first thing is we should
prevent, it should not happen. Even if it happens we have to limit the extent to which it is
going to cause the damage and the otherwise, we have to mitigate the escalation of
adjacent events.
So, if 1 event takes place the other event should not take place. So, we have to put some
barriers in between so that the 1 event does not lead into the other event. So, ensure
safety within onsite occupied building. So, we have to provide safety within the onsite
occupied building. So, occupied building means: that where people are present. So, we
have to provide safety for those buildings also.
Then, control access of unauthorized personnel which is very clear, that only authorized
personnel should be given entry into the plant. Then facilitate access for emergency
services. So, that point we have already seen, that we have to provide the access the
emergency services. If the accident take place, we should have escape route as well as
we should have a access through which the emergency service is can go in or the fire
tenders can go in or the other people who are going, to take out the people from the plant
they should have a adequate access.
(Refer Slide Time: 20:08)

Now, let us talk about the inherent safety. Intensification to reduce inventories; so first
thing is, we should only put only those materials inventory which are required.
Sometimes there are certain things that are lying in the inventory, which are not at all
required or which were required at some stage of time and now they are not required, but
these may lead to certain kinds of accidents. So intensification means: that we have to
keep a focus in order to reduce the inventories.
If you remember our lectures, on inventory management, we have seen that access
inventory is never desirable. So, from safety point of view also the inventory should be
less. So, intensification to reduce inventories is the first point if we want to have a
inherent safety in our plant, then substitution of hazardous substances by less hazardous
alternatives. So, in designing of the plant layout, we have seen that we should keep a
separate space for hazardous substances.
Then, inherent safety says that if we even if we have to keep certain hazardous
substances, we should keep those substances which are less hazardous as compared to
the very or we can say high prone or we can say the substances which are more
hazardous. Then, attenuation to reduce hazardous process conditions, temperature,
pressure. So, wherever there are chances that the temperature rise is very high and it may
lead into some kind of accident. So, we have to see to it that those type of conditions do
not prevail.
So first point is, material should be less, second point is less hazardous material in place
of more hazardous material and third point is the conditions we have to focus, that the
temperature and pressure should be maintained in such away so that the accidents do not
take place. Then simpler systems processes to reduce potential loss of containment or
possibility of errors causing hazardous events. So, sometimes the systems are so complex
that that may lead into a hazardous event.

So, we have to design the system in such a way, that it is very simpler and it is very
simple and it does not lead into any kind of accident. So, another thing is to reduce the
potential loss of containment. So, containment means: that we have no escape route and
we are contained in a particular area. So, simpler systems or processes to reduce
potential loss of containment or possibility of errors causing a hazardous event; then fail-
safe design for example: valve position on failure.
So, fail-safe design means: that even is some failure takes place, then you should have a
valve or some kind of sensors to check that yes, there is bound to be a failure or there is
going to be a failure in this region and we can attack the problem before it happens or we
can stop the equipment, we can stop the machine in order to prevent the accident. So, just
to summarize 3, 4 points are there on in inherent safety, we will carry forward this
discussion in the next slide.
First thing is to reduce the inventories, second thing is hazardous substances should be
replaced with less hazardous substances and then hazardous operating condition should
be minimized. Temperature and pressure should be contained properly; simpler systems
processes to reduce potential loss of containment or possibility of errors causing a
hazardous event; so to reduce potential loss of containment. So, there may be some loss
that may take place, because of containment that we have to avoid. Then the fail safe
design where we have to install sensors and valves in order to prevent the accidents.
(Refer Slide Time: 24:04)

Then the inherent safety index is an in other important point that we are going to discuss
So, we have seen that there are different ways in which the accident may take place; we
have to provide for a particular system, for a particular working condition in which the
accidents do not take place. The operators feel safe in discharging their duties or in
working in the plant, but still accidents do happen. And then we have to have a
quantified technique, which would help us to check the risk that how much is the risk
involved in this particular type of system or process?
So, the inherent safety index is the only 1 that whole process routes can be assessed and.
so the most suitable route for further development can be found. So, always we have to
minimize the risk. This method also compares the inherent safety index of a plant with
the cost of capital and production. It is believed that inherently safe plants are cost
effective plant or cost effective plants.
So, basically we mean to say here is, that inherent safety index of a plant with the cost of
capital and production. So, always there are risks involved and we have to minimize
these risk. So, if we design the plant in such a way so that the risk is minimum, the
accidents are less and then we will say these are the most cost effective plants. Because,
we are not incurring any direct costs of accident, we are not incurring any indirect cost of
accidents and therefore, the plants are very cost effective. These do not identify specific
hazard; these means: these indices or risk indices.
Risk indices do not identify specific hazard, but rather point out the areas of high
concentration of risk for this deeper analysis supplementary-safety measures are
required. So, basically we would be able to understand we would be able to quantify the
areas where the risk is high. Or the risk indices would help us to identify the areas where
the risk is high.
So, wherever the risk is high that area is prone to accident. And wherever, the risk is less
we will say “The chances of accidents are very less here”. So, these indices will help us
to understand that which areas we should focus in order to reduce the accidents in our
plant.
(Refer Slide Time: 26:41)

These methods are qualitative quantitative. And are fairly simple and quick to use. So,
quantitative means we were some value some numerical value for these indices. And,
then for different areas within a plant we will have different values for the risk indices.
And we have to check that where the chances of accident are more? And where the
chances of accident are less?
So, these are quantitative in nature. They cover range hazards of the material process
conditions and inventory. So, we will get a range that this material is hazardous in this
range. Similarly, process hazards also we will get as well as inventory we will get that
this is the range in which this is going to be hazardous. So, they cover range hazards of
the materials process conditions and inventory.
Now, there is one such index called the DOW-MOND index highlights particular
hazards and calculates various indices for fire and different types of explosion, plus an
overall rating. So, once we get the rating we know that yes this is the danger level or this
is the risk level in this particular area of the plant. So, depending upon the method either
graphs or equations are used to find to find to related hazards. Usually graphs are easier
to visualize.
So, what has been said in these 2 slides is? That there are certain Quantitative techniques
which can be used to assess the risks involved at different stages of the process or at
different locations of the plant. And these indices would be helpful to us in order to
understand the prevention of the accidents. So, wherever the indices give us an idea that
yes this area is prone to accident we can focus as a management. On those areas that we
should have adequate risk prevention or accident prevention policies and procedures to
be followed in that particular area. Wherever, the chances of accidents are more. So,
indices are very important. Otherwise, it would be all subjective in nature it would vary
from person to person. Some person will say “Yes, that this particular machine is more
prone to failure”. Some person will say “It is less prone to failure”.
But in order to counter that subjectivity a kind of objectivity is introduced into by into a
system with the help of these risk indices. And these would help the management in
taking adequate preventive measures in order to avoid the accidents. Now, Domino
Effects already we have seen I have explained with an example of a cycle which all the
cycles are parked in a row. If, you push 1 cycle all the cycles would fall. So, 1 cycle
would push the other cycle other cycle will push the third cycle and all the cycles would
be on flow if you give a slightest of push. So, that basically is the domino effect.
(Refer Slide Time: 29:50)

So, hazard assessment of a site layout is critical to ensure consequence loss of

containment and minimum chance of escalation. So, we have to ensure that there are
minimum chances of escalation. That if, 1 event has taken place it should not lead into
the other event. Or there should be some valve or some control mechanism in between
the happening of the 2 events and that has to be avoided. And if, that happens then the
event or the Domino’s Effect would take place and it would lead into a complete
catastrophe. So, hazard assessment of a site layout is critical to ensure consequence loss
of containment and minimum chance of escalation. Domino may be by the fire,
explosion or toxic gas cloud. So, the domino may take place, because of any reason it
can be by fire, it can be by explosion or toxic gas cloud.
(Refer Slide Time: 30:48)

Now, we will see by 1 by 1. How these things are going to be there? And how these can
be avoided? A fire can spread in 4 ways direct burning including running liquid fires;
convection, radiation or conduction. The spread of fire from its origin to other parts of
the premises can be prevented by vertical and horizontal compartmentation using fire-
resisting walls and floors.
(Refer Slide Time: 31:06)
So, basically compartmentation is going to help. If, we have a very large hall and
suppose, 1 area of the hall catches fire. Then, the fire is bound to spread to the complete
hall, but if we have different compartments and the whole hall is divided into 5 or 6
different compartments and fire takes place in one particular area, then if we have fire
resistant walls as well as fire resistant roof. Then that fire would be contained in that
particular compartment only.
So, it would not spread to the other compartments. So, the spread of fire from its origin
to other parts of the premises can be prevented by vertical and horizontal
compartmentation using fire-resisting walls and floors. So, that I have already explained.
That it can be divided into different compartments and this would help us to arrest the
fire that has taken place in any particular area of the plant.
Then, consideration should also be given to the spread of flammable material via drains,
ducts and ventilation systems. So, if in 1 area the fire has taken place it can go to the
other area through the drains or through the ducts or through the ventilation system. So,
that also has to be avoided. So, that consideration should be there whenever we are
designing the building or the plant.
(Refer Slide Time: 32:54)

Delayed ignition following a release may result in spread of flames through such systems
via dispersed flammable gases and vapours. So, these are the some of the Domino Affect
that in 1 area the damage has taken place or the fire has taken place. How it is going to
spread to the other areas? And that we have to arrest and that we have to check. So, we
have to check the flammable gases and vapours from causing fire into the other areas.
Then, protection against so Domino Effects by convection, conduction and radiation can
be prevented by inherent safety principles. So, we have already seen what are the
inherent safety guidelines? And if, we follow those guidelines if we layout the plant in
such away. Then domino because of or the Domino Effects. Because of conduction,
convection and radiation cannot be can be avoided and will not be able to cause much
damage.
Or the extent of the damage could be minimized. So, the other method such as Active or
Passive fire protection measures may be considered. So, we will see what are these
active and passive fire prevention measures? So, what are these Active and Passive fire
protection measures?
(Refer Slide Time: 34:03)

So, we have to check that the fire does not spread. So, use of fire extinguishers or water
sprinklers constitute Active Fire Protection System. So, this is very clear fire
extinguishers all of us have seen water sprinklers also we have seen. So, these are the
Active Fire Protection System. Passive Fire Protection includes coating of fire resistant
insulating media or the insulating material applied to a vessel or steel surface or a fire
wall.
So, we can coat the surface or a fire wall by fire resistant material. So, that is the Passive
Fire Protection System. So, the Passive fire protection system includes coating of the fire
resistant insulating media applied to a vessel of steel surface or a fire wall. An important
criterion in deciding which system is most appropriate for fire exposure protection is the
likely duration of the exposure to fire as Passive fire protection is only effective for short
duration exposure.
So, we can see that if the short duration exposure is there to the fire may be 1 to 2 hours
then the Passive Fire Protection is only effective. And if, the fire is for long duration then
we have to go for the Active Fire duration Prevention System or Fire Protection System.
The following site factors should be considered in determining whether Active and
Passive Fire Protection measures are required.
(Refer Slide Time: 35:36)

So, we have to see that certain points we have to bear in mind when we are making this
decision. Then, we have to see fire hazard posed by substance that what is the hazard?
What is the substance? That is burning should we go for Active or should we go for
Passive. Or what are the chances of the material that we are storing? If it is, the very
hazardous material, then we have to check a decision whether Active or Passive or a
combination of both.
Toxicity of substances and smoke produced it is also a criteria which we have to bear in
mind. While taking a decision regarding the Active or the Passive Fire Protection
System. Similarly, inventory size what is the size of the inventory? If the inventory size
is very big and the fire takes place. And we are not able to arrest the fire within 4 or 5
years. Then, we have to go for the Active Fire Protection Systems like, sprinklers. But if
we it could be contained in half an hour 145 minute, then we may even think of Passive
Fire Protection Systems.
(Refer Slide Time: 36:53)

Then frequency of hazardous operation is also an important criterion which has to be

born in mind. Then, we also have to see the distance to other hazardous installations; also
available access to fight fire; we have to keep all these things in mind whenever, we are
taking our decision regarding Active and Active and Passive Fire Protection Systems.
That where whether, we have a access to fight the fire or not. Then, if we do not have
access or water sprinklers cannot go and pore the water out there.
So, then we have to go for a Passive Fire Protection System. Then fire-fighting capability
of onsite emergency response team; that has to be born in mind similarly, the response
time for the nearest fire brigade; that also we have to take into the account as well the
resources that are available with the fire brigade. So, all these things we have to keep in
mind whenever we are going to fight against the fire.
(Refer Slide Time: 37:48)

Now, coming onto Explosion. We have seen that how fire takes place? They we have to
bear in mind so many numbers of guidelines which would help us to prevent fire. We
have to also bear in mind that what kind of Fire Protection System we should put in
place? We can have Active Fire Protection System, we can have Passive Fire Protection
System. Similarly, we have to take into account certain guidelines whenever we are
designing the system in order to be safe according to the explosion.
So, if explosion takes place the plant or the system should be safe. So, the explosion
propagation may be directly by pressure waves or indirectly by missiles. So, we have to
see that how the explosion is going to take place? Or how the explosion may take place?
And what principles or guidelines we should bear in mind whenever we are designing a
plant or a building which is safe to explosion.
So,, then as for fires as we have already seen inherently safe methods that should be
considered are: we have seen that there are some inherently safe methods that help us to
prevent the fire. Similarly, for explosion also we have to see what are these methods? So,
arranging separation distances such that damage to adjacent plants will not occur even in
the worst case. So, that is the same kind of inherent safe mode or inherent safety method
that we have considered for fire.
So, there we have seen that the fire may spread to the other portion or to the other side
through radiation, conduction, convection. So, we have to check that that thing does not
happen in case of an explosion also. So, those things have to be arrested provision of
barriers for example, blast walls, location of strong buildings; So, we have to provide
blast walls or which the walls which would prevent the explosion to transfer from 1 part
of the building to the other part of the building as well as location in strong buildings.
So, we have to provide adequate safety measures or adequate valves or sensors or
accident control devices which would not allow the explosion to cause explosion to
cause extensive damage. Protecting plant against damage for example: provision of
thicker walls on vessels. So, that is another important point of avoiding the damage due
to explosion.
(Refer Slide Time: 40:20)

Direct explosion relief vents away from the vulnerable areas for example: other plants or
buildings, roadways near site boundaries. So, we have to provide explosion relief vents.
So, these vents would help to avoid the damage that may be caused due to explosion.
Now, another kind of hazard or another kind of accidents that may take place are due to
toxic gas releases. So, toxic gas releases may cause Domino Effects by rendering
adjacent plants in operable and injuring operators.
(Refer Slide Time: 40:50)

So, basically if there is a gas release or there is a toxic gas release that has happened that
is going to cause the effect on the adjacent buildings adjacent plants adjacent site as well
as the operators were working in the vicinity may also get affected. So, that kind of
Domino Effect has to be arrested preventing, mitigating of such effects may be affected
by provision of automatic control systems using inherently safer principles and a suitable
control room.
So, basically we have 2 arrest these kind of damages or these kind of hazards that may
take place. So, how these are happening? These are happening because, of the release of
the gases. So, how we can check? We can have a control mechanism we can have a
sensor in place, which could sense that yes some leakage has taken place and it would
automatically generate an alarm and that alarm would make the personnel aware that yes
some kind of gas release or toxic gas release has taken place and it should be plugged in.
So, if they are able to plug in the defect or the leak at the shortest possible duration then
the control mechanism is very effective. And the damage would be minimal or the
damage would be prevented, reduction of consequences of event on and off site.
(Refer Slide Time: 42:40)

So, location or locating all high-volume storage of flammable toxic materials well
outside process areas; So, first thing is regarding the storage that high-volume storage of
flammable toxic materials well outside the process areas which is very clear. Locating
hazardous plant away from the main roadways through the site; this is, also very clear.
That hazardous plant should be at a distance.
Fitting remote actuated isolation valves where high inventories of hazardous materials
may be released into vulnerable areas. So, this is kind of a control mechanism in order to
avoid the accidents because, of storage or high-volume storage of hazardous materials.
Then provision of ditches, dykes, embankments, sloping terrain to contain and control
releases and limit the safety and environmental effects.
So, we can have ditches or embankments which would provide the, which would prevent
the release of the gases or the release of the liquid from 1 side to the other side and the
damage can be minimized. So, reduction of consequences of event. So, basically an
event has taken place and we are going to reduce the consequences of that event On site
as well as Off site. So, again carrying forward the discussion related to reduction of
consequences of event on and off site, sitting of plants within buildings as secondary
containment.
(Refer Slide Time: 44:15)

So, the siting of plants within buildings as secondary containment. So, the buildings
would act as secondary containment Primary containment is the plant, secondary
containment is the building. So, siting of plants within buildings as secondary
containment. Siting of plants in the open air to ensure rapid dispersion of minor releases
of flammable gases and vapours and thus prevent concentrations building up which may
lead to flash fires and explosion.
So, sometimes the plant should be placed or those, so should be sited in such a place
where there is a provision of open air. So, even if there are slight releases of toxic gases
or flammable substances inside the plant it goes out to the atmosphere. But if that if that
kind of scenario is not there. Open air is not available or the vents to the open air is not
available then what is going to happen?
This is going to build up the flammable substance or a toxic substance is going to build
up in the atmosphere within the plant and in some case it may cause a flash fire. And that
may call lead to an accident or sometimes it may even take the proportion of an
explosion which has to be avoided at all costs. So, we have to provide the provision for
open airs Hazardous area classification for flammable gases, vapours and dusts to
designate areas where ignition sources should be eliminated.
So, wherever we have some hazardous material or gases or vapours are there. There we
have to avoid the use of ignition sources. So, fire has to be avoided there Lighting of
match stick has to be avoided there. So, to designate areas where ignition sources should
be eliminated there should be no ignition source. If you take, an example if we go to a
petroleum pump we are always advised not to light the cigarette there we are advised not
to light the match stick there. Why because the area is such that it may lead to a fire.
(Refer Slide Time: 46:35)

Now, positioning of occupied buildings, so whenever we are considering industrial

safety where should we position the buildings? The distance between the occupied
buildings and the plant buildings will be governed by the need to reduce the dangers of
explosion, fire and toxicity. We have seen that the hazards are there because of explosion
or fire or toxicity. So, the distance between the occupied building and the plant this is
going to be dictated by the risk involved in these explosion fire and toxicity.
In particular, evacuation route should not be blocked by poor plant layout. This if, you
remember we started today’s lecture with the plant layout considerations that how the
plant should be laid out in order to minimize the accident? So, evacuation route should
not be blocked by a poor plant layout and personnel with more general site
responsibilities should usually be the housed in buildings sited in non-hazard area around
the main entrance.
So, person who have general site responsibilities those should be located just near the
main entrance. So, in particular evacuation route should not be blocked by poor point
layout; first point very clear to everybody and personnel with more general site
responsibility. So, the officials of the company should usually be house and buildings
sited in a non-hazard area near the main entrance. So, the people who are very higher up
in the hierarchy or who are having the general responsibility of running the plant should
be located the non-hazard area near to the main entrance, which is quite debatable.
Positioning of occupied buildings consideration should be given to sitting of occupied
buildings outside the main fence, which is very clear.
(Refer Slide Time: 48:13)

In all cases occupied buildings should not be sited downwind of hazardous plant area.
So, downwind means again we have to see here that the Domino Effect may take place
the fire is there in the plant, but with the wind the fire may be transferred to the housing
area or the occupied buildings that has to be avoided. So, that is an important
consideration that has to be born in mind.
(Refer Slide Time: 48:50)

Now, Aggregation trapping of flammable vapours: Building design should be such that
all parts of the building should be properly ventilated either forced or naturally. So,
either we should we provide forced ventilation or it could be a natural ventilation, but
ventilation should always be there. Otherwise, the trapping of flammable vapours may
lead to flash fires at the at any particular movement of time.
So, again to give a slight summary of what we have covered building design should be
such that all parts of the buildings should be properly ventilated either forced or naturally
which is very important point. Then, flammable storages should be sited in the open air.
So, that the minor leaks are thermal out breathing can be dissipated by natural
ventilation. We that sometime thermal out breathing takes place, some of the machines
while they are in operation we will release out some heat to the atmosphere.
So, we have to provide for dissipation of that thermal breathing or thermal out. Out
breathing, then flammable storages should be sited in the open air. So, wherever there are
some flammable substances those should be always located in open air or there should be
proper ventilation. So that even minor leakage of gases or vapour is taking place that
should not add up or build up, which may lead further to the flash fire.
So, these 2 are the very important point that we have summarized twice in order to keep
in mind which or which may lead into a very big accident or accident of a very large
extent. Segregation of incompatible substances the following issues may contribute
towards the major accident or hazard: Failure to understand the properties of substances
handled.
(Refer Slide Time: 50:39)

So, sometimes we are handling some substances there are some substances which are
being used in the industry, but we do not know how to handle them? Although
precautions are there although some guidelines are there, but a new personnel joined a
company he is not able to understand that how to handle this particular substance? And
because of, wrong handling of the substance sometimes accidents may take place.
Failure to identify hazards associated with mixing substances and domino effects.
Sometimes, we are not knowing that within a plant if we mixed a particular substance a
with a substance b what is going other be the reaction or whether this reaction is going to
lead into explosion. So, that kind of know how should always be available with all the
workers who are working with those substances.
Similarly, failure of quality assurance procedures. So, we are getting some substance, but
we are not ensuring the quality of that substance. So, if we are not ensuring the quality
sometimes it may be of poor quality and may result into or may get or may catch fire or
may result into an explosion. Or may release some vapours which may lead into a
complete failure or which may lead into a toxic gas release and may cause big hazard or
may cause an accident also.
So, segregation of incompatible substance is also very important. So, this addresses to
the needs of inventory management where we have to manage the materials and
substances in such away so that they may now lead into the accident. So, the failure to
understand the properties of substances handled? Failure to identify the hazards
associated with mixing substances and the domino if event thereafter? And failure of
quality assurance procedures may sometimes lead into the accidents.
So, we have seen that what the various types of causes of accidents are: cause accidents
may be fire, accident may be by explosion, accident may be by toxic gas releases. We
have sent that there are some inherent safety principle, inherent safety methods that
should always be born in mind whenever, we are designing the plant layout. We have
also seen that what are the guidelines which have to be kept in mind? When, we are
laying out a plant.
Similarly, for the buildings also we have seen we have summarized also for the buildings
the proper ventilation should be there as well as there should not be build up of vapours
or flammable gases which may result into flash fire. So, I think today’s lecture would
definitely give you an overview of the hazards that are associated while running a plant
and the kind of principles that as an engineer we should bear in mind in order to avoid
these accidents.
Thank you.